ARRANGEMENT FOR THE REPAIR OF THE BLADES OF BLISK DRUMS BY MEANS OF LASER DEPOSITION WELDING

• US 20100176097A1
• Filed: 01/12/2010
• Published: 07/15/2010
• Est. Priority Date: 01/12/2009
• Status: Active Grant

• Current Assignee: Rolls-Royce Deutschland Limited & Company KG (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce Deutschland Limited & Company KG (Rolls-Royce Holdings Plc)
• Inventors: ZHU, Leping
• Granted Patent: US 8,247,733 B2
• Time in Patent Office: Days
• US Class Current: 219/121.630
• CPC Class Codes: B23K 2101/001 Turbines
• CPC Class Codes: B23K 26/03 Observing, e.g. monitoring, the workpiece
• CPC Class Codes: B23K 26/1482 Detachable nozzles, e.g. exchangeable or provided with breakaway lines
• CPC Class Codes: B23K 26/342 Build-up welding
• CPC Class Codes: F01D 5/005 Repairing methods or devices
• CPC Class Codes: F05D 2230/234 Laser welding
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft
• CPC Class Codes: Y10T 29/49238 Repairing, converting, servicing or salvaging
• CPC Class Codes: Y10T 29/49318 Repairing or disassembling
• CPC Class Codes: Y10T 29/49325 Shaping integrally bladed rotor

Abstract

An arrangement for the repair of BLISK blades damaged at their leading and trailing edges by use of laser deposition welding, includes a laser source and laser optics for generating a focused laser beam (26) and a powder line (35) connected to a powder reservoir for supplying metal powder to be melted by the laser beam to the weld area. A modular, tubularly elongated welding apparatus (7) with a connection module (13) which is connected to a laser source and in which the entering laser beam is deflected in longitudinal direction and parallelized, and to the one side of the connection module (13) is connected to a camera module for a CCD camera (12) enabling the precise positioning of the welding apparatus and the deposition of the molten metal powder on the respective blade to be monitored and controlled.

Claims

1. An arrangement for repairing blades of BLISK drums for gas turbines by laser deposition welding, comprising:

a laser source and laser optics for generating a focused laser beam;

a powder line connected to a powder reservoir for supplying a metal powder jet to a weld area to be melted by the laser beam;

a welding apparatus of modular type, including

a connection module which is connected to the laser source and in which the entering laser beam is shaped and deflected,

a camera module connected to one side of the connection module for a CCD camera, and

a beam-shaping module connected at an opposite side for shaping and focusing the laser beam, and

a slender welding-head module adjoining the beam-shaping module with the laser beam and the powder line extending in longitudinal direction of said welding-head module and being directed in a deposition head towards a sideward exit port, and

a protective-gas shielding module adjoining the exit port and being connected to a protective-gas source, forming an open protective-gas duct to protect a metal deposit applied to the blade edge against contamination during melting and cooling.

2. The arrangement of claim 1, wherein the protective-gas shielding module includes a fixed duct portion arranged on the welding-head module and an exchangeable, mobile duct portion suited to a respective blade shape and size as well as a slotted sliding element temporarily attached to the blade to be repaired and bearing the welding apparatus with the protective-gas shielding module during the deposition process.

3. The arrangement of claim 2, and further comprising collimating and focusing lenses positioned in the connection and beam-shaping module for beam-shaping and focussing as well as a cooling circuit connected to a water source for cooling the lenses.

4. The arrangement of claim 3, wherein the beam-shaping module is connected to the protective-gas source to prevent optical elements of the welding apparatus from being contaminated.

5. The arrangement of claim 4, and further comprising deflecting mirrors arranged in the connection module and in the welding-head module for deflecting the laser beam, and a mirror for deflecting the white-light beam to the CCD camera.

6. The arrangement of claim 5, and further comprising a fixation element provided on one of the connection module and the beam-shaping module for attaching the welding apparatus to an industrial robot.

7. The arrangement of claim 6, and further comprising a light-fiber connector provided on the connection module for coupling the laser light into the connection module, the light-fiber connector being connected to the laser source via a light-fiber cable.

8. The arrangement of claim 1, and further comprising collimating and focusing lenses positioned in the connection and beam-shaping module for beam-shaping and focussing as well as a cooling circuit connected to a water source for cooling the lenses.

9. The arrangement of claim 8, wherein the beam-shaping module is connected to the protective-gas source to prevent optical elements of the welding apparatus from being contaminated.

10. The arrangement of claim 9, and further comprising deflecting mirrors arranged in the connection module and in the welding-head module for deflecting the laser beam, and a mirror for deflecting the white-light beam to the CCD camera.

11. The arrangement of claim 10, and further comprising a fixation element provided on one of the connection module and the beam-shaping module for attaching the welding apparatus to an industrial robot.

12. The arrangement of claim 1, and further comprising a light-fiber connector provided on the connection module for coupling the laser light into the connection module, the light-fiber connector being connected to the laser source via a light-fiber cable.

13. The arrangement of claim 12, wherein the beam-shaping module is connected to the protective-gas source to prevent optical elements of the welding apparatus from being contaminated.

14. The arrangement of claim 13, and further comprising deflecting mirrors arranged in the connection module and in the welding-head module for deflecting the laser beam, and a mirror for deflecting the white-light beam to the CCD camera.

15. The arrangement of claim 14, and further comprising a fixation element provided on one of the connection module and the beam-shaping module for attaching the welding apparatus to an industrial robot.

16. The arrangement of claim 15, and further comprising a light-fiber connector provided on the connection module for coupling the laser light into the connection module, the light-fiber connector being connected to the laser source via a light-fiber cable.

17. The arrangement of claim 1, wherein the beam-shaping module is connected to the protective-gas source to prevent optical elements of the welding apparatus from being contaminated.

18. The arrangement of claim 1, and further comprising deflecting mirrors arranged in the connection module and in the welding-head module for deflecting the laser beam, and a mirror for deflecting the white-light beam to the CCD camera.

19. The arrangement of claim 1, and further comprising a fixation element provided on one of the connection module and the beam-shaping module for attaching the welding apparatus to an industrial robot.

20. The arrangement of claim 1, and further comprising a light-fiber connector provided on the connection module for coupling the laser light into the connection module, the light-fiber connector being connected to the laser source via a light-fiber cable.