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

Patent metadata

Field	Value
Publication number	US-10569361-B2
Application number	US-201415032415-A
Country	US
Kind code	B2
Filing date	Sep 16, 2014
Priority date	Oct 30, 2013
Publication date	Feb 25, 2020
Grant date	Feb 25, 2020

Abstract

A method of reworking or repairing a component includes removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity that results in a through hole; sealing the through hole with a backing; and 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, a first layer of the multiple of layers includes a perimeter of the multiple of laser powder deposition spots that overlap a wall of the cavity and the backing.

First claim

What is claimed:

1. A method of reworking a component, comprising:
removing a defect from a component manufactured of a non-fusion weldable base alloy to form a cavity that results in a through hole;
sealing the through hole with a backing; and
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, a first layer of the multiple of layers includes a perimeter of the multiple of laser powder deposition spots that at least partially overlap a wall of the cavity and the backing.

2. The method as recited in claim 1 , wherein the first layer of the multiple of layers forms a complete perimeter formed prior to any other layers.

3. The method as recited in claim 2 , further comprising forming a desired surface roughness on the backing.

4. The method as recited in claim 3 , wherein the desired surface roughness on the backing provides about equal laser energy absorption between the backing and the wall.

5. The method as recited in claim 3 , wherein the desired surface roughness on the backing is at least about 125 micro inches (0.003 mm).

6. The method as recited in claim 3 , wherein the backing is between about 0.010 to 0.020 inches (0.254-0.508 mm).

7. The method as recited in claim 3 , wherein the backing is between about 0.010 to 0.020 inches (0.254-0.508 mm).

8. The method as recited in claim 1 , wherein the each spot in a layer is located between two spots from a prior layer.

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

10. The method as recited in claim 9 , wherein the non-fusion weldable base alloy is a high gamma prime nickel based alloy.

11. A method of reworking a component, comprising:
removing a defect from a component manufactured of a non-fusion weldable base alloy to form a cavity that results in a through hole;
forming a desired surface roughness on a backing;
sealing the through hole with the backing; and
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.

12. The method as recited in claim 11 , further comprising completely sealing the backing along a wall of the cavity and the backing.

13. The method as recited in claim 11 , wherein a first layer of the multiple of layers includes a perimeter of the multiple of laser powder deposition spots that overlap a wall of the cavity and the backing.

14. The method as recited in claim 13 , wherein the first layer of the multiple of layers forms a complete perimeter around an interface between the backing and the wall.

15. The method as recited in claim 11 , wherein the desired surface roughness on the backing provides about equal laser energy absorption between the backing and the wall.

16. The method as recited in claim 11 , wherein the each spot in a layer is located between two spots from a prior layer.

17. The method as recited in claim 11 , wherein the desired surface roughness on the backing is at least about 125 micro inches (0.003 mm).

Assignees

• United Technologies Corp

Inventors

• Lin Wangen

Classifications

• F05D2230/31

  Layer deposition · CPC title

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title

• B22F5/009

  of turbine components other than turbine blades (of turbine blades B22F5/04) · CPC title

• F05D2230/80

  Repairing, retrofitting or upgrading methods · CPC title

• B22F2007/068

  repairing articles · CPC title