Additive layer repair of a metallic component

Patent metadata

Field	Value
Publication number	US-2016341044-A1
Application number	US-201615154474-A
Country	US
Kind code	A1
Filing date	May 13, 2016
Priority date	May 21, 2015
Publication date	Nov 24, 2016
Grant date	—

Abstract

A method of repairing a metallic component (formed from a first material) by powder feeding laser deposition, comprises the step of depositing a plurality of first repair layers onto a repair surface of the component to form a first repair zone, the first of the plurality of first repair layers comprising a mixture of A/B by weight of the first material and a second material, each nth successive one of the plurality of first repair layers comprising a change in the proportion of the second material in the mixture, the last of the plurality of first repair layers comprising a mixture of C/D by weight of the first material and the second material.

First claim

What is claimed is:

1 . A method of repairing a metallic component by powder feeding laser deposition, the metallic component being formed from a first material, the method comprising the step of:
depositing a plurality of first repair layers onto a repair surface of the component to form a first repair zone, the first of the plurality of first repair layers comprising a mixture of A/B by weight of the first material and a second material, each n th successive one of the plurality of first repair layers comprising a change in the proportion of the second material in the mixture, the last of the plurality of first repair layers comprising a mixture of C/D by weight of the first material and the second material.

2 . The method as claimed in claim 1 , wherein the integer ‘n’ is selected from the range comprising 10 to 1,000.

3 . The method as claimed in claim 1 , wherein the ratio A/B is selected from the range comprising 80/20 to 5/95.

4 . The method as claimed in claim 1 , wherein the ratio C/D is selected from the range comprising 0/100 to 40/60.

5 . The method as claimed in claim 1 , wherein the change in the proportion of the second material in the mixture comprises an increase in the proportion of the second material in the mixture.

6 . The method as claimed in claim 1 , the method comprising the additional step of:
depositing a plurality of second repair layers of the second material onto the first repair zone to form a second repair zone.

7 . The method as claimed in claim 1 , the method comprising the additional step of:
depositing a plurality of third repair layers of a third material onto the second repair zone to form a third repair zone.

8 . The method as claimed in claim 7 , wherein the third material is metallurgically compatible with both the first material and the second material.

9 . The method as claimed in claim 1 , wherein the first material and the second material have the same metallurgical composition.

10 . The method as claimed in claim 1 , the first material being provided as a powder having a first mean particle size, and the second material being provided as a powder having a second mean particle size, and
wherein if the first mean particle size is smaller than the second mean particle size, then, for the same volume of material, the time required to melt the first material will be less than the time required to melt the second material, otherwise if the second mean particle size is smaller than the first mean particle size, then, for the same volume of material, the time required to melt the second material will be less than the time required to melt the first material.

11 . The method as claimed in claim 1 , the second material being provided as a powder having a second mean particle size, and the third material being provided as a powder having a third mean particle size, and
wherein if the second mean particle size is smaller than the third mean particle size, then, for the same volume of material, the time required to melt the second material will be less than the time required to melt the third material, otherwise if the third mean particle size is smaller than the second mean particle size, then, for the same volume of material, the time required to melt the third material will be less than the time required to melt the second material.

12 A method of repairing a metallic component by powder feeding laser deposition, the metallic component being formed from a first material, the method comprising the step of:
depositing a plurality of second repair layers of a second material onto a repair surface of the component to form a second repair zone; and
depositing a plurality of third repair layers of a third material onto the second repair zone to form a third repair zone.

13 . A metallic component comprising:
a base region formed from a first material; and a first repair zone superposed on the base region,
the first repair zone being formed from a plurality of first repair layers, the first of the plurality of first repair layers comprising a mixture of A/B by weight of the first material and a second material, each n th successive one of the plurality of first repair layers comprising a change in the proportion of the second material in the mixture, the last of the plurality of first repair layers comprising a mixture of C/D by weight of the first material and the second material.

14 . The metallic component as claimed in claim 13 , wherein the integer ‘n’ is selected from the range comprising 10 to 1,000.

15 . The metallic component as claimed in claim 13 , wherein the ratio A/B is selected from the range comprising 80/20 to 5/95.

16 . The metallic component as claimed in claim 13 , wherein the ratio C/D is selected from the range comprising 0/100 to 40/60.

17 . The metallic component as claimed in claim 13 , wherein the change in the proportion of the second material in the mixture comprises an increase in the proportion of the second material in the mixture.

18 . The metallic component as claimed in claim 13 , further comprising:
a second repair zone superposed on the first repair zone,
the second repair zone comprising a plurality of second repair layers of the second material.

19 . The metallic component as claimed in claim 13 , further comprising:
a third repair zone superposed on the second repair zone,
the third repair zone comprising a plurality of third repair layers of a third material.

Assignees

• Rolls Royce Plc

Inventors

• Heason Christopher P
• Baxter Gavin J

Classifications

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title

• B23K35/3053

  Fe as the principal constituent · CPC title

• F01D5/147

  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

• B23P6/007 Primary

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

• F01D5/005 Primary

  Repairing methods or devices · CPC title