In Situ Gas Turbine Prevention of Crack Growth Progression Via Laser Welding

• US 20170218763A1
• Filed: 02/03/2016
• Published: 08/03/2017
• Est. Priority Date: 02/03/2016
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Diwinsky, David Scott, Roberts, Herbert Chidsey
• Granted Patent: US 10,443,385 B2
• Time in Patent Office: Days
• CPC Class Codes: B23K 2101/001 Turbines
• CPC Class Codes: B23K 2103/26 Alloys of Nickel and Cobalt and Chromium
• CPC Class Codes: B23K 26/032 using optical means
• CPC Class Codes: B23K 26/0884 in at least in three axial directions, e.g. manipulators, robots
• CPC Class Codes: B23K 26/144 the fluid stream containing particles, e.g. powder
• CPC Class Codes: B23K 26/342 Build-up welding
• CPC Class Codes: B23K 26/702 Auxiliary equipment
• CPC Class Codes: B23P 6/007 using only additive methods, e.g. build-up welding
• CPC Class Codes: B23P 6/045 of turbine components, e.g. moving or stationary blades, rotors, etc.
• CPC Class Codes: F01D 5/005 Repairing methods or devices
• CPC Class Codes: F05D 2230/234 Laser welding
• CPC Class Codes: F05D 2230/80 Repairing, retrofitting or upgrading methods
• CPC Class Codes: F05D 2260/83 Testing, e.g. methods, components or tools therefor
• CPC Class Codes: G01N 21/954 Inspecting the inner surface of hollow bodies, e.g. bores

Abstract

Methods for material build-up on a tip of a blade of a gas turbine engine are provided. The method can include inserting a material supply adjacent to the tip and directing a laser onto the interface of the material supply and the tip such that the material supply melts and attaches to the tip. Methods are also provided for remotely stopping a crack in a component of a gas turbine engine. The method can include inserting an integrated repair interface attached to a cable delivery system within a gas turbine engine; positioning the tip adjacent to a defect within a surface of the component; supplying a new material to the fillable area to fill the defect; and directing a laser to the new material within the fillable area to fuse the new material to the component within the defect.

Claims

1. A method of material build-up on a tip of a blade of a gas turbine engine, the method comprising:

inserting a material supply adjacent to the tip; and

directing a laser onto the interface of the material supply and the tip such that the material supply melts and attaches to the tip.

2. The method of claim 1, wherein the material supply is a preform positioned adjacent to the tip by sliding the preform between the tip and the shroud.

3. The method of claim 1, wherein the laser emits electromagnetic radiation having a wavelength of about 0.5 μ

m to about 25 μ

m.

4. The method of claim 1, wherein the laser emits electromagnetic radiation at a power level of about 0.02 W to about 75 kW.

5. The method of claim 1, wherein the laser is attached to a robotic arm

6. The method of claim 5, wherein the interface precision is about 0.05 inches or less.

7. The method of claim 5, wherein directing a laser onto the interface comprises

inserting an integrated repair interface attached to a cable delivery system within a gas turbine engine, wherein the integrated repair interface comprises a laser;

positioning the tip adjacent to the interface of the material supply and the tip of the blade; and

directing the laser to the interface.

8. The method of claim 7, further comprising:

temporarily attaching the tip adjacent to the defect within the surface on the component.

9. The method of claim 8, wherein the tip is attached using a tripod grip, a glue, or a vacuum sucker.

11. The method of claim 1, further comprising:

inserting an optical probe through the access port or an adjacent access port of the gas turbine engine, the optical probe being configured to provide a view of the interface within the gas turbine engine.

10. The method of claim 10, wherein an optical probe is attached to the robotic arm.

12. A method of remotely stopping a crack in a component of a gas turbine engine, the method comprising:

inserting an integrated repair interface attached to a cable delivery system within a gas turbine engine;

positioning the tip adjacent to a defect within a surface of the component, wherein the defect defines a fillable area;

supplying a new material to the fillable area to fill the defect; and

directing a laser to the new material within the fillable area to fuse the new material to the component within the defect.

13. The method of claim 12, wherein the laser emits electromagnetic radiation having a wavelength of about 0.5 μ

m to about 25 μ

m.

14. The method of claim 12, wherein the new material is supplied as a solid particle into the defect.

15. The method of claim 14, wherein the solid particle is supplied into the defect at an average particle size of about 25 μ

m to about 150 μ

m.

16. The method of claim 14, wherein the solid particle is supplied into the defect at a temperature within about 25% of its melting point.

17. The method of claim 14, wherein the new material is supplied via a conduit from external of the engine, wherein conduit is a high temperature conduit extending lengthwise between the material supply end of the repair tool and the tip end of the repair tool.

18. The method of claim 14, further comprising:

inserting an optical probe through the access port or an adjacent access port of the gas turbine engine, the optical probe being configured to provide a view of the defect within the gas turbine engine.

19. The method of claim 14, further comprising:

temporarily attaching the tip adjacent to the defect within the surface on the component.

20. The method of claim 19, wherein the tip is attached using a tripod grip, a glue, or a vacuum sucker.