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

Patent metadata

Field	Value
Publication number	US-11517981-B2
Application number	US-201916385539-A
Country	US
Kind code	B2
Filing date	Apr 16, 2019
Priority date	Oct 30, 2013
Publication date	Dec 6, 2022
Grant date	Dec 6, 2022

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, comprising:
casting a component from a base alloy;
removing a casting defect from the component manufactured of the base alloy to form a cavity that extends into the component from a surface of the component;
at least partially filling the cavity with a plurality of layers of laser powder deposition spots, each of the laser powder deposition spots comprising a filler alloy, and a first of the laser powder deposition spots having a circular cross-sectional geometry when viewed in a plane parallel to a plane of the surface; and
sealing a through hole with a backing prior to the at least partially filling of the cavity, wherein the removing of the casting defect forms the through hole.

2. The method of claim 1 , further comprising applying a base alloy cap at least partially within the cavity and over the filler alloy.

3. The method of claim 2 , further comprising applying a coating over the base alloy cap.

4. The method as recited in claim 2 , further comprising electro-spark depositing the base alloy cap.

5. The method as recited in claim 4 , wherein the base alloy cap is about 0.010 inches (0.25 mm) thick.

6. The method of claim 1 , further comprising applying a coating over the filler alloy and the surface.

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

8. The method as recited in claim 7 , wherein the base alloy comprises a high gamma prime nickel based alloy.

9. The method as recited in claim 7 , wherein the base alloy comprises a polycrystalline cast nickel base superalloy.

10. The method as recited in claim 1 , further comprising casting the component to form a portion of a mid-turbine frame.

11. A method, comprising:
removing a casting defect from a component manufactured of a base alloy to form a cavity in the component; and
depositing a plurality of layers of laser powder deposition spots within the cavity, each of the laser powder deposition spots comprising a filler alloy, and the laser powder deposition spots comprising a first spot, a second spot, a third spot and a fourth spot;
wherein the first spot contacts and partially overlaps the second spot and the third spot in a lateral direction;
wherein the first spot contacts and partially overlaps the fourth spot in a transverse direction that is perpendicular to the lateral direction.

12. The method of claim 1 , wherein
the cavity extends into the component from a surface of the component; and
one of the laser powder deposition spots has a circular cross-sectional geometry when viewed in a plane parallel to a plane of the surface.

13. The method of claim 11 , further comprising applying a base alloy cap at least partially within the cavity and over the filler alloy.

14. The method of claim 13 , further comprising applying a coating over the alloy cap.

15. A method, comprising:
removing a casting defect from a component manufactured of a base alloy to form a cavity that extends into the component from a surface of the component; and
depositing a plurality of layers of laser powder deposition spots within the cavity, each of the laser powder deposition spots comprising a filler alloy, and each of the laser powder deposition spots in a first of the plurality of layers at least partially overlapping another one of the laser powder deposition spots in the first of the plurality of layers;
wherein a width of a first of the laser powder deposition spots along a first axis is equal to a width of the first of the laser powder deposition spots along a second axis that is perpendicular to the first axis; and
wherein the first axis and the second axis define a plane that is parallel to a plane of the surface.

16. The method of claim 15 , wherein one of the laser powder deposition spots has a circular cross-sectional geometry when viewed in the plane.

17. The method of claim 15 , further comprising:
applying a base alloy cap at least partially within the cavity and over the filler alloy; and
applying a coating over the base alloy cap.

Assignees

• United Technologies Corp
• Raytheon Tech Corp

Inventors

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

Classifications

• B22F2007/068

  repairing articles · CPC title

• F01D5/005 Primary

  Repairing methods or devices · CPC title

• F05D2230/10

  by removing material · CPC title

• B23P6/007

  using only additive methods, e.g. build-up welding · CPC title

• C22C19/057

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