REPAIRED SUPERALLOY COMPONENTS AND METHODS FOR REPAIRING SUPERALLOY COMPONENTS

• US 20130323533A1
• Filed: 06/05/2012
• Published: 12/05/2013
• Est. Priority Date: 06/05/2012
• Status: Abandoned Application

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Cui, Yan, DiMascio, Paul Stephen, Kottilingam, Srikanth Chandrudu, Tollison, Brian Lee, Lin, Dechao
• Application Number:
  US13/488,535
• Publication Number:
  US 20130323533A1
• Time in Patent Office: Days
• US Class Current: 428/680
• CPC Class Codes: B23K 15/0073 with interposition of particular material to facilitate connecting the parts, e.g. using a filler
• CPC Class Codes: B23K 2101/001 Turbines
• CPC Class Codes: B23K 26/211 with interposition of special material to facilitate connection of the parts
• CPC Class Codes: B23P 6/005 using only replacement pieces of a particular form
• CPC Class Codes: C22C 19/051 and Mo or W
• CPC Class Codes: C22C 19/055 with the maximum Cr content being at least 20% but less than 30%
• CPC Class Codes: C22C 19/056 with the maximum Cr content being at least 10% but less than 20%
• CPC Class Codes: F01D 5/005 Repairing methods or devices
• CPC Class Codes: F05D 2230/233 Electron beam welding
• CPC Class Codes: F05D 2240/121 related to the leading edge of a stator vane
• CPC Class Codes: F05D 2300/175 Superalloys
• CPC Class Codes: F05D 2300/518 Ductility
• CPC Class Codes: F05D 2300/607 Monocrystallinity
• CPC Class Codes: Y10T 428/12944 Ni-base component
• CPC Class Codes: Y10T 428/12986 Adjacent functionally defined components

Abstract

Methods for repairing superalloy components include disposing a single crystal coupon in a void of the superalloy component, disposing one or more shims between the single crystal coupon and the superalloy component, and, welding the one or more shims to join with the single crystal coupon and the superalloy component using a high energy density beam welder.

Claims

1. A method for repairing a superalloy component, the method comprising:

disposing a single crystal coupon in a void of the superalloy component;

disposing one or more shims between the single crystal coupon and the superalloy component; and

,

welding the one or more shims to join with the single crystal coupon and the superalloy component using a high energy density beam welder.

2. The method of claim 1 further comprising excavating the void prior to disposing the single crystal coupon in the void.

3. The method of claim 2, wherein excavating the void comprises removing one or more defects from the superalloy component.

4. The method of claim 1 further comprising shaping the single crystal coupon to compliment the void prior to disposing the single crystal coupon in the void.

5. The method of claim 1, wherein the superalloy component comprises a hot gas path turbine component.

6. The method of claim 1, wherein the void is on a leading edge of a nozzle.

7. The method of claim 1, wherein the superalloy component comprises nickel-base alloy.

8. The method of claim 1, wherein the high energy density beam welder comprises an electron beam welder.

9. The method of claim 1 further comprising heat treating the superalloy component after welding.

10. The method of claim 1, wherein at least one of the one or more shims comprises a composition of from about 9 percent to about 16 percent chromium, from about 7 percent to about 14 percent cobalt, from about 10 percent to about 20 percent molybdenum, from about 1 percent to about 5 percent iron, from about 0.05 percent to about 0.75 percent aluminum, from about 0.5 percent to about 2 percent titanium, from about 0.02 percent to about 0.1 percent carbon, from about 0.55 percent to about 2.75 percent combined titanium and aluminum, and the balance nickel.

11. The method of claim 10, wherein the composition is about 12.5 percent chromium, about 10.5 percent cobalt, about 15 percent molybdenum, about 3 percent iron, about 0.25 percent aluminum, about 1.1 percent titanium, about 0.06 percent carbon, about 1.65 percent combined titanium and aluminum and the remainder nickel.

12. A repaired superalloy component comprising:

a single crystal coupon disposed in a void of the repaired superalloy component; and

,

one or more welded shims disposed between and joining the single crystal coupon and the repaired superalloy component, wherein the one or more welded shims were welded using a high energy density beam welder.

13. The repaired superalloy component of claim 12, wherein the superalloy component comprises nickel-base alloy.

14. The repaired superalloy component of claim 13, wherein the superalloy component comprises René

108.

15. The repaired superalloy component of claim 12, wherein the single crystal coupon comprises René

N5.

16. The repaired superalloy component of claim 12, wherein the repaired superalloy component comprises a hot gas path turbine component.

17. The repaired superalloy component of claim 12, wherein the single crystal coupon is disposed proximate a leading edge of the hot gas path turbine component.

18. The repaired superalloy component of claim 12, wherein at least one welded shim comprises a more ductile superalloy material than the single crystal coupon.

19. The repaired superalloy component of claim 12, wherein at least one of the one or more welded shims comprises a composition of from about 9 percent to about 16 percent chromium, from about 7 percent to about 14 percent cobalt, from about 10 percent to about 20 percent molybdenum, from about 1 percent to about 5 percent iron, from about 0.05 percent to about 0.75 percent aluminum, from about 0.5 percent to about 2 percent titanium, from about 0.02 percent to about 0.1 percent carbon, from about 0.55 percent to about 2.75 percent combined titanium and aluminum, and the balance nickel.

20. The repaired superalloy component of claim 19, wherein the composition is about 12.5 percent chromium, about 10.5 percent cobalt, about 15 percent molybdenum, about 3 percent iron, about 0.25 percent aluminum, about 1.1 percent titanium, about 0.06 percent carbon, about 1.65 percent combined titanium and aluminum and the remainder nickel.