Method of repairing superalloy directional castings
First Claim
1. A method of repairing a cast article of a superalloy composition having a directionally oriented microstructure and growth axis and an imperfection, comprising the steps of:
- (a) forming an aperture in said article in an area of imperfection, such that a plug member can be inserted into said aperture;
(b) selecting a filler material of said superalloy composition having a directionally oriented microstructure and a growth axis, such that said filler material growth axis is alignable to said article growth axis, said filler material having a composition substantially identical to said article;
(c) forming said plug member out of said filler material, said plug member having an inner end and an outer surface between said inner and outer end, said plug member of dimensions such that said plug member can be received in said aperture for orientation of said article growth axis;
(d) inserting said plug into said aperture whereby said filler material growth axis is oriented in alignment with said article growth axis;
(e) applying a bonding material between said plug outer surface and said aperture inner surface, before or after insertion of said plug into said aperture;
(f) heating said article such that said bonding material joins said aperture inner surface and said plug outer surface; and
(g) removing material from said outer end of said plug such that said outer end of said plug is approximately level with said outer surface of said article.
1 Assignment
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Accused Products
Abstract
A method of repairing cracks, imperfections, and the like in a cast article of superalloy composition having a directionally oriented microstructure and growth axis. An aperture, usually frustois created in the article in the location of the crack or imperfection. A plug, having a second directionally oriented microstructure having a directional microstructure with a growth axis and a superalloy composition substantially identical to the article superalloy composition, is created. Such plug further possesses an inner end, an outer end, and a surface therebetween. The plug is inserted into the aperture whereby the plug growth axis is oriented in alignment with the article growth axis. Bonding material is applied between the surfaces of the plug and the aperture, before or after insertion of the plug into the aperture. The article is thereafter heated such that the bonding material joins the surface of the plug and the aperture. The outer end of the plug thereafter is polished so that such outer end is approximately level with the article″s′outer wall. The process can include creating a frame of reference between the plug and the aperture, such that the growth axis of the plug″s′second directional microstructure can be aligned with the first growth axis of the article″s′first directional microstructure upon insertion of the plug into the aperture. A plug made in accordance with the aforesaid method is further disclosed and claimed.
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Citations
21 Claims
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1. A method of repairing a cast article of a superalloy composition having a directionally oriented microstructure and growth axis and an imperfection, comprising the steps of:
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(a) forming an aperture in said article in an area of imperfection, such that a plug member can be inserted into said aperture;
(b) selecting a filler material of said superalloy composition having a directionally oriented microstructure and a growth axis, such that said filler material growth axis is alignable to said article growth axis, said filler material having a composition substantially identical to said article;
(c) forming said plug member out of said filler material, said plug member having an inner end and an outer surface between said inner and outer end, said plug member of dimensions such that said plug member can be received in said aperture for orientation of said article growth axis;
(d) inserting said plug into said aperture whereby said filler material growth axis is oriented in alignment with said article growth axis;
(e) applying a bonding material between said plug outer surface and said aperture inner surface, before or after insertion of said plug into said aperture;
(f) heating said article such that said bonding material joins said aperture inner surface and said plug outer surface; and
(g) removing material from said outer end of said plug such that said outer end of said plug is approximately level with said outer surface of said article. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A plug for filling an aperture in a cast article having a directionally oriented microstructure and a growth axis, comprising:
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(a) a filler material of a superalloy composition having a directionally oriented microstructure and a growth axis such that said filler material growth axis is alignable to said article growth axis, and said filler material superalloy composition having a composition substantially identical to said article superalloy composition; and
(b) an indexing means for alignment of said filler material growth axis and said article growth axis when said plug is inserted in said aperture in said article. - View Dependent Claims (18, 19, 20, 21)
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Specification