Laser powder deposition weld rework for gas turbine engine non-fusion weldable nickel castings

Patent metadata

Field	Value
Publication number	US-10265802-B2
Application number	US-201415026459-A
Country	US
Kind code	B2
Filing date	Oct 24, 2014
Priority date	Oct 30, 2013
Publication date	Apr 23, 2019
Grant date	Apr 23, 2019

Abstract

A method of reworking an aerospace component includes removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity. The cavity is then at least partially filled with a multiple of layers of discrete laser powder deposition spots of a filler alloy. A cast component for a gas turbine engine includes a cast component non-fusion weldable base alloy with a cavity filled with a multiple of layers of laser powder deposition spots of a filler alloy. The filler alloy may be different than the non-fusion weldable base alloy. A layer of non-fusion weldable base alloy is at least partially within the cavity and over the filler alloy.

First claim

What is claimed is:

1. A method of reworking a component, comprising:
removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity;
at least partially filling the cavity with a multiple of layers of a multiple of laser powder deposition spots, each of the multiple of laser powder deposition spots formed of a filler alloy;
applying a non-fusion weldable base alloy cap at least partially within the cavity and over the filler alloy; and
applying a coating over the non-fusion weldable base alloy cap.

2. The method as recited in claim 1 , wherein the filler alloy is a fusion weldable powder material.

3. The method as recited in claim 2 , wherein the non-fusion weldable base alloy is a high gamma prime nickel based alloy.

4. The method as recited in claim 2 , wherein the non-fusion weldable base alloy is a polycrystalline cast nickel base superalloy.

5. The method as recited in claim 2 , wherein the non-fusion weldable base alloy is a polycrystalline cast nickel base superalloy.

6. The method as recited in claim 1 , further comprising electro-spark depositing the non-fusion weldable base alloy cap.

7. The method as recited in claim 6 , wherein the non-fusion weldable base alloy cap is about 0.010 inches (0.25 mm) thick.

8. The method as recited in claim 1 , further comprising casting the component of the non-fusion weldable base alloy.

9. The method as recited in claim 8 , further comprising casting the component to form a portion of a mid-turbine frame.

10. The method as recited in claim 8 , wherein removing the casting defect results in a through hole, and sealing the through hole with a backing prior to at least partially filling the cavity.

11. A cast component for a gas turbine engine, comprising:
a cast component manufactured of non-fusion weldable base alloy with a cavity at least partially filled with a multiple of layers of a multiple of laser powder deposition spots, each of the multiple of laser powder deposition spots formed of a filler alloy, wherein the filler alloy is different than the non-fusion weldable base alloy;
a non-fusion weldable base alloy cap at least partially within the cavity and over the filler alloy; and
a coating over the non-fusion weldable base alloy cap.

12. The cast component as recited in claim 11 , wherein the non-fusion weldable base alloy is a high gamma prime nickel based alloy.

13. The cast component as recited in claim 11 , wherein the non-fusion weldable base alloy is a polycrystalline cast nickel base superalloy.

14. The cast component as recited in claim 11 , wherein the non-fusion weldable base alloy is a polycrystalline cast nickel base superalloy.

15. The cast component as recited in claim 11 , wherein the non-fusion weldable base alloy cap is about 0.010 inches (0.25 mm) thick.

16. The cast component as recited in claim 15 , wherein the cast component as a portion of a mid-turbine frame.

Assignees

• United Technologies Corp

Inventors

• Lin Wangen
• Larson Gary J
• Whitman Giovanni
• Poeppel Scott
• Wilson Joseph

Classifications

• C22C19/057

  with the maximum Cr content being less 10% · CPC title

• B23K2103/08

  Non-ferrous metals or alloys · CPC title

• B23K26/342 Primary

  Build-up welding · CPC title

• F05D2230/80

  Repairing, retrofitting or upgrading methods · CPC title

• F01D9/041

  using blades (F01D5/148 takes precedence) · CPC title