Repair of dual walled metallic components using directed energy deposition material addition

Patent metadata

Field	Value
Publication number	US-2016251965-A1
Application number	US-201615053057-A
Country	US
Kind code	A1
Filing date	Feb 25, 2016
Priority date	Feb 26, 2015
Publication date	Sep 1, 2016
Grant date	—

Abstract

A technique for repairing a dual walled component comprising a spar comprising a plurality of pedestals and a coversheet attached to the plurality of pedestals may include removing a damaged portion of the coversheet from the dual walled component to expose a plurality of exposed pedestals and define a repair location and an adjacent coversheet portion. The technique also may include attaching a material to the plurality of exposed pedestals and adjacent coversheet portion using directed energy deposition material addition to form a repaired coversheet portion.

First claim

1 . A method for repairing a dual walled component comprising a spar comprising a plurality of pedestals and a coversheet attached to the plurality of pedestals, the method comprising:
removing a damaged portion of a coversheet from a dual walled component to expose a plurality of exposed pedestals and define a repair location and an adjacent coversheet portion, wherein the dual walled component comprises:
a spar comprising a plurality of pedestals, wherein the plurality of pedestals comprises the plurality of exposed pedestals; and
the coversheet, wherein the coversheet is attached to the plurality of pedestals; and
attaching a material to the plurality of exposed pedestals and adjacent coversheet portion using directed energy deposition material addition to form a repaired coversheet portion.

2 . The method of claim 1 , wherein the material comprises a preformed replacement coversheet portion, and wherein attaching the material to the plurality of exposed pedestals and the adjacent coversheet portion using directed energy deposition material addition comprises:
positioning the preformed replacement coversheet portion at the repair location; directing energy at each of a plurality of locations at which the preformed replacement coversheet portion is adjacent to the plurality of exposed pedestals to join the preformed replacement coversheet portion to the plurality of exposed pedestals; and providing powder to a side of the preformed replacement coversheet portion opposite of the plurality of exposed pedestals, wherein the energy joins at least some of the powder to the preformed replacement coversheet portion at at least one location adjacent to an exposed pedestal of the plurality of exposed pedestals.

3 . The method of claim 2 , wherein the powder substantially fills a depression in the preformed replacement coversheet portion made from joining the preformed replacement coversheet portion to the exposed pedestal.

4 . The method of claim 1 , wherein the material comprises a powder, and wherein attaching the material to the plurality of exposed pedestals and the adjacent coversheet portion using directed energy deposition material addition comprises:
filling space between the plurality of exposed pedestals with a stop material, wherein the stop material defines a surface substantially aligned with a pedestal-contacting surface of the adjacent coversheet portion; directing a powder to the surface of the stop material; directing energy to the powder at locations adjacent to the stop material, the plurality of exposed pedestals, and the adjacent coversheet portion to form the repaired coversheet portion by directed energy deposition material addition.

5 . The method of claim 1 , wherein the repaired coversheet portion comprises an alloy substantially similar to the alloy of the adjacent coversheet portion.

6 . The method of claim 1 , wherein the repaired coversheet portion comprises an alloy different than the alloy of the adjacent coversheet portion.

7 . The method of claim 1 , wherein removing the damaged portion of the coversheet comprises removing at least a damaged portion of at least one pedestal of the plurality of pedestals, wherein the coversheet is attached to the at least one pedestal prior to removing the damaged portion of the coversheet.

8 . The method of claim 1 , wherein removing the damaged portion of the coversheet comprises removing an undamaged portion of the coversheet, wherein the undamaged portion of the coversheet is adjacent to the damaged portion of the coversheet.

9 . The method of claim 1 , further comprising:
forming at least one film cooling hole in the repaired portion of the coversheet.

10 . The method of claim 1 , further comprising:
forming a thermal barrier coating on at least the repaired portion of the coversheet.

11 . A dual walled component comprising:
a spar comprising a plurality of pedestals; a coversheet attached to a first set of pedestals from the plurality of pedestals; and a repaired coversheet portion attached to a second set of pedestals from the plurality of pedestals and to the coversheet, wherein the repaired coversheet portion includes material attached using directed energy deposition material addition.

12 . The dual walled component of claim 11 , wherein the repaired coversheet portion comprises a preformed replacement coversheet portion and the material attached using directed energy deposition material addition, wherein the material attached using directed energy deposition material addition is disposed in depressions in the preformed replacement coversheet portion.

13 . The dual walled component of claim 11 , wherein the repaired coversheet portion comprises powder joined using directed energy deposition material addition.

14 . The dual walled component of claim 11 , wherein the coversheet comprises a first alloy, and wherein the repaired coversheet portion comprises a second, different alloy.

15 . The dual walled component of claim 11 , wherein the coversheet and the repaired coversheet portion comprises the same alloy.

16 . The dual walled component of claim 11 , wherein the coversheet and the repaired coversheet portion comprise a plurality of film cooling holes.

17 . The dual walled component of claim 11 , further comprising a thermal barrier coating on the coversheet and the repaired coversheet portion.

18 . The dual walled component of claim 11 , further comprising a gas turbine engine component, wherein the gas turbine engine component comprises the spar, the coversheet, and the repaired coversheet portion.

Assignees

• Rolls Royce Corp

Inventors

• Henderkott Joseph Peter
• Shuck Quinlan Yee

Classifications

• F05D2230/234

  Laser welding · CPC title

• F01D5/147 Primary

  Construction, i.e. structural features, e.g. of weight-saving hollow blades (F01D5/148, F01D5/16 and F01D5/20 take precedence; blade shape F01D5/141; blades with cooling or heating channels or cavities F01D5/18; heating, heat-insulating or cooling means on blades F01D5/18) · CPC title

• F05D2260/202

  by film cooling · CPC title

• F23R3/002

  Wall structures (F23R3/02 and F23R3/007 take precedence) · CPC title

• B23P6/007

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