Reparatur von superlegierten Komponenten durch Hinzufügen von pulverförmigem legiertem Werkstoff und pulverförmigem Flussmittel

Verfahren zum Reparieren oder Herstellen eines superlegierten Bauteils (50) durch Abscheiden mehrerer Schichten (22, 24, 26, 28) zusätzlichen superlegierten Werkstoffs mit einer Eigenschaft, die sich von einem darunterliegenden, ursprünglichen superlegierten Werkstoff (30) unterscheidet. Die Eigenschaft, die zwischen dem ursprünglichen Werkstoff und dem zusätzlichen Werkstoff geändert wird, kann zum Beispiel die Werkstoffzusammensetzung, die Kornstruktur, die Kornhauptachse, die Korngrenzenfestigung und/oder die Porosität sein. Ein Bereich (60) des Bauteils, der aus dem zusätzlichen Werkstoff gebildet wird, wird eine verbesserte Leistung im Vergleich zum ursprünglichen Werkstoff aufweisen, beispielsweise eine größere Beständigkeit gegen Rissbildung (58).

METHOD OF WELDING

Virgin metal and metal alloy components are welded with and without filler material using a laser without cleaning the surfaces to be joined of mill scale and/or surface oxides, paints grease and other forms of contamination, and without edge preparation. The uncleaned, unprepared surfaces are placed in contact with each other, and a 100% through the thickness laser keyhole weld without filler metal is made in one pass, full penetration is achieved by two laser keyhole welds without filler metal (one made from each side), or resistively heated filler wire is fed into the metal pool of a laser conduction weld in one oe more passes along each side of the confronting surfaces to be joined. Quality welds are made despite gaps of varying size up to about 0.125 inches between the parts to be joined.

PROJECTION RESISTANCE WELDING OF SUPERALLOYS

Superalloy components are joined by mating a recess (44) formed in one component (40) with a corresponding projection (52) formed in another component (50) along a contact surface. The components are compressed along the contact surface and resistance heat welded to each other. Current is passed between the components at a selected flow rate and application time until localized melting occurs along the contact surface, and they are mutually affixed to each other. When repairing a damaged surface portion of a superalloy material component, the damaged portion is removed to form an excavated recess. A repair splice is formed, preferably of a same material with similar mechanical structural properties, having a mating projection with profile conforming to the corresponding recess profile. The splice and substrate are resistance heat welded under compression pressure until localized melting occurs along the contact surface, so that they are mutually affixed.

REPAIR OF DIRECTIONALLY SOLIDIFIED ALLOYS

A method for epitaxial addition of repair material onto a process surface (38) of a directionally solidified component (30). The component is positioned in a fluidized bed (34) to drift particles of a repair material over the process surface as laser energy (36) is rastered across the surface to melt the particles and to fuse repair material onto the entire surface simultaneously. The component is moved downward (39) in the bed in a direction parallel to the grain orientation in the component as material is added to the surface, thereby providing continuous epitaxial addition of material to the surface without recrystallization.

HOT GAS FILTERING APPARATUS

A filtering apparatus (20) for separating particulate matter from a gas stream. The filtering apparatus (20) has a pressure vessel (21) defining an interior chamber having a dirty gas inlet (30) opening and a clean gas exit (28) opening. A tubesheet (8) is coupled within the pressure vessel (21) thereby dividing said pressure vessel into a dirty gas side (9a) and a clean gas side (9b). A support pipe (11) for supporting a plenum chamber (26) within the pressure vessel (21) dirty gas side (9a) is securely coupled with the tubesheet. The plenum chamber (26) for supporting a plurality of filter elements (70) is coupled to the support pipe (11). The plenum chamber (26) has a side wall (40) having at least one dirty gas port (44) and clean gas exit (46) formed therein. The side wall further defines a clean gas chamber (41). A plurality of filter element guides (52) are securely coupled within the clean gas chamber (41) for supporting at least one filter element (70) and preventing filter elements ...

Grain growth management system and methods of using the same

System, methods for improving grain growth in a cast melt of a superalloy are provided. The system includes at least a mold having a shape defining a part of a turbo machine, e.g., a turbine blade. A cast melt, e.g., a superalloy, is poured into the mold, and one or more heating/cooling elements are arranged in the cast melt. The system further includes a controller operatively connected to the elements for controlling the electrical current of, e.g., a heating wire of the heating element, or controlling the flow-rate for, e.g., a coolant of the cooling element. By controlling, i.e., adjusting the current and/or flow-rate, via the controller, a temperature gradient may be induced to improve grain growth.

Laserauftrags-Oberflächensteuerung unter Verwendung von Flussmittel und Elektrochemie

Verfahren und Vorrichtung (20) zum Ausbilden einer glatten Metalloberfläche (42) auf ein Metallsubstrat (22). Eine Metallschmelze (32), die unter einer Schicht aus geschmolzener elektrolytischer Schlacke (34) auf dem Metallsubstrat erstarrt, wird einem Gleichstrom (12) zwischen einer Kathode (28) im Kontakt mit der geschmolzenen Schlacke und dem Substrat unterzogen, wodurch eine anodische Einebnung der Oberfläche verursacht wird. Die Kathode kann in einer Schicht aus Flussmaterial (26) vergraben sein, die durch einen das Substrat überquerenden Laserstrahl (30) geschmolzen wird. Ein Füllmaterial (24) kann gleichzeitig in einem additiven Prozess geschmolzen werden. Das Flussmaterial enthält elektrolytische, optisch durchlässige und die Viskosität reduzierende Bestandteile.

Füllgeflecht für Laserplattierung

FLUX MEDIATED DEPOSITION OF METALLIC GLASS

A method and resulting gas turbine engine component () having a protective layer of metallic glass () deposited over a superalloy substrate (). A further layer of ceramic insulating material () may be deposited over the metallic glass. The metallic glass functions as a bond coat to provide thermal insulation and mechanical compliance. The metallic glass may be deposited onto the substrate by a flux mediated laser deposition process wherein powdered alloy material () is melted together with powdered flux material (). The flux material can facilitate the glass forming process by adding to the solidification confusion effect and/or by providing an active cooling effect. 1. A method comprising:depositing powdered alloy material and powdered flux material onto a surface of a crystalline alloy material;melting the deposited powdered alloy material and powdered flux material to form a melt pool covered by a layer of liquid slag;cooling the melt pool at a rate sufficient to form a solidified layer of metallic glass under a layer of solidified slag; andremoving the solidified slag to reveal the layer of metallic glass deposited onto the crystalline alloy material.2. The method according to claim 1 , wherein the crystalline alloy material is a superalloy and the metallic glass has a glass transition temperature of at least 600° C.3. The method according to claim 1 , wherein the metallic glass comprises at least 30% by weight of Group V elements.4. The method according to claim 1 , wherein the powdered flux material comprises atoms having respective atomic radii at least 10% smaller than claim 1 , or at least 10% larger than claim 1 , an atomic radius of a metallic element present in a highest mole fraction of the powdered alloy material.5. The method according to claim 1 , wherein the melting and cooling steps are performed in an atmosphere containing methane and water.6. The method according to claim 1 , further comprising cooling the melt pool in a manner such that grains ...

SPLICE INSERT REPAIR FOR SUPERALLOY TURBINE BLADES

A damaged portion of a superalloy material turbine blade body is removed, forming an excavated recess. A repair splice is formed of a same material with similar mechanical structural properties, having a mating outer profile conforming to the corresponding recess profile. The repair splice is inserted and captured within the recess, so that the blade body and repair splice are mechanically interlocked. Given similarities in mechanical properties of both the blade body and the mechanically interlocked splice the repaired blade's overall mechanical structural properties are similar to those of an undamaged blade. The repair splice is affixed to the blade body so that the interlocking respective portions of each do not separate. Localized affixation and subsequent cosmetic blade surface repair can be performed with softer, low temperature application braze and weld alloys ...

Laser waveguide with coaxial filler wire feed

A laser waveguide (22) with a tubular wall (24) that conducts laser energy (30) from a near end (23) to a far end (27) of the waveguide. A filler feed wire (36) slides through the hollow center of the waveguide. A laser emitter (40) delivers laser beam energy (30) to a first end of the waveguide within an acceptance angle A. The laser beam may be non-parallel to an axis (25) of the waveguide by at least 20 degrees to provide room for the laser emitter beside the feed wire. The near end of the waveguide may be flared (23C) to accept a laser beam at a greater angle from the axis. The beam exits the waveguide (32) with an annular energy distribution about the feed wire, and may be focused toward the feed wire by a lens (34) having an axial hole (37) for the wire.

HEISSGASFILTER

LASER WELDING OF A SLEEVE WITHIN A TUBE

... 34 The invention relates to a method for welding a sleeve within a tube of a steam generator, the sleeve being in close contact with the tube. A welding head of a weld head apparatus is positioned within the tube at a predetermined weld site, a laser beam is directed to the welding head, the beam is focused with a focusing means, the focused laser beam is reflected with a welding mirror means into contact with a portion of the sleeve to be welded to the tube, the welding mirror means is maintained a predetermined focal distance from the inside surface of the sleeve, and the welding head is rotated to complete a weld fusion path about the inner periphery of the sleeve. Shielding gas is used to shield the weld site. A robotic arm positions the weld head apparatus within the steam generator. At each end of the sleeve, multiple discrete weld paths or a continuous helical multiple weld path are welded. The sleeve is preferably welded to the tube along the weld path with a fusion width at the ...

ADVANCED PASS PROGRESSION FOR BUILD-UP WELDING

A method of build-up welding including depositing of a weld material (12) on a substrate (10) in a series of weld passes in side-by-side relation to form a first weld layer (12a), wherein substantially all weld passes forming the first weld layer (12a) are deposited in a first pass direction (d1). Subsequently, a series of weld passes are deposited in side-by-side relation on the first layer to form a second weld layer (12b), wherein substantially all weld passes forming the second weld layer (12b) are deposited in a second pass direction (d2) opposite to the first pass direction (d1). Each weld pass of each layer may be deposited at a location where it is restrained on no more than one lateral side extending parallel to the weld pass.

OPTICALLY CONDUCTIVE FILLER FOR LASER PROCESSING

A filler feed wire (20) including both a laser conductive element (26) and a filler material (22) extending along a length of the wire. Laser energy (30) can be directed into a proximal end (32) of the laser conductive element for melting a distal end (34) of the feed wire to form a melt pool (24) for additive fabrication or repair. The laser conductive element may serve as a flux material. In this manner, laser energy is delivered precisely to the distal end of the feed wire, eliminating the need to separately coordinate laser beam motion with feed wire motion.

METHOD OF JOINING OR REPAIRING SUPERALLOY STRUCTURES USING PROJECTION RESISTANCE BRAZING : CORRESPONDING SUPERALLOY COMPONENT

Superalloy components (40, 50) are joined by mating a recess (44) formed in one component (40) with a corresponding projection (52) formed in another component (50) along a contact surface. The components are compressed along the contact surface and resistance heat brazed to each other. Current is passed between the components (40, 50) at a selected flow rate and application time until brazing alloy (60) melting occurs along the contact surface, and they are mutually affixed to each other. When repairing a damaged surface portion of a superalloy material component (40), the damaged portion is removed to form an excavated recess (44). A repair splice (50) is formed, preferably of a same material with similar mechanical structural properties, having a mating projection (52) with profile conforming to the corresponding recess (44) profile. The splice (52) and substrate (40, 50) are resistance heat brazed under compression pressure until brazing alloy (60) melting occurs along the contact surface ...

DISCHARGE ACTUATED SOLID STATE ADDITIVE MANUFACTURING

A method for forming an impact weld used in an additive manufacturing process is provided. The method includes providing a metallic material for impact welding to a substrate. The metallic material is propelled toward the substrate with a sufficient velocity to form an impact weld for welding the metallic material to the substrate. Further, the method includes traversing the substrate in a direction relative to a direction from which the metallic material is propelled and repeating the propelling so that a layer of additive material is deposited on the substrate as desired. In addition, a method for forming an impact welding used in an additive manufacturing process via discharge actuated arrangement is provided.

LASER PROCESSING OF A BED OF POWDERED MATERIAL WITH VARIABLE MASKING

An additive manufacturing apparatus () and process including selectively heating a processing plane of a bed of powdered material () that includes a powdered metal material (′), and may also include a powdered flux material (″). The heating may be accomplished by directing an energy beam, such as a laser beam (), toward a processing plane () of the bed. One or more masking elements () are disposed between a source () of the beam and the processing plane; and the masking elements are variable to change a beam pattern at the processing plane according to a predetermined shape of a component () to be formed or repaired. 1. An additive manufacturing apparatus , comprising:a chamber;a bed of powdered material including powdered metal material in the chamber;an energy beam that selectively scans portions of a processing plane of the bed of powdered material to heat and melt the powdered material which solidifies to form a metal deposit layer; andone or more variable masking elements disposed between a source of the energy beam and the processing plane of the bed of powdered material, the one or more masking elements comprising one or more optically transmissive portions that define a pattern of the energy beam at the bed processing plane;wherein the one or more masking elements are operable to change the energy beam pattern at the bed processing plane according to a predetermined shape of a component to be formed or repaired.2. The apparatus of claim 1 , wherein the one or more masking elements includes a plurality of masking elements aligned side by side claim 1 , disposed in the same plane and at least some of the masking elements are moveable in at least one direction according to the predetermined shape of the component.3. The apparatus of claim 1 , wherein the one or more masking elements includes a plurality of masking elements wherein a first masking element is disposed underneath a second masking element.4. The apparatus of claim 3 , wherein the first masking ...

METHOD OF DETERMINING BOND COVERAGE IN A JOINT

A method of determining bonding agent coverage in a joint between a first substrate ( 10 ) and a second substrate ( 12 ), including: dispersing a marker material ( 18 ) throughout a bonding agent ( 16 ); melting the bonding agent ( 16 ) but not the marker material; solidifying the melted bonding agent ( 16 ) to form an actual bond ( 24 ) in a joint between the first substrate ( 10 ) and the second substrate ( 12 ); detecting the marker material ( 18 ) in the joint through at least one of the substrates to ascertain an actual bond ( 24 ); and comparing the actual bond ( 24 ) to an expected bond ( 28 ) for the joint to determine the bonding agent coverage.

FUNCTIONAL BASED REPAIR OF SUPERALLOY COMPONENTS

A method of repairing or manufacturing a superalloy component (50) by depositing a plurality of layers (22, 24, 26, 28) of additive superalloy material having a property that is different than an underlying original superalloy material (30). The property that is changed between the original material and the additive material may be material composition, grain structure, principal grain axis, grain boundary strengthener, and/or porosity, for example. A region (60) of the component formed of the additive material will exhibit an improved performance when compared to the original material, such as a greater resistance to cracking (58).

ADVANCED PASS PROGRESSION FOR BUILD-UP WELDING

A method of build-up welding including depositing of a weld material (12) on a substrate (10) in a series of weld passes in side-by-side relation to form a first weld layer (12a), wherein substantially all weld passes forming the first weld layer (12a) are deposited in a first pass direction (d1). Subsequently, a series of weld passes are deposited in side-by-side relation on the first layer to form a second weld layer (12b), wherein substantially all weld passes forming the second weld layer (12b) are deposited in a second pass direction (d2) opposite to the first pass direction (d1). Each weld pass of each layer may be deposited at a location where it is restrained on no more than one lateral side extending parallel to the weld pass.

Flussmittelunterstützte Entfernung von Wärmedämmschichten mittels Laser

Ein Verfahren zum Entfernen eines keramischen Wärmedämmschichtsystems (18). Dem Wärmedämmschichtsystem wird in Gegenwart eines Flussmittels (22) Laserenergie (20) zugeführt, um eine Schmelze (26) zu bilden. Nach dem Entfernen der Energie erstarrt die Schmelze, um eine Schlackeschicht (28) zu bilden, die lockerer an dem darunter liegenden metallischen Substrat (12) haftet als das ursprüngliche Wärmedämmschichtsystem. Die Schlacke wird dann mithilfe eines mechanischen Verfahrens wie Granulatstrahlen (30) gebrochen und von dem Substrat gelöst. Es kann genügend Energie zugeführt werden, um das Beschichtungssystem in seiner gesamten Tiefe zusammen mit einer dünnen Schicht (34) des Substrats zu schmelzen, wodurch nach dem erneuten Erstarren eine aufgefrischte Oberfläche (36) auf dem Substrat gebildet wird.

REPAIR OF DIRECTIONALLY SOLIDIFIED ALLOYS

A method for epitaxial addition of repair material onto a process surface (38) of a directionally solidified component (30). The component is positioned in a fluidized bed (34) to drift particles of a repair material over the process surface as laser energy (36) is rastered across the surface to melt the particles and to fuse repair material onto the entire surface simultaneously. The component is moved downward (39) in the bed in a direction parallel to the grain orientation in the component as material is added to the surface, thereby providing continuous epitaxial addition of material to the surface without recrystallization.

HEISSGASFILTER

VERFAHREN FÜR DAS SELEKTIVE LASERSTRAHLHARTLÖTEN

Ein Verfahren für das selektive Laserstrahlhartlöten wird bereitgestellt. Das Verfahren beinhaltet das Bereitstellen eines Pulvers (10) mit mehreren Elternkernpartikeln (20) und mehreren Hartlotpartikeln (30); Einstellen einer Temperatur einer Energiequelle (170); Anwenden der Energiequelle (170) auf das Pulver (10); und Gestatten, dass das erhitzte Pulver (10) erstarrt. Die mehreren Elternkernpartikel (20) werden durch die Mehrheit von Hartlotmaterial (30) zu einer gewünschten Komponente miteinander verschmolzen.

Verfahren zum Ausbilden von dreidimensionalen Verankerungsstrukturen auf einer Fläche durch Ausbreiten von Energie durch eine Mehrkernfaser

Es wird ein Verfahren zum Ausbilden von dreidimensionalen Verankerungsstrukturen auf einer Fläche geschaffen. Dieses Verfahren kann zu einem Wärmebarrieren-Beschichtungssystem führen, das eine verstärkte Haftung für seine es bildenden Beschichtungen aufweist. Das Verfahren umfasst das Aufbringen eines ersten Laserstrahls (20) durch einen ersten Abschnitt (7) einer Mehrkernfaser (4) auf eine Fläche (12) eines festen Materials (14) zum Ausbilden eines verflüssigten Betts (16) auf der Fläche (12) des festen Materials (14), dann das Aufbringen eines Impulses von Laserenergie (24) durch einen zweiten Abschnitt (6) der Mehrkernfaser (4) auf einen Abschnitt des verflüssigten Betts (16) zum Hervorrufen einer Störung, wie z. B. eines Spritzers (28) von verflüssigtem Material, außerhalb des verflüssigten Betts (16). Eine dreidimensionale Verankerungsstruktur (30) kann somit bei Verfestigung des Spritzers (28) von verflüssigtem Material auf der Fläche (12) ausgebildet werden.

OPTIMIERUNG DER SCHMELZBADFORM IN EINEM FÜGEVERFAHREN

Es wird ein Schweißverfahren bereitgestellt, das das Aufbringen einer ersten Energiemenge (118) und einer zweiten Energiemenge (122) auf ein Substrat (105) umfasst, die wirksam sind, um ein Schmelzbad (100) bereitzustellen, das eine kurvilineare (152) und/oder kurviplanare (160) Fest/Flüssig-Grenzfläche um zumindest eine Hinterkantenregion (106) und innerhalb einer Tiefe (D) des Schmelzbades (100) umfasst.

EVALUATING A PROCESS EFFECT OF SURFACE PRESENTATION ANGLE

An apparatus (10) and method for evaluating an effect of a surface presentation angle (A). The apparatus supports a plurality of samples (12) separated by support plates (18) between end plates (22) in a shish kebab arrangement. A groove (34) is formed on each side of each support plate for receiving an edge of each respective sample at a different angle relative to an axis of impingement (32). A clamping mechanism (20) holds the end plates, support plates and samples together in the fixed orientation exposing each sample surface at a different presentation angle, yet at the same distance from a process end effector (30). The sample impingement surfaces are exposed to the process, and the effect of the different surface presentation angles is determined from the samples. Process variables to counter the effects of surface presentation angle may be identified and controlled.

HOT GAS FILTERING APPARATUS

A filtering apparatus (20) for separating particulate matter from a gas stream. The filtering apparatus (20) has a pressure vessel (21) defining an interior chamber having a dirty gas inlet (30) opening and a clean gas exit (28) opening. A tubesheet (8) is coupled within the pressure vessel (21) thereby dividing said pressure vessel into a dirty gas side (9a) and a clean gas side (9b). A support pipe (11) for supporting a plenum chamber (26) within the pressure vessel (21) dirty gas side (9a) is securely coupled with the tubesheet. The plenum chamber (26) for supporting a plurality of filter elements (70) is coupled to the support pipe (11). The plenum chamber (26) has a side wall (40) having at least one dirty gas port (44) and clean gas exit (46) formed therein. The side wall further defines a clean gas chamber (41). A plurality of filter element guides (52) are securely coupled within the clean gas chamber (41) for supporting at least one filter element (70) and preventing filter elements ...

Flux assisted laser removal of thermal barrier coating

A method of removing a ceramic thermal barrier coating system (18). Laser energy (20) is applied to the thermal barrier coating system in the presence of a flux material (22) in order to form a melt (26). Upon removal of the energy, the melt solidifies to from a layer of slag (28) which is more loosely adhered to the underlying metallic substrate (12) than the original thermal barrier coating system. The slag is then broken and released from the substrate with a mechanical process such as grit blasting (30). Sufficient energy may be applied to melt an entire depth of the coating system along with a thin layer (34) of the substrate, thereby forming a refreshed surface (36) on the substrate upon resolidification.

MECHANISCH-THERMISCHER HYBRIDPROZESS ZUR BESCHICHTUNGSENTFERNUNG

GAS TUNGSTEN ARC WELDING USING FLUX COATED ELECTRODES

A method of applying a weld using a gas tungsten arc welding procedure. A filler element is provided to a welding location. The filler element (14) includes a first material used during formation of a weld, and a second material that is capable of producing a slag upon melting thereof. A welding arc (30) provides heat that melts portions of first and second components (16, 18) and the filler element proximate to the welding location (42) to form a weld pool. The second material melts and forms a slag, which flows to an outer surface of the weld pool and shields the weld pool from exposure to reactive elements in the atmosphere. Upon cooling of the weld pool, the weld pool solidifies to form a weld between the first component and the second component ...

Method to form oxide dispersion strengthended (ODS) alloys

Method for forming an oxide dispersion strengthened alloy. An alloy material (24) is melted with an energy beam (28) to form a melt pool (30) in the presence of a flux material (26), and particles (36) of a metal oxide are directed into the melt pool such that the particles are dispersed within the melt pool. Upon solidification, an oxide dispersion strengthened alloy (44) is formed as a layer bonded to an underlying substrate (20) or as an object contained on a removable support.

LASER METALWORKING USING REACTIVE GAS

A method of metalworking a substrate () previously strengthened in a gas heat treatment to form precipitates throughout an entire volume of the substrate (), where the precipitates have an active chemical element incorporated during the gas heat treatment. The method includes: melting a portion of the substrate () during a full penetration metalworking process to form a molten portion (); generating a metalworking atmosphere () having a supply of an active chemical element in a gas state during the metalworking process; exposing the molten portion () to the metalworking atmosphere (); and cooling the molten portion () while maintaining exposure to the metalworking atmosphere () to form a solidified portion () comprising precipitates comprising the active chemical element, where the precipitates are present throughout an entire volume of the solidified portion (), and thereby re-strengthen the entire volume of the solidified portion (). 1. A method of metalworking a substrate previously strengthened in a gas heat treatment to form precipitates throughout an entire volume of the substrate , the precipitates comprising an active chemical element incorporated during the gas heat treatment , the method comprising:melting a portion of the substrate during a full penetration metalworking process to form a molten portion;generating a metalworking atmosphere comprising a majority by volume of an active chemical element in a gas state during the metalworking process;exposing the molten portion to the metalworking atmosphere;cooling the molten portion into an unrestrengthened solidified portion abutting the melted portion while exposing the unrestrengthened solidified portion to the metalworking atmosphere comprising the active chemical element to form a restrengthened solidified portion comprising precipitates comprising the active chemical element, wherein the precipitates are present throughout an entire volume of the solidified portion, and thereby re-strengthen the entire ...

Tungsten submerged arc welding using powdered flux

A tungsten submerged arc welding process wherein a non-consumable electrode (18) provides an arc (16) under a protective bed of flux powder (26), thereby eliminating the need for an inert cover gas supply. The arc melts a feed material in the form of alloy powder (22) or filler wire (40) along with a surface of a substrate (12) to form a layer of cladding material (10, 32) covered by a layer of slag (20, 44). The flux and slag function to shape the deposit, to control cooling, to scavenge contaminants and to shield the deposit from reaction with air, thereby facilitating the deposit of previously unweldable superalloy materials.

Unterhalb der Oberfläche stattfindende Laserbearbeitung einer Wirbelschicht

Ein System und ein Verfahren der additiven Herstellung unter Verwendung eines fluidisierten Betts (einer Wirbelschicht) aus pulverisiertem Material (14), das pulverisiertes Metallmaterial (14') und pulverisiertes Flussmittel (14'') umfasst, umfasst das Erwärmen des pulverisierten Materials mit einem Energiestrahl (20), der von einem Ort unterhalb einer oberen Oberfläche (25) des pulverisierten Materials zugeführt wird. Das pulverisierte Bett wird durch die Einführung eines inerten oder nicht-inertem Gases in eine Kammer (12) fluidisiert. Während sich das pulverisierte Material erwärmt, schmilzt und erstarrt, bildet sich eine Schlackeschicht (32) auf dem abgeschiedenen Metall (38) und wird anschließend entfernt, so dass fluidisiertes Pulver, das sich auf einem zuvor abgeschiedenen Bereich (34) abgesetzt hat, erwärmt, geschmolzen und verfestigt werden kann, um eine Komponente (22) aufzubauen.

Vorrichtung für die Laserbearbeitung verborgener Oberflächen

Ein Laseremitter (36) emittiert ein Laserstrahl (37) durch eine Optik (38), die den Strahl fokussiert, und eine Strahlablenkeinrichtung (40) lenkt den Strahl um. Eine längliche Sonde (30) empfängt den Strahl an einem proximalen Ende (50) und besitzt einen abgesetzten Spiegel (24), der den Strahl zu einer verborgenen Oberfläche (32) reflektiert, die durch das Abtasten des Strahls bearbeitet werden soll. Ein programmierbarer Controller (54) steuert die Fokussierung und die Ablenkung des Strahls, um den Brennpunkt und den Einfallspunkt (39) in drei Dimensionen zu bewegen, was bewirkt, dass der Punkt die verborgene Oberfläche überquert. Die Sonde kann optional Parallelverschiebungs- (42) und Drehaktuatoren (44) und einen Drehaktuator (58) für den abgesetzten Spiegel, durch den Controller gesteuert, besitzen. Die Sonde kann L-förmig sein (30A, 30B), um eine dazwischenliegende Struktur (27) zu erreichen. Ein Autofokusmechanismus (67) kann vorgesehen sein, um den Strahl während des Scannens zu ...

Verfahren zum Bearbeiten eines Bauteils mit einem Energiestrahl

Verfahren zum Bearbeiten eines Bauteils (10) mit einem Energiestrahl. Eine Maske (70, 80) ist zwischen einer Quelle des Energiestrahls und dem Bauteil angeordnet. Die Maske ist mit einem strahldurchlässigen Teil (71) konfiguriert, das gegenseitig gegenüberliegenden Teilen (12, 14) des Bauteils entspricht. Simultanes Aufheizen der gegenseitig gegenüberliegenden Teile des Bauteils wird mit Energieteilstrahlen, die durch die strahldurchlässigen Teile der Maske hindurchgehen, durchgeführt. Das simultane Aufheizen ist dafür ausgelegt, einen thermisch induzierten Verzug des Bauteils innerhalb einer vordefinierten Toleranz zu halten. Scannen der Maske mit dem Energiestrahl kann ohne genaues Verfolgen der gegenseitig gegenüberliegenden Teile des Bauteils durchgeführt werden, wodurch eine Notwendigkeit für komplizierte numerische Programmierung zum Verfolgen einer relativ komplexen Geometrie, die durch die gegenseitig gegenüberliegenden Teile des Bauteils definiert wird, vermieden wird.

Cladding of alloys using flux and metal powder cored feed material

A metal cladding process utilizing a feed material (66) formed as a hollow sheath (68) containing a powdered core (70) including powdered metal and powdered flux material. The powdered metal and flux may have overlapping mesh size ranges. The sheath may be an extrudable subset of elements of a desired superalloy cladding material, with the powdered metal and powdered flux materials complementing the sheath to form the desired superalloy material when melted. The powdered metal may include an excess of titanium to compensate for a reaction of titanium with oxygen or carbon dioxide in a shielding gas. Heat for melting may be provided by an energy beam (64) or by utilizing the feed material as an electrode in a cold metal arc welding torch (54).

Deconstructable assembly and method

An assembly (10) that can be both joined and parted by temperature processing. A parting member (20) captured between two members of the assembly exhibits a state change as a function of temperature such that the two members can be joined with a meltable joining material (18) at a joining temperature, operated at an operating temperature lower than the joining temperature, and then separated at a parting temperature higher or lower than the operating and joining temperatures as a result of a parting force caused by the state change of the parting member. In one embodiment, the parting member has a coefficient of thermal expansion higher than a coefficient of thermal expansion of the assembly members such that differential thermal expansion causes the parting member to expand across the interface (16) between the members to generate the parting force.

Functional based repair of superalloy components

A method of repairing or manufacturing a superalloy component (50) by depositing a plurality of layers (22, 24, 26, 28) of additive superalloy material having a property that is different than an underlying original superalloy material (30). The property that is changed between the original material and the additive material may be material composition, grain structure, principal grain axis, grain boundary strengthener, and/or porosity, for example. A region (60) of the component formed of the additive material will exhibit an improved performance when compared to the original material, such as a greater resistance to cracking (58).

CLADDING OF ALLOYS USING FLUX AND METAL POWDER CORED FEED MATERIAL

A metal cladding process utilizing a feed material () formed as a hollow sheath () containing a powdered core () including powdered metal and powdered flux material. The powdered metal and flux may have overlapping mesh size ranges. The sheath may be an extrudable subset of elements of a desired superalloy cladding material, with the powdered metal and powdered flux materials complementing the sheath to form the desired superalloy material when melted. The powdered metal may include an excess of titanium to compensate for a reaction of titanium with oxygen or carbon dioxide in a shielding gas. Heat for melting may be provided by an energy beam () or by utilizing the feed material as an electrode in a cold metal arc welding torch (). 1. A method comprising:providing a feed material comprising a sheath containing a powdered core material, the powdered core material comprising powdered metal material and powdered flux material;melting the feed material onto a substrate to form a melt pool; andallowing the melt pool to cool to form a layer of clad material of a desired composition covered by a layer of slag.2. The method of claim 1 , further comprising:selecting the sheath to be formed of an extrudable subset of elements of a desired superalloy material; andselecting the powdered metal and powdered flux materials to comprise elements that complement the sheath to form the clad material as the desired superalloy material when melted onto the substrate.3. The method of claim 2 , further comprising forming the sheath from one of the group of nickel claim 2 , nickel-chromium claim 2 , and nickel-chromium-cobalt.4. The method of claim 1 , further comprising:selecting the desired composition of clad material to include titanium;providing a shielding gas comprising carbon dioxide or oxygen during the step of melting; andproviding the powdered core material to comprise titanium to compensate for a loss of titanium due to reaction with the oxygen or carbon dioxide and subsequent ...

Evaluating a process effect of surface presentation angle

An apparatus (10) and method for evaluating an effect of a surface presentation angle (A). The apparatus supports a plurality of samples (12) separated by support plates (18) between end plates (22) in a shish kebab arrangement. A groove (34) is formed on each side of each support plate for receiving an edge of each respective sample at a different angle relative to an axis of impingement (32). A clamping mechanism (20) holds the end plates, support plates and samples together in the fixed orientation exposing each sample surface at a different presentation angle, yet at the same distance from a process end effector (30). The sample impingement surfaces are exposed to the process, and the effect of the different surface presentation angles is determined from the samples. Process variables to counter the effects of surface presentation angle may be identified and controlled.

Method to form dispersion strengthened alloys

A method for forming a dispersion strengthened alloy. An alloy material (8) is melted with a heat source (28) to form a melt pool (30) in the presence of a flux material (26), and strengthening particles (36) are directed into the melt pool such that the particles are dispersed within the melt pool. Upon solidification, a dispersion strengthened alloy (44) is formed as a layer or weld joint bonded to an underlying substrate or as an object contained in a removal support.

Additive Fertigung unter Verwendung von gegossenem Band-Superlegierungsmaterial

Ein Verfahren zur additiven Fertigung, das umfasst: Anordnen einer Schicht (10) aus bandgegossenem Superlegierungsblechmaterial über einer Unterkomponente (12), wobei eine Lücke (20) zwischen der Schicht und der Unterkomponente gelassen wird; und Ausbilden einer Schweißung (14) in der Schicht. Eine Schrumpfung in der Schicht, die durch die Schweißung verursacht wird, wird durch eine Verringerung der Lücke bei verringerter Schrumpfspannung in der Schweißung aufgefangen. Die Schicht kann aus mehr als einem Stück (16) ausgebildet sein und die Schweißung kann die Stücke zusammenfügen, und zwar mit oder ohne Zusammenfügen der Schicht mit der Unterkomponente. Die Lücke kann aufgrund der unterschiedlichen thermischen Ausdehnung wieder wachsen, wenn die resultierende Komponente in Betrieb genommen wird, wodurch sie als ein passiv geregelter Kühlkanal fungiert.

ABRASIONS- UND HOCHTEMPERATURBESTÄNDIGE BESCHICHTUNG UND MATERIAL, DAS VERDICHTETE GEOMETRISCHE HOHLKÖRPER ENTHÄLT

Anordnung für die Laserbearbeitung eines Turbinenbauteils

Die Erfindung betrifft eine Anordnung (10) zur Reparatur eines Gasturbinenmotor-Bauteils (20) durch Laserablagerung. Eine Verarbeitungsoberfläche des Bauteils (20) wird bezüglich einer Vorrichtung zur Ablagerung von Lasermaterial (12) präzise positioniert, wobei durch den Betrieb verursachte Formveränderungen des Bauteils (20) durch Anpassung einer von der Verarbeitungsoberfläche entfernten, beweglichen Plattform (28) ausgeglichen werden, wodurch eine Vielzahl von Bauteilen (20) mit ähnlichem Design verarbeitet werden kann, ohne dass eine teilespezifische Prüfung der Abmessungen oder eine Reprogrammierung der Vorrichtung (12) notwendig wäre.

Catalytic oxidation element for a gas turbine engine

A gas turbine engine ( 10 ) includes a catalytic oxidation element ( 62 ). The catalytic oxidation element includes a pressure boundary element ( 24 ) receiving a first fluid flow ( 16 ). An opening ( 28 ) in an upstream portion ( 26 ) of the pressure boundary element allows fluid communication across the pressure boundary element between the first and a second fluid flow ( 20 ) to generate a combustion mixture flow ( 30 ). A catalytic surface ( 34 ) disposed on a downstream portion ( 32 ) of the pressure boundary element is exposed to the combustion mixture flow for at least partially combusting the combustion mixture flow.

GRAIN GROWTH MANAGEMENT SYSTEM AND METHODS OF USING THE SAME

System, methods for improving grain growth in a cast melt of a superalloy are provided. The system includes at least a mold having a shape defining a part of a turbo machine, e.g., a turbine blade. A cast melt, e.g., a superalloy, is poured into the mold, and one or more heating/cooling elements are arranged in the cast melt. The system further includes a controller operatively connected to the elements for controlling the electrical current of, e.g., a heating wire of the heating element, or controlling the flow-rate for, e.g., a coolant of the cooling element. By controlling, i.e., adjusting the current and/or flow-rate, via the controller, a temperature gradient may be induced to improve grain growth.

LASERADDITIVE HERSTELLUNG UNTER VERWENDUNG VON IN EINEM FLÜSSIGEN TRÄGER SUSPENDIERTEM FÜLLMATERIAL

Ein Verfahren beinhaltet: Fließenlassen eines flüssigen Trägermediums (12) mit einer Zufuhr (14) von Metallpartikeln (16) über einer Oberfläche (20) eines Substrats (10); Richten eines Energiestrahls (30) durch das fließende flüssige Trägermedium zu der Oberfläche; und Erwärmen mindestens einiger der Metallpartikel in dem flüssigen Trägermedium mit dem Energiestrahl, um eine metallische Abscheidung (32) auszubilden, die an die Substratoberfläche gebondet ist und die von dem flüssigen Trägermedium bedeckt ist.

Verbundmaterialien und Verfahren zur Laserfertigung und -reparatur von Metallen

Vorliegend offenbarte Verbundmaterialien (2, 8) beinhalten eine Metalllegierung (4, 10) und eine Flussmittelzusammensetzung (6, 12). Die Metalllegierung kann eine Superlegierung sein, und ein Volumenverhältnis der Flussmittelzusammensetzung zur Metalllegierung kann im Bereich von ungefähr 30:70 bis ungefähr 70:30 liegen. Die Verbundmaterialien können in Form von Teilchen (2) vorliegen, die einen Kern (6) umfassen, der von einer metallischen Schicht (4) umgeben ist, wobei der Kern die Flussmittelzusammensetzung umfasst und die metallische Schicht die Metalllegierung umfasst. Die Verbundmaterialien können auch in Form von verschmolzenen Materialien (8) vorliegen, wobei die Metalllegierung (10) und die Flussmittelzusammensetzung (12) zufällig verteilt und zufällig orientiert sind. Ebenfalls offenbart sind Prozesse, umfassend Schmelzen von Verbundmaterialien unter Ausbildung von Metallabscheidungen (32).

Verfahren zum Ausbilden von dreidimensionalen Verankerungsstrukturen auf einer Fläche

Es wird ein Verfahren zum Ausbilden von dreidimensionalen Verankerungsstrukturen auf einer Fläche geschaffen. Dies kann zu einem Wärmebarrieren-Beschichtungssystem führen, das eine verstärkte Haftung für seine es bildenden Beschichtungen aufweist. Das Verfahren umfasst das Aufbringen eines Laserstrahls (10) auf eine Fläche (12) eines festen Materials (14) zum Ausbilden eines verflüssigten Betts (16) auf der Fläche des festen Materials, dann das Aufbringen eines Impulses von Laserenergie (18) auf einen Abschnitt des verflüssigten Betts zum Erzeugen einer Störung, wie z. B. eines Spritzers (20) oder einer Welle (25) von verflüssigtem Material, außerhalb des verflüssigten Betts. Eine dreidimensionale Verankerungsstruktur (22) kann somit bei Verfestigung des Spritzers oder der Welle von verflüssigtem Material auf der Fläche ausgebildet werden.

METHODS AND PREFORMS TO MASK HOLES AND SUPPORT OPEN-SUBSTRATE CAVITIES DURING LASER CLADDING

This invention relates to methods in which a protective material (44) is introduced into a metallic component, or is used to block a hole (48) in the metallic component, a filler material (34) is pre-placed or directed to an external surface of the metallic component, the filler material is heated with at least one energy beam (40) to melt or sinter a metal powder (36) contained in the filler material to form a cladding layer (16), and the protective material is removed from the metallic component, such that the protective material contains, or generates upon being heated, a protective substance. The present invention also relates to preforms (72) containing an upper section (74) containing a powdered metal (36) and a flux (38), and a lower section (76) containing a protective material (78), such that the protective material contains, or generates upon being heated, a protective substance.

Methods of brazing wide gaps in nickel base superalloys without substantial degradation of properties

Nickel base superalloys, including in some embodiments 5% to 7% Fe, which were previously developed and used for their corrosion resistance, also possess favorable characteristics for use as a braze filler in repair or joining of superalloy substrates, such as those used to form turbine engine blades and vanes, heat exchangers, vessels, and piping. In particular, such corrosion-resistant nickel base superalloys have favorable characteristics for wide-gap brazing of gaps greater than one millimeter in superalloy substrates that preserves favorable material properties throughout the braze region in the substrate.

Laserverarbeitung eines Betts aus pulverförmigen Material mit veränderbarer Maskierung

Additive Fertigungsvorrichtung (10) und additives Fertigungsverfahren, die das selektive Erhitzen einer Verarbeitungsebene eines Betts aus pulverförmigem Material (14), das ein pulverförmiges Metallmaterial (14') einschließt und auch ein pulverförmiges Flussmittel (14'') einschließen kann, einschließt. Das Erhitzen kann durch das Richten eines Energiestrahls wie eines Laserstrahls (20) in Richtung einer Verarbeitungsebene (27) des Betts bewerkstelligt werden. Ein oder mehrere Maskierungselemente (61, 62) sind zwischen einer Quelle (18) des Strahls und der Verarbeitungsebene angeordnet, und die Maskierungselemente sind veränderbar, um ein Strahlmuster in der Verarbeitungsebene gemäß einer vorbestimmten Form der zu formenden oder reparierenden Komponente (22) zu ändern.

SLAG REMOVAL APPARATUS AND METHOD

An apparatus () and method () operable to: feed () a granulated feedstock () into a chamber (); apply () a melting or sintering energy () in programmable scans () producing a material deposit () overlaid with slag () in the chamber (); position () a slag removal device () such that its cutting surface () is coincident with a top surface () of the material deposit; cut or break the slag free () from the material deposit with the slag removal device; separate () the removed slag from a reusable portion of the granulated feedstock in a separator (); and feed () the reusable portion of the granulated feedstock to the top surface of the material deposit for repeating () the above operations. 1. A method comprising:forming a deposit of a material by heating a granulated feedstock wherein a slag layer is formed on a top surface of the deposit;removing the slag and a reusable portion of the feedstock with a slag removal device mounted on a drive mechanism that moves the slag removal device relative to the top surface of the deposit;collecting the removed slag and the reusable portion of the feedstock into a separating device; andseparating the removed slag from the reusable feedstock with the separating device.2. The method of claim 1 , further comprising adjusting a depth of removal of the slag relative to the top surface of the deposit claim 1 , wherein the slag removal device breaks or cuts the slag free from the deposit claim 1 , and breaks the slag into pieces larger than a maximum granule size of the feedstock.3. The method of claim 2 , wherein the slag removal device comprises a scraper or planer.4. The method of claim 1 , further comprising:providing a chamber that surrounds the deposit; andproviding a positioner that supports the deposit and positions it vertically in the chamber, providing an adjustable depth of removal of the slag.5. The method of claim 4 , further comprising:positioning the top surface of the deposit flush with a top rim of the chamber; ...

Vorrichtung und Verfahren für mobile Reparatur und Herstellung für die Gasturbinenmotorwartung

Eine Aufbereitung von Heißgaspfadkomponenten von Gasturbinenmotoren können nun lokal anstelle der traditionellen Verwendung einer spezialisierten festen regionalen Reparatureinrichtung durchgeführt werden. Eine mobile Herstellungsplattform (10) ist mit der Fähigkeit versehen, keramikbeschichtete Superlegierungs-Legierungskomponenten zu untersuchen und zu reparieren, einschließlich der Fähigkeit zum Durchführen einer flussunterstützten Laserbearbeitung (68) von pulverförmigen Materialien. Die mobile Plattform kann eine Pulvermischfähigkeit (32) enthalten für ein kundenspezifisches Onsite-Mischen proprietärer Pulverzusammensetzungen aus einem standardisierten Pulverlager (34). Ein Kommunikationselement (36) befördert die proprietären Pulverzusammensetzungen von einem abgesetzten Home-Office-Ort (38). Superlegierungskomponenten können nun durch qualifizierte Techniker anstelle zertifizierter Schweißer an Ort und Stelle repariert (62) oder hergestellt (80) werden. Die mobile Plattform kann ...

Akustische Manipulation und Laserverarbeitung von Teilchen zur Reparatur und Herstellung von metallischen Bauteilen

Ein offenbartes Verfahren beinhaltet die Schritte des Erzeugens mindestens einer stehenden Ultraschallwelle (6') zwischen mindestens einem Satz sich gegenüberliegender Ultraschallwandler (20A, 20B), die metallhaltige Teilchen (22, 24, 26) in einen Schwingungsknoten (14) ausgeben, der innerhalb der stehenden Ultraschallwelle angeordnet ist, sodass die Teilchen in dem Schwingungsknoten eingefangen werden, Positionierens einer Substratoberfläche (160) in Nähe des Schwingungsknotens, Schmelzens der Teilchen mit einem Energiestrahl zum Bilden eines Schmelzbades (170) in Kontakt mit der Oberfläche und Ermöglichens der Abkühlung und Erstarrung des Schmelzbades zu einer Metallabscheidung (176), die an der Oberfläche haftet. Vorrichtungen für die Ausführung solcher Verfahren sind ebenfalls offenbart.

Artikulierende Bauplattform für laserbasierte additive Fertigung

Vorrichtung (10) für additive Fertigung, umfassend: einen Behälter (12), der so konfiguriert ist, dass er ein Bett aus pulverförmigem Metallmaterial begrenzt; eine Fluidisierungsanordnung (18), die dazu konfiguriert ist, das Bett aus pulverförmigem Material zu fluidisieren; ein Artikulationsmechanismus (40), der sich in dem Behälter befindet und dazu konfiguriert ist, eine Komponente (38) zu tragen und sie um mindestens eine horizontale Achse zu drehen; und einen Energiestrahl (34), der dazu konfiguriert ist, Abschnitte (36) einer Oberfläche des Betts aus pulverförmigem Metallmaterial selektiv zu scannen, um die selektiv gescannten Abschnitte auf die Komponente aufzuschmelzen oder aufzusintern.

Stud welding repair of superalloy components

Superalloy components are joined or repaired by mating a recess formed in one component substrate with a corresponding projection formed in another component along a contact surface and welding them together with a stud welding apparatus. A mating superalloy repair stud is formed with a stud projection whose profile conforms to the substrate recess profile along a corresponding contact surface. Both the stud and substrate are coupled to a stud welding apparatus, with the stud projection and substrate recess oriented in an opposed spaced relationship with a gap there between. The stud welding apparatus passes current between the stud projection and recess and forms an arc there between, to melt their respective opposed surfaces. The melted stud projection and substrate recess opposed surfaces are pressed into contact with each other with the stud welding apparatus, forming a weld there between.

RESISTANCE WELD ADDITIVE MANUFACTURING

A method of additive manufacturing, including resistance welding together contacting surfaces of adjacent substrate sheets, wherein weld nuggets overlap adjacent weld nuggets and collectively form a respective layer that bonds a portion of an entirety of an area of the respective contacting surfaces, thereby forming an assembled structure of at least three substrate sheets, wherein each substrate sheet includes a respective portion of a final structure.

ADDITIVE MANUFACTURING USING FORGE WELDING

Systems and methods for additively manufacturing or repairing a component using forge welding. The system includes a build platform with support. Additive materials are fed to a deposit location on the build platform. The methods include pressing the additive material onto the deposit location and repeating steps until the total additive manufactured component or repair is complete.

Laserwellenleiter mit koaxialem Fülldrahtvorschub

Ein Laserwellenleiter (22) mit einer rohrförmigen Wand, der Laserenergie von einem nahen Ende (23) zu einem fernen Ende (27) des Wellenleiters leiters. Ein Füllvorschubdraht (36) gleitet durch die hohle Mitte des Wellenleiters. Ein Laseremitter (40) liefert Laserstrahlenergie (30) an ein erstes Ende des Wellenleiters innerhalb eines Akzeptanzwinkels A. Der Laserstrahl kann um mindestens 20 Grad nicht parallel zu einer Achse 25 des Wellenleiters verlaufen, um Platz für den Laseremitter neben dem Vorschubdraht bereitzustellen. Das nahe Ende des Wellenleiters kann aufgeweitet sein (23C), um einen Laserstrahl in einem größeren Winkel von der Achse zu akzeptieren. Der Strahl verlässt den Wellenleiter (32) mit einer ringförmigen Energieverteilung um den Vorschubdraht und kann durch eine Linse (34) mit einem axialen Loch (37) für den Draht zu dem Vorschubdraht fokussiert sein.

Gas turbine engine component with performance feature

A gas turbine engine component (50, 100, 150, 160, 174, 206, 236), including: a surface (54) subject to loss caused by a wear instrument during operation of the component in a gas turbine engine and a performance feature (80, 82, 102, 152, 162, 172, 200, 230) associated with the surface. The surface and the performance feature interact in a manner that changes with the loss such that a change in performance of the gas turbine engine resulting from the loss is mitigated.

LASER WAVEGUIDE WITH COAXIAL FILLER WIRE FEED

A laser waveguide (22) with a tubular wall (24) that conducts laser energy (30) from a near end (23) to a far end (27) of the waveguide. A filler feed wire (36) slides through the hollow center of the waveguide. A laser emitter (40) delivers laser beam energy (30) to a first end of the waveguide within an acceptance angle A. The laser beam may be non-parallel to an axis (25) of the waveguide by at least 20 degrees to provide room for the laser emitter beside the feed wire. The near end of the waveguide may be flared (23C) to accept a laser beam at a greater angle from the axis. The beam exits the waveguide (32) with an annular energy distribution about the feed wire, and may be focused toward the feed wire by a lens (34) having an axial hole (37) for the wire.

METHOD FOR CREATING A TEXTURED BOND COAT SURFACE

A method for forming a textured bond coat surface (48) for a thermal barrier coating system (44) of a gas turbine component (34). The method includes selectively melting portions of a layer of alloy particles (16) with a patterned energy beam (20) to form successive layers of alloy material (16, 16) until a desired surface geometric feature (26) is achieved. The energy beam pattern may be indexed between layers to form a protruding undercut (28) in the geometric feature. The patterned energy beam may be formed by directing laser energy from a diode laser (30) through a cartridge filter (32). Particles of a flux material (18) may be melted along with the alloy particles to form a protective layer of slag (22) over the melted and cooling alloy material.

METHOD FOR DEPOSITING A DESIRED SUPERALLOY COMPOSITION

Processes for depositing a desired superalloy composition are provided. An elongated core member (), such as made up of a wrought nickel-base alloy or a wrought cobalt-base alloy, may be drawn in connection with a wire drawing process. Elongated core member () includes at least one strengthening constituent having a reduced concentration to provide a desired level of ductility appropriate for the drawing of elongated core member (). A coating () is applied to elongated core member (). Coating () is configured to introduce a sufficient concentration of the strengthening constituent to form the desired superalloy composition when the coating and the elongated core member are melted together. This melting may occur during a welding process conducive to depositing the desired superalloy composition. The welding process may be performed in the context of repairing, rebuilding, and manufacturing superalloy components, such as for a gas turbine engine. 1. A method for depositing a desired superalloy composition , the method comprising:drawing an elongated core member comprising a wrought nickel-base alloy or a wrought cobalt-base alloy, the elongated core member comprising at least one strengthening constituent having a reduced concentration to provide a desired level of ductility appropriate for the drawing of the elongated core member; andapplying a coating to the elongated core member, the coating introducing a sufficient concentration of said at least one strengthening constituent to form the desired superalloy composition when the coating and the elongated core member are melted together.2. The method of claim 1 , wherein the at least one strengthening constituent is a gamma prime constituent.3. The method of claim 2 , wherein the at least one gamma prime strengthening constituent is titanium claim 2 , and the reduced concentration is in range from zero percent by weight to two percent by weight relative to a total weight of the elongated core member.4. The method of ...

Asymmetric heat sink welding using a penetration enhancing compound

A method for welding a tube member to a tubesheet includes positioning an open end of a tube member adjacent to a first side of the tubesheet and with the tube member extending through the tubesheet past a second side of the tubesheet. A penetration enhancing compound is applied to an inner side of the tube member at a location adjacent to a junction between an outer side of the tube member and the tubesheet second side. An arc welding operation is performed at the location of the penetration enhancing compound to effect formation of a weld joint at the junction between the tube member outer side and the tubesheet second side.

Laser re-melt repair of superalloys using flux

A method of repairing service-induced surface cracks (92) in a superalloy component (90). A layer of powdered flux material (100) is applied over the cracks and is melted with a laser beam (98) to form a re-melted zone (104) of the superalloy material under a layer of slag (106). The slag cleanses the melt pool of contaminants that may have been trapped in the cracks, thereby eliminating the need for pre-melting fluoride ion cleaning. Optionally, alloy feed material may be applied with the powdered flux material to augment the volume of the melt or to modify the composition of the re-melted zone.

Electroslag and electrogas repair of superalloy components

Superalloy component castings, such as turbine blades and vanes, are fabricated or repaired by an electroslag or electrogas welding process that at least partially replicates the crystal structure of the original cast substrate in a cast-in-place substrate extension. The process re-melts the base substrate surface and grows it with new molten filler material. As the base substrate and the filler material solidify, the newly formed re-cast component has a directionally solidified uniaxial substrate extension portion that at least in part replicates the crystalline structure of the base substrate. The re-cast component can be fabricated with a unified single crystal structure, including the extension portion. In other applications, a substrate extension can replicate a directionally solidified uniaxial crystal structure of an original base substrate casting. Polycrystalline substrate base structures can be re-cast with a substrate extension that replicates base substrate crystals that are ...

VERFAHREN ZUR AUSBILDUNG VON OXIDDISPERSIONSVERFESTIGTEN (ODS-)LEGIERUNGEN

Verfahren zur Ausbildung einer oxiddispersionsverfestigten Legierung. Ein Legierungsmaterial (24) wird mit einem Energiestrahl (28) unter Ausbildung einer Schmelze (30) in Gegenwart eines Flussmittels (26) geschmolzen, und Teilchen (36) eines Metalloxids werden in die Schmelze geleitet, so dass die Teilchen in der Schmelze dispergiert sind. Beim Erstarren wird eine oxiddispersionsverfestigte Legierung (44) als eine Schicht, die mit einem zugrunde liegenden Substrat (20) verbunden ist, oder als ein auf einem entfernbaren Träger enthaltenes Objekt ausgebildet.

Method and apparatus for cooling superalloy turbine components during component welding

Superalloy components, such as steam and gas turbine blades or vanes, are cooled during welding fabrication or repair, so as to reduce likelihood of weld metal and weld heat affected zone cracking during weld solidification and during post weld heat treatment. More particularly the invention relates to cooling superalloy steam and gas turbine components, such as turbine blades or vanes during weld repair. A heat sink apparatus includes a heat sink having a first surface adapted for abutting orientation with a turbine component second surface; and a non-gaseous, conformable, heat conductive material adapted for conforming contact with both surfaces. The heat conductive material fills gaps between the heat sink and turbine component abutting surfaces, and facilitates enhanced conductive heat transfer, in order to minimize negative heat effects from welding. The apparatus may be incorporated in a cooling system that varies heat sink cooling capacity in response to sensed component temperature ...

METHOD FOR SOLID STATE ADDITIVE MANUFACTURING

A method for forming an impact weld used in an additive manufacturing process. The method includes providing a wire having a powder filler metal core located within a sheath. The wire is then inserted within a conduit having an opening. Further, the method includes providing at least one energy pulse that interacts with the sheath to pinch off at least one segment of the wire, wherein the energy pulse causes propulsion of the segment toward a substrate with sufficient velocity to form an impact weld for welding the metal core to the substrate. In particular, the energy pulse is an electromagnetic pulse, a laser energy pulse or a high electric current pulse.

FILLER ADDITIVES TO AVOID WELD CRACKING

There is provided a feed material, wherein the feed material has an elongated body that includes an amount of an alloy filler material and an amount of one or more elemental metal additives effective to scavenge at least one tramp element upon melting of the feed material.

Schweissprozess und Schweissstoss mir reduzierter Einspannung

Schweißverbindung (30), welche asymmetrische Seiten aufweist und eine verringerte Behinderung der Schrumpfung des Schweißgutes sowie eine verringerte Tendenz zur Rissbildung an der Schweißmittellinie gewährleistet. Die Schweißverbindung kann eine erste Seite (38) aufweisen, die unter einem Winkel (A1) von 35–60° bezüglich der Komponentenfläche (36) ausgebildet ist, und eine zweite Seite (40), die unter einem Winkel (A2) von 10–35° bezüglich der Fläche ausgebildet ist. Die Seiten können sich derart erstrecken, dass sie sich schneiden (44), ohne dass die Notwendigkeit einer flachen Bodenfläche (20) besteht, wie es für Schweißverbindungen (10) nach dem Stand der Technik typisch ist. Die erfindungsgemäße Schweißverbindung kann ausgebildet werden, indem ein Schaftfräswerkzeug (60) in die Fläche hinein und entlang derselben bewegt wird, wobei seine Drehachse (64) quer zu der Fläche verläuft.

MECHANISCH-THERMISCHER HYBRIDPROZESS ZUR BESCHICHTUNGSENTFERNUNG

Ein Verfahren zum Entfernen einer Beschichtung (14) von einem Substrat (12) durch Beaufschlagen der Beschichtung sowohl mit schwingender mechanischer Energie (16, 20) als auch einem Energiestrahl (32). Lokalisierte Kombination aus thermisch und mechanisch induzierten Spannungen in der Beschichtung führen zur Ausbildung von Rissen (34) in der Beschichtung.

ADDITIVE MANUFACTURING USING A FLUIDIZED BED OF POWDERED METAL AND POWDERED FLUX

An additive manufacturing apparatus and process for selectively heating a fluidized bed of powdered material (), including powdered metal material () and powdered flux material ()′ with an energy beam (). The powdered material is held within a chamber () to repair or manufacture a component (). The powdered bed is fluidized by introduction of a non-inert gas into the chamber. Relative movement between the energy beam and component is controlled in accordance with a predetermined shape of the component. As the powdered material is heated, melted and solidified, a layer of slag () forms over a deposited metal () and is then removed so that fluidized powdered metal settling on a previously deposited metal substrate () can be heated, melted and solidified to build up the component. 1. An additive manufacturing apparatus comprising:a chamber;a fluidized bed of powdered material including powdered metal material and powdered flux material in the chamber;an energy beam that selectively scans portions of a surface of the bed of powdered material to heat and melt the powdered material which then solidifies to form metal deposits; and,one or more controllers to control relative movement between the energy beam and the metal deposits according to a predetermined shape of a component.2. The apparatus of claim 1 , wherein the powdered metal comprises metal particles having a mesh-size range that overlap a mesh-size range of particles making up the powdered flux material.3. The apparatus of claim 1 , further comprising a slag removal tool positioned adjacent to the component to remove slag which forms on the metal deposits.4. The apparatus of claim 1 , wherein the energy beam is a laser beam.5. The apparatus of claim 1 , further comprising a source of a non-inert gas in fluid communication with an interior of the chamber.6. The apparatus of claim 1 , wherein the powdered metal material and powdered flux material include granulated particles formed as composite metal-flux ...

LASER MELT PARTICLE INJECTION HARDFACING

A method for hardfacing a surface including: depositing a powder (68) having alloy particles onto a surface (70) of a substrate (66); rastering a laser beam (60) across the surface to melt the powder and to form a weld pool (78) having a width (64); directing particles (74) of a material exhibiting a different property than the substrate into the weld pool in a spray pattern having a width less than the width of the weld pool; and establishing the rastering and directing steps such that material circulation within the weld pool is effective to distribute the particles in the weld pool into a pattern having a width greater than the width of the spray pattern prior to re-solidification of the weld pool.

Coatings for high temperature components

A method for forming a coating on a substrate is provided. To an assembly 10 including a substrate 12, a porous matrix 14 on the substrate 12, and an impregnating material 16 on or within the porous matrix 14, the method includes applying an amount of energy 18 from an energy source 20 effective to melt the impregnating material 16 and a portion of the substrate. In this way, the impregnating material 16 impregnates the porous matrix 14. The method further includes cooling the assembly 10 to provide a coating 26 comprising the porous matrix 14 integrated with the substrate 12.

Verbesserte Anhaftung von Beschichtungen unter Verwendung von Bondierzusammensetzungen

Ein hierin offenbarter mehrschichtiger Gegenstand (1) enthält ein metallisches Substrat (2), eine Schutzschicht (6) und eine Klebbondierschicht (14), die eine sauerstoffhaltige Verbindung einschließt, die die Klebbondierschicht mit dem metallischen Substrat, der Schutzschicht oder beiden verklebt. Ein Verfahren zur Bildung des mehrschichtigen Gegenstands schließt die Schritte des Erhitzens einer schützenden Bondierzusammensetzung (20) zur Bildung einer Schmelze (24) in Kontakt mit einer metallhaltigen Oberfläche (2), Abkühlenlassen und Erstarrenlassen der Schmelze zu der an der metallhaltigen Oberfläche angebrachten Klebbondierschicht (14), Aufbringen eines keramischen Materials (26) auf die Klebbondierschicht und Erhitzen des keramischen Materials zur Bildung der an der Klebbondierschicht angebrachten Schutzschicht (6) ein.

Reparatur eines Substrats mit von einer Komponente gestütztem Zusatzwerkstoff

Bei einem Verfahren zum Reparieren eines Komponentensubstrats (18), insbesondere eines Substrats (18), das aus einer Superlegierung wie etwa einer nickelbasierten Superlegierung besteht, wird ein Abschnitt des Substrats (18) an einem geschädigten Bereich (26), der repariert werden soll, entfernt, indem eine Reparaturöffnung (28) durch das Substrat (18) hindurch gebildet wird. Die Reparaturöffnung (28) ist einem inneren Hohlraum (20) der Komponente (10) benachbart. Der Hohlraum (20) wird mit einem Zusatzwerkstoff (30) wie etwa einer pulverisierten Metalllegierung gefüllt, die eine Zusammensetzung aufweist, welche derjenigen des Substrats (18) entspricht. Danach wird dem Zusatzwerkstoff (30) über die Reparaturöffnung (28) Wärme zugeführt, um den Zusatzwerkstoff zu schmelzen, welcher abkühlen gelassen wird, um einen Reparatur-Materialauftrag (36, 40, 50) zu bilden, der mit dem Substrat (18) und über die Öffnung (28) verschmilzt. Etwaiger nicht verbrauchter Zusatzwerkstoff (30) wird anschließend ...

Corrugated catalyst support structure for use within a catalytic reactor

A catalytic section of a combustor is formed from a spaced tandem array of corrugated panels. The exterior top and bottom surfaces of the panels are coated with a catalyst and the space between panels defines a passage for a fuel-rich/air mixture. The interior of the corrugated panels define cooling air passages for maintaining the catalyst and substrate on which it is formed, at acceptable temperatures.

Flussmittelvermittelte Abscheidung von metallischem Glas

Verfahren und resultierende Gasturbinenmotorkomponente (40) mit einer schützenden Schicht aus metallischem Glas (14), die über einem Superlegierungssubstrat (12) abgeschieden worden ist. Über dem metallischen Glas kann eine weitere Schicht aus keramischem Isoliermaterial (42) abgeschieden worden sein. Das metallische Glas wirkt als Bindungsbeschichtung, um für Wärmeisolierung und mechanische Konformität zu sorgen. Das metallische Glas kann durch ein flussmittelvermitteltes Laserabscheideverfahren auf dem Substrat abgeschieden werden, wobei pulverisiertes Legierungsmaterial (18) zusammen mit pulverisiertem Flussmittelmaterial (20) geschmolzen wird. Das Flussmittelmaterial kann das Glasbildungsverfahren erleichtern, indem zu dem Verfestigungs-Irritationseffekt beigetragen wird und/oder eine aktive Kühlwirkung bereitgestellt wird.

Method for building a gas turbine engine component

A method, including: providing a layer of powder material (156) on a substrate (130); and traversing an energy beam (15) across the layer of powder material to form a cladding layer (10), wherein the cladding layer forms a layer of an airfoil. The traversing step includes: starting a first path (40) and a second path (44) of traversal of the energy beam from a common initiation point (48); forming a portion (60) of a first side wall (18) of the cladding layer and a first rib section (24) by traversing the energy beam along the first path and concurrently forming a portion (62) of a second side wall (16) of the cladding layer by traversing the energy beam along the second path; and creating not more than one initiation point (72, 96, 118) for each rib section (24, 26, 28) in the cladding layer.

Bildung und Reparatur von oxiddisperionsgehärteten Legierungen durch Legierungsschmelzen mit Oxideinspritzung

Schmelzenergie, veranschaulicht durch einen Bogen (24), wird an ein Metalllegierungsmaterial (22, 23) geliefert, um ein Schmelzbad (26) zu bilden. Ein Metalloxidmaterial (34) wird an das Schmelzbad geliefert (33) und darin verteilt. Die Schmelzenergie und die Oxidlieferungen werden gesteuert (44), um das Legierungsmaterial zu schmelzen, aber nicht, um das meiste des Metalloxidmaterials zu schmelzen. Die Lieferungen werden so gesteuert, dass die Schmelzenergie nicht von der Metalloxidlieferung abgefangen wird. Die Schmelzenergie kann gesteuert werden, um eine Temperatur des Schmelzbads zu erzeugen, die nicht den Schmelzpunkt des Metalloxids erreicht. Lieferungen der Schmelzenergie und des Oxids können sich abwechseln, so dass sie zeitlich nicht überlappen. Eine Vorrichtung (22) und ein Prozess (18, 19, 20) eines kalten Metallübergangs können zum Beispiel in Kombination mit einer Oxidpartikelimpulslieferungseinrichtung (42, 46) verwendet werden.

Method for solid state additive manufacturing

A method for forming an impact weld used in an additive manufacturing process. The method includes providing a wire having a powder filler metal core located within a sheath. The wire is then inserted within a conduit having an opening. Further, the method includes providing at least one energy pulse that interacts with the sheath to pinch off at least one segment of the wire, wherein the energy pulse causes propulsion of the segment toward a substrate with sufficient velocity to form an impact weld for welding the metal core to the substrate. In particular, the energy pulse is an electromagnetic pulse, a laser energy pulse or a high electric current pulse.

Verfahren zum Bearbeiten einer Komponente mit einem Energiestrahl

Ein Verfahren zum Bearbeiten einer Komponente (10) mit einem Energiestrahl (13) umfasst simultanes Scannen und Aufheizen eines ersten Teils (12) und eines zweiten angrenzenden Teils (14) der Komponente mit einem Energiestrahl (13). An einem Punkt oder einem Gebiet des Auseinanderlaufens der Teile der Komponente wird der Energiestrahl gesteuert, sich wiederholt zwischen den Teilen der Komponente hin und zurück zu bewegen. Dieses simultane Aufheizen der angrenzenden Teile (12, 14) der Komponente ist dafür ausgelegt, ein thermisch induziertes Verziehen der Komponente innerhalb einer vordefinierten Toleranz zu halten. Dieses Zweifachwegbearbeiten kann an einem Bett von verflüssigtem pulverigem Material durchgeführt werden, das ein pulveriges Metallmaterial und ein pulveriges Flussmaterial beinhaltet.

Füllgeflecht für Laserplattierung

Eine Beschichtungsanordnung (16), die aufweist: eine Lage (18) Haftschichtmaterial (20); und ein lichtdurchlässiges Wärmedämmschicht(TBC)-Geflecht (28), das ein TBC-Material (24) aufweist und in seiner Position relativ zur Lage Haftschichtmaterial befestigt ist. Die Beschichtungsanordnung kann über einem Superlegierungssubstratmaterial (12) angeordnet und mit einem Laserstrahl (62) geschmolzen werden, um die Wärmedämmschicht auf das Substrat metallurgisch zu binden.

Laservorprozessierung zur Stabilisierung von Hochtemperaturbeschichtungen und Oberflächen

Laservorprozessierung zur Stabilisierung von Hochtemperaturbeschichtungen und -oberflächen. Ein Verfahren beinhaltet das Schmelzen einer Oberfläche eines Metallsubstrats (2) mit einem Energiestrahl (22) zur Bildung eines Schmelzbades (24), das Kühlen und Erstarren lassen des Schmelzbades zu einer schmelzprozessierten Legierungsschicht (28), die mit dem Metallsubstrat verbunden ist, und das Beschichten der schmelzprozessierten Legierungsschicht mit einer Legierungsschutzschicht (4) zur Bildung eines beschichteten Substrats. Eine Flusszusammensetzung (18) kann auch auf der Oberfläche des Metallsubstrats abgeschieden werden, so dass das Schmelzprozessieren auch eine Schlackenschicht (30) bildet, die zumindest teilweise die schmelzprozessierte Legierungsschicht bedeckt. Ein Schutzmaterial (34), das eine Kohlenstoffquelle enthält, kann ebenfalls auf der Oberfläche des Metallsubstrats abgeschieden werden, so dass das Schmelzprozessieren eine mit Kohlenstoff angereicherte schmelzprozessierte Legierungsschicht ...

VERFAHREN ZUM SCHWEISSPLATTIEREN ÜBER ÖFFNUNGEN

Ein Verfahren umfasst Überbrücken einer verhältnismäßig größeren Öffnung (50) mit einer Stützstruktur (72) zur Unterteilung der verhältnismäßig größeren Öffnung in mehrere verhältnismäßig kleinere Öffnungen (78); Platzieren von Superlegierungspulver über den kleineren Öffnungen und in Kontakt mit der Stützstruktur; und Schmelzen des Superlegierungspulvers zur Bildung einer Plattierungsschicht (104), die die Öffnung überbrückt und mit der Stützstruktur metallurgisch verbunden ist.

Multipurpose single external seal filter assembly for metallic and ceramic tube filters with integral locking means

A filter assembly (60) for holding a filter element (28) within a hot gas cleanup system pressure vessel is provided, containing: a filter housing (62), said filter housing inner walls defining a joint (98), said walls defining an interior volume (67); a one piece, fail-safe/regenerator device (68) within the interior chamber (67) of the filter housing (62) having outer walls defining a joint (98') which mates with the filter assembly joint (98), containing outward-extending radial flanges (99 and 99') with mating holes (100 and 100') through both the housing (62) and fail-safe/regenerator device (68) for seating an essential sealing means (70) between the joints (98 and 98').

GAS TUNGSTEN ARC WELDING USING FLUX COATED ELECTRODES

A method of applying a weld using a gas tungsten arc welding procedure. A filler element is provided to a welding location. The filler element includes a first material used during formation of a weld, and a second material that is capable of producing a slag upon melting thereof. A welding arc provides heat that melts portions of first and second components and the filler element proximate to the welding location to form a weld pool. The second material melts and forms a slag, which flows to an outer surface of the weld pool and shields the weld pool from exposure to reactive elements in the atmosphere. Upon cooling of the weld pool, the weld pool solidifies to form a weld between the first component and the second component. 1. A method of applying a weld between components formed from superalloys in a gas turbine engine using a gas tungsten arc welding procedure comprising:placing a first component formed from a first superalloy in close proximity to a second component formed from a second superalloy to define a welding location between a first section of the first component and a second section of the second component;providing a filler element to the welding location, the filler element comprising at least a first material and a second material, the first material for use during formation of a weld between the first section of the first component and the second section of the second component, the first material comprising a third superalloy, the second material capable of producing a slag upon melting thereof;providing an electrical current to a non-consumable tungsten electrode in close proximity to the welding location to create a welding arc that provides heat that melts portions of the first and second components and the filler element proximate to the welding location; the first material liquefies and forms a weld pool with the melted portions of the first and second components; and', 'the second material forms a slag, which flows to an outer surface of ...

SUPERALLOY LASER CLADDING WITH SURFACE TOPOLOGY ENERGY TRANSFER COMPENSATION

A superalloy substrate, such as a turbine blade or vane, is fabricated or repaired by laser beam welding to clad one or more layers on the substrate. Laser optical energy is transferred to the welding filler material and underlying substrate to assure filler melting and adequate substrate surface wetting for good fusion. Energy transfer is maintained below a level that jeopardizes substrate thermal degradation. Optical energy transfer to the filler and substrate is maintained uniformly as the laser beam and substrate are moved relative to each other along a translation path by varying the energy transfer rate to compensate for localized substrate topology variations. 1. A method for cladding superalloy components , comprising:introducing filler material on a component superalloy substrate surface;focusing a laser beam on the filler material and substrate;transferring optical energy from the laser to the filler material and substrate that fuses the filler material to the substrate as a filler layer without causing thermal degradation to the substrate; andmoving the substrate and laser beam relative to each other while maintaining uniform energy transfer.2. The method of claim 1 , the maintaining uniform energy transfer step comprising varying optical energy transfer based on component surface topology.3. The method of claim 1 , the maintaining uniform energy transfer step comprising varying relative movement rate of the substrate and laser beam.4. The method of claim 1 , the maintaining uniform energy transfer step comprising varying laser power output.5. The method of claim 1 , the moving step further comprising rastering the laser beam and substrate relative to each other.6. The method of claim 5 , the rastering further comprising multi-dimensional rastering.7. The method of the maintaining uniform energy transfer step further comprising monitoring energy transfer in a closed feedback loop and varying energy transfer rate based on the monitored energy transfer.8. ...

FILLER ROTATED FRICTION STIR WELDING

A friction stir welding method including: feeding a filler material through a first passage in a friction stir weld tool and into a substrate during friction stir welding of the substrate; and rotating the filler material with respect to the substrate while feeding the filler material. In this method, heat generated by rotational frictional contact of the filler material contributes to plasticization of the filler material.

FLUX ENHANCED HIGH ENERGY DENSITY WELDING

A method of shielding a weld. The method includes melting a substrate to form a weld pool using a high energy density welding technique of plasma arc welding, laser beam welding, or electron beam welding; and delivering a flux to the weld pool to produce a slag effective to shield against atmospheric contaminants. 1. A method of shielding a weld , comprisingmelting a first substrate using a high energy density welding technique selected from a group consisting of plasma arc welding, laser beam welding, and electron beam welding;delivering a flux to a point of welding to form a weld pool comprising the melted first substrate, wherein the flux produces a slag effective to shield a weld bead from atmospheric contaminants.2. The method of claim 1 , wherein the flux also develops a flux shielding gas that shields the weld pool from the atmospheric contaminants.3. The method of claim 1 , comprising melting a second substrate using the high energy density welding technique and joining the first substrate to the second substrate by the high energy density welding technique claim 1 , wherein the weld pool comprises the melted second substrate.4. The method of claim 1 , wherein the weld is a full penetration weld claim 1 , and the method comprises forming a root surface slag on a weld pool root surface effective to shield the weld pool root surface from the atmospheric contaminants.5. The method of claim 1 , wherein the flux also performs at least one process selected from the group consisting of removing impurities from the weld pool claim 1 , deoxidizing the weld pool claim 1 , and contributing to a weld pool chemistry.6. The method of claim 1 , wherein the flux is delivered to the point of welding in parallel with the high energy density welding technique.7. The method of claim 1 , wherein a filler material is also delivered to the point of welding.8. The method of claim 7 , wherein the flux comprises a powder form and the flux is mixed with powder filler to form a powder ...

Aufbau und Reparatur von hohlen Bauteilen

Ein Verfahren zum Aufbauen oder Reparieren eines hohlen superlegierten Bauteils (20, 61) durch Bilden einer Öffnung (38, 62) in einer Wand (28) des Bauteils, Füllen des Hohlraums (22B, 64) hinter der Öffnung mit einem flüchtigen Trägerwerkstoff (34, 52, 54, 68), um ein Füllerpulver (36) über der Öffnung zu tragen, Führen eines Energiestrahls (42) über das Füllerpulver, um eine Abscheidung (44) zu bilden, die die Öffnung überspannt und verschließt, wobei die Abscheidung mit den Rändern (32, 62) der Öffnung verschmolzen ist. Das Füllerpulver weist mindestens Metall auf und kann ferner Flussmittel aufweisen. Das Trägermaterial kann Füllerpulver, einen Festkörper (54), einen Einsatz in Form eines Schaums (52), ein Flussmittelpulver (34) und/oder ein anderes Keramikpulver (68) aufweisen. Das Trägerpulver kann eine kleinere Korngröße aufweisen als das Füllerpulver.

Rasterartiges Laserschmelzen eines bogenförmigen Oberflächenpfads mit gleichförmiger Leistungsdichtenverteilung

Verfahren zum Fortführen einer Schmelzfront (55) entlang einem bogenförmigen Verlaufspfad (20) durch ein Muster (LP) von querlaufenden Laserabtastlinien (S1–S8) mit unterschiedlichen Längen. Mehrere Flächenbänder (B1–B8) unterteilen eine Breite des bogenförmigen Pfads konzeptuell. Die mehreren querlaufenden Abtastlinien verteilen die Laserenergie zwischen den Bändern mit einer vorbestimmten Gleichmäßigkeit, die eine relativ gleichförmige Leistungsdichte entlang der Schmelzfront bereitstellt. Die Abtastlinien können sich von einer schwächer gekrümmten Seite (24) des bogenförmigen Pfads durch ein Band (B4 oder B8) mit der größten Fläche zu einer stärker gekrümmten Seite (22) des Pfads erstrecken. Zumindest eine der Abtastlinien (S1, S8) kann alle Bänder durchqueren. Andere Abtastlinien sind kürzer und erstrecken sich um variierende Distanzen in die inneren Bänder hinein (B1–B3 oder B1–B7), wodurch die Leistungsdichte über die Bänder normalisiert wird.

Funktional gradiertes Wärmedämmschichtsystem

Funktional gradierte Wärmedämmschicht (30), die als eine Vielzahl von Schichten (34, 36, 44, 46) von Materialien ausgebildet ist, die durch einen Prozess der Pulverabscheidung abgeschieden werden, wobei sich die Zusammensetzung der verschiedenen Schichten über eine Dicke der Beschichtung ändert. Es kann ein Zusammensetzungsgradient innerhalb einer einzelnen Schicht (58) infolge des Auftriebs von keramischen Partikeln (62) innerhalb eines Schmelzebades (56) von Haftschichtmaterial (64) existieren. Der Prozess der Pulverabscheidung beinhaltet pulverisiertes Flussmittel (20), welches schmilzt, um während des Abscheidungsprozesses eine Schutzschicht aus Schlacke (28) zu bilden.

Verfahren zur Erzeugung einer strukturierten Haftschichtoberfläche

Verfahren Ausbilden einer strukturierten Haftschichtoberfläche (48) für ein Wärmedämmschichtsystem (44) einer Gasturbinenkomponente (34). Das Verfahren beinhaltet das selektive Schmelzen von Abschnitten einer Schicht von Legierungspartikeln (16) mit einem mit einem Muster versehenen Energiestrahl (20), um aufeinander folgende Schichten von Legierungsmaterial (16', 16'') zu bilden, bis ein gewünschtes geometrisches Merkmal (26) der Oberfläche erzielt worden ist. Das Energiestrahlmuster kann zwischen Schichten modifiziert werden, um eine vorstehende Hinterschneidung (28) in dem geometrischen Merkmal auszubilden. Der mit einem Muster versehene Energiestrahl kann gebildet werden, indem Laserenergie von einer Laserdiode (30) durch ein Patronenfilter (32) hindurch gelenkt wird. Partikel eines Flussmittels (18) können zusammen mit den Legierungspartikeln geschmolzen werden, um eine Schutzschicht aus Schlacke (22) über dem geschmolzenen und abkühlenden Legierungsmaterial auszubilden.

Laser Deposit Surface Control Using Select Fluxes and Electrochemistry

Method and apparatus (20) for forming a smooth metal surface (42) on a metal substrate (22). A melt pool (32) solidifying under a layer of molten electrolytic slag (34) on the metal substrate is subjected to a DC current (12) between a cathode (28) in contact with the molten slag and the substrate, thereby causing anodic leveling of the surface. The cathode may be buried in a layer of flux material (26) which is melted by a laser beam (30) traversing the substrate. A filler material (24) may be melted coincidently in an additive process. The flux material includes electrolytic, optically transmissive and viscosity reducing constituents.

INERTIA FRICTION WELD OF SUPERALLOY WITH ENHANCED POST WELD HEAT TREATMENT

A method of inertia friction welding a superalloy substrate, the method including: rotating and forcing a deposit material () against the superalloy substrate (); plastically deforming at least one of the deposit material () and the superalloy substrate () to form a weld joining the deposit material () to the superalloy substrate (), thereby forming an assembly; and heat-treating the assembly. Heat-treating includes: a post-weld intermediate stress-relief (ISR) treatment; a solutionizing treatment; and a precipitation hardening heat treatment. 1. A method of inertia friction welding a super alloy substrate , the method comprising:rotating and forcing a deposit material against the superalloy substrate;plastically deforming at least one of the deposit material and the superalloy substrate to form a weld joint joining the deposit material to the superalloy substrate, thereby forming an assembly; andheat-treating the assembly, wherein the heat-treating comprises a post-weld intermediate stress-relief (ISR) treatment, followed by a solutionizing treatment, followed by a precipitation hardening heat treatment.2. The method of claim 1 , comprising performing the ISR treatment at an ISR treatment temperature below a superalloy substrate solutionizing temperature.3. The method of claim 1 , comprising providing a joint residual stress reduction from before to after the ISR treatment of approximately 20%.4. The method of claim 1 , comprising providing a joint residual stress reduction from before to after the ISR treatment of approximately 90%.5. The method of claim 1 , comprising reducing a joint residual stress after the ISR treatment to less than 35% of a superalloy substrate yield strength.6. The method of claim 1 , comprising reducing a joint residual stress after the ISR treatment to less than 5% of a superalloy substrate yield strength.7. The method of claim 1 , comprising heating the assembly during the ISR treatment to an assembly ISR treatment temperature of at ...

SPLICE INSERT REPAIR FOR SUPERALLOY TURBINE BLADES

A damaged portion of a superalloy material turbine blade body is removed, forming an excavated recess. A repair splice is formed of a same material with similar mechanical structural properties, having a mating outer profile conforming to the corresponding recess profile. The repair splice is inserted and captured within the recess, so that the blade body and repair splice are mechanically interlocked. Given similarities in mechanical properties of both the blade body and the mechanically interlocked splice the repaired blade's overall mechanical structural properties are similar to those of an undamaged blade. The repair splice is affixed to the blade body so that the interlocking respective portions of each do not separate. Localized affixation and subsequent cosmetic blade surface repair can be performed with softer, low temperature application braze and weld alloys. 1. A repaired turbine blade comprising a blade body having an excavated recess and a mating , mechanically interlocking repair splice inserted and captured within the recess , with the repair splice affixed to the blade body for retention thereof.2. The repaired turbine blade of claim 1 , wherein the recess and repair splice have mating profiles that locally vary claim 1 , and only allow unidirectional insertion and withdrawal of the repair splice.3. The repaired turbine blade of claim 1 , wherein the recess comprises at least one through-slot passing fully through the blade body.4. The repaired turbine blade of claim 3 , wherein the through-slot cross-sectional profile locally varies and allows only unidirectional insertion and withdrawal of the mating repair splice.5. The repaired turbine blade of claim 3 , wherein the through-slot and repair splice are planar.6. The repaired turbine blade of claim 1 , wherein the recess comprises a blind recess formed partially within the blade body thickness for engagement with a mating projecting portion formed in the repair splice.7. The repaired turbine blade ...

PROJECTION RESISTANCE BRAZING OF SUPERALLOYS

Superalloy components are joined by mating a recess formed in one component with a corresponding projection formed in another component along a contact surface. The components are compressed along the contact surface and resistance heat brazed to each other. Current is passed between the components at a selected flow rate and application time until brazing alloy melting occurs along the contact surface, and they are mutually affixed to each other. When repairing a damaged surface portion of a superalloy material component, the damaged portion is removed to form an excavated recess. A repair splice is formed, preferably of a same material with similar mechanical structural properties, having a mating projection with profile conforming to the corresponding recess profile. The splice and substrate are resistance heat brazed under compression pressure until brazing alloy melting occurs along the contact surface, so that they are mutually affixed. 1. A joined superalloy component comprising:a superalloy substrate defining a recess having a recess profile;a mating superalloy splice having a splice projection captured within the substrate recess, with a projection profile conforming with the substrate profile along a contact surface within the recess; and interposing brazing alloy between the recess and repair splice along the contact surface;', 'compressing the substrate and splice projection together along the contact surface at a selected pressure;', 'conductively contacting the substrate and splice with separate electric resistance brazing electrodes; and', 'passing current at a selected flow rate and application time period through the substrate and splice projection between the electrodes until melting of the brazing alloy occurs along the contact surface, and ceasing further current flow after the substrate and splice projection are mutually affixed to each other., 'the substrate and splice affixed to each other along the contact surface by the process of electric ...

PROJECTION RESISTANCE WELDING OF SUPERALLOYS

Superalloy components are joined by mating a recess formed in one component with a corresponding projection formed in another component along a contact surface. The components are compressed along the contact surface and resistance heat welded to each other. Current is passed between the components at a selected flow rate and application time until localized melting occurs along the contact surface, and they are mutually affixed to each other. When repairing a damaged surface portion of a superalloy material component, the damaged portion is removed to form an excavated recess. A repair splice is formed, preferably of a same material with similar mechanical structural properties, having a mating projection with profile conforming to the corresponding recess profile. The splice and substrate are resistance heat welded under compression pressure until localized melting occurs along the contact surface, so that they are mutually affixed. 1. A joined superalloy component comprising:a superalloy substrate defining a recess having a recess profile;a mating superalloy splice having a splice projection captured within the substrate recess, with a projection profile conforming with the substrate profile along a contact surface within the recess; and compressing the substrate and splice projection together along the contact surface at a selected pressure;', 'conductively contacting the substrate and splice with separate electric resistance welding electrodes;', 'passing current at a selected flow rate and application time period through the substrate and splice projection between the electrodes until localized melting occurs along the contact surface, and ceasing further current flow after the substrate and splice projection are mutually affixed to each other., 'the substrate and splice affixed to each other along the contact surface by the process of electric resistance welding by2. The component of claim 1 , wherein the recess and splice projection conforming profiles form ...

SELECTIVE LASER MELTING / SINTERING USING POWDERED FLUX

An additive manufacturing process () wherein a powder () including a superalloy material and flux is selectively melted in layers with a laser beam () to form a superalloy component (). The flux performs a cleaning function to react with contaminants to float them to the surface of the melt to form a slag. The flux also provides a shielding function, thereby eliminating the need for an inert cover gas. The powder may be a mixture of alloy and flux particles, or it may be formed of composite alloy/flux particles. 1. A process comprising:placing a first layer of powder comprising alloy material and flux material on a surface;indexing an energy beam across the first layer of powder to selectively solidify a region of alloy under an overlying layer of slag;removing the slag;repeating the placing, indexing and removing steps with a pattern of indexing effective to form a desired component shape.2. The process of claim 1 , further comprising forming the layer of powder as a mixed layer of alloy particles and flux particles.3. The process of claim 2 , wherein a mesh size range of the alloy particles and a mesh size range of the flux particles overlap.4. The process of claim 1 , further comprising forming the layer of powder as a layer of composite alloy and flux particles.5. The process of claim 1 , wherein the alloy material comprises a composition beyond a zone of weldability defined on a graph of superalloys plotting titanium content verses aluminum content claim 1 , wherein the zone of weldability is upper bounded by a line intersecting the titanium content axis at 6 wt. % and intersecting the aluminum content axis at 3 wt. %6. The process of claim 5 , further comprising post weld heat treating the component shape without inducing reheat cracking.7. The process of performed without providing a protective cover of inert gas.8. The process of claim 1 , wherein the flux material is formulated to contribute to a deposit chemistry of the solidified region of alloy.9. The ...

DEPOSITION OF SUPERALLOYS USING POWDERED FLUX AND METAL

A method for depositing superalloy materials. A layer of powder () disposed over a superalloy substrate () is heated with an energy beam () to form a layer of superalloy cladding () and a layer of slag (). The layer of powder includes flux material and alloy material, formed either as separate powders or as a hybrid particle powder. A layer of powdered flux material () may be placed over a layer of powdered metal (), or the flux and metal powders may be mixed together (). An extrudable filler material () such as nickel, nickel-chromium or nickel-chromium-cobalt wire or strip may be added to the melt pool to combine with the melted powder to give the superalloy cladding the composition of a desired superalloy material. 1. A method comprising:cleaning a surface of a superalloy substrate, the superalloy substrate comprising a composition beyond a zone of weldability defined on a graph of superalloys plotting titanium content verses aluminum content, wherein the zone of weldability is upper bounded by a line intersecting the titanium content axis at 6 wt. % and intersecting the aluminum content axis at 3 wt. %;pre-placing or feeding a layer of powdered material comprising flux material and metal material onto the cleaned surface;melting the powdered material into a melt pool and floating slag layer, the melt pool having a composition of a desired superalloy material comprising a composition beyond the zone of weldability;allowing the melt pool and slag layer to cool and solidify, leaving a layer of the desired superalloy material clad over the superalloy substrate; andpost weld heat treating the clad superalloy material and substrate superalloy material without weld solidification cracking and strain age cracking.2. The method of claim 1 , further comprising:pre-placing the layer of powdered material as mixed flux and superalloy powder to a depth from 2.5 to 5.5 mm; andmelting the powdered material with laser energy at a power level from 0.6 to 2 kilowatts using ...

LASER RE-MELT REPAIR OF SUPERALLOYS USING FLUX

A method of repairing service-induced surface cracks () in a superalloy component (). A layer of powdered flux material () is applied over the cracks and is melted with a laser beam () to form a re-melted zone () of the superalloy material under a layer of slag (). The slag cleanses the melt pool of contaminants that may have been trapped in the cracks, thereby eliminating the need for pre-melting fluoride ion cleaning. Optionally, alloy feed material may be applied with the powdered flux material to augment the volume of the melt or to modify the composition of the re-melted zone. 1. A method comprising:applying powdered flux material to a surface of a superalloy substrate containing a defect;traversing an energy beam across the surface to form a re-melted zone in the substrate covered by an overlying slag layer; andallowing the re-melted zone to solidify under the slag layer to form a repaired surface free of the defect.2. The method of claim 1 , wherein the energy beam is a laser beam.3. The method of claim 1 , further comprising applying a filler material to the surface during the step of traversing an energy beam such that melted filler material is additive to the re-melted zone.4. The method of claim 3 , further comprising applying the filler material to the surface as powdered alloy material.5. The method of claim 4 , wherein a mesh size range of the powdered alloy material overlaps with a mesh size range of the powdered flux material.6. The method of claim 3 , further comprising applying the filler material as wire or strip material.7. The method of claim 1 , wherein the superalloy substrate comprises a composition beyond a zone of weldability defined on a graph of superalloys plotting titanium content verses aluminum content claim 1 , wherein the zone of weldability is upper bounded by a line intersecting the titanium content axis at 6 wt. % and intersecting the aluminum content axis at 3 wt. %.8. The method of claim 1 , further comprising applying heat to ...

LASER MICROCLADDING USING POWDERED FLUX AND METAL

A laser microcladding process utilizing powdered flux material (). A jet () of propellant gas containing powdered alloy material () and the powdered flux material are directed toward a substrate (). The powdered materials are melted by a laser beam () to form a weld pool () which separates into a layer of slag () covering a layer of clad alloy material (). The flux material deoxidizes the weld pool and protects the layer of clad alloy material as it cools, thereby allowing the propellant gas to be nitrogen or air rather than an inert gas. In one embodiment, the substrate and alloy materials are superalloys with compositions beyond the traditional zone of weldability. 1. A method comprising:using a propellant gas to direct powdered alloy material and powdered flux material toward a substrate;melting the powdered alloy material and powdered flux material with an energy beam to form a weld pool on the substrate; andallowing the weld pool to solidify and cool on the substrate as a layer of clad alloy material covered by a layer of slag.2. The method of claim 1 , further comprising selecting the propellant gas to be air or nitrogen.3. The method of claim 1 , further comprising selecting the powdered alloy material and the powdered flux material to have overlapping mesh size ranges.4. The method of claim 1 , further comprising melting the powdered alloy material and powdered flux material with a laser beam.5. The method of claim 4 , further comprising melting the powdered alloy material and powdered flux material with a diode laser beam.6. The method of claim 1 , further comprising:melting the powdered alloy material and powdered flux material with a laser beam having a beam diameter D; andrastering the laser beam by repeated changes in direction such that an amount of overlap O of the beam diameter at its locations of change of direction is between 25-90% of D.7. The method of claim 1 , further comprising forming the powdered alloy material and powdered flux material as ...

ADVANCED PASS PROGRESSION FOR BUILD-UP WELDING

A method of build-up welding including depositing of a weld material on a substrate in a series of weld passes in side-by-side relation to form a first weld layer, wherein substantially all weld passes forming the first weld layer are deposited in a first pass direction. Subsequently, a series of weld passes are deposited in side-by-side relation on the first layer to form a second weld layer, wherein substantially all weld passes forming the second weld layer are deposited in a second pass direction opposite to the first pass direction. Each weld pass of each layer may be deposited at a location where it is restrained on no more than one lateral side extending parallel to the weld pass. 1. A method of repairing or modifying a turbine engine component defining a substrate by performing a build-up welding operation on a welding surface of the substrate , the method comprising:providing a substrate defining a welding surface; depositing a plurality of sequential weld passes in side-by-side relation on the welding surface to form a first weld layer, wherein substantially all weld passes forming the first weld layer are deposited in a first pass direction; and', 'depositing a plurality of sequential weld passes in side-by-side relation on the first weld layer to form a second weld layer, wherein substantially all weld passes forming the second weld layer are deposited in a second pass direction opposite to the first pass direction., 'depositing a weld material on the welding surface, including2. The method of claim 1 , wherein the weld passes of the second weld layer are generally parallel to the weld passes of the first weld layer.3. The method of claim 1 , including one or more additional weld layers formed above the second weld layer claim 1 , wherein each successive weld layer is formed with substantially all weld passes deposited in a direction opposite from the direction of weld passes in an immediately preceding weld layer.4. The method of claim 1 , wherein each ...

METHOD FOR RESISTANCE BRAZE REPAIR

Metallic components, including superalloy components such as turbine vanes and blades, are joined or repaired by electric resistance with a high electrical resistivity brazing alloy composition. In some embodiments the brazing alloy comprises filler metal selected from the group consisting of nickel, iron, and cobalt base alloy and elements selected from the group consisting of phosphorous (P), boron (B), silicon (Si), germanium (Ge), sulfur (S), selenium (Se), carbon (C), tellurium (Te) and manganese (Mn). In performing the method of the present invention a high electrical resistivity brazing alloy composition is introduced within a substrate defect or interposed between two substrates that are to be joined. An electric current is passed through the brazing alloy until the alloy melts and bonds to the adjoining substrate. High resistivity of the brazing alloy concentrates heat generated by the current flow in the brazing alloy rather than in the substrate. 1. A method for resistance brazing of a metallic component , comprising:introducing a brazing alloy proximal a metallic substrate, the brazing alloy having a higher electrical resistivity than the substrate; andpassing electric current through the brazing alloy until the alloy melts and bonds to the substrate.2. The method of claim 1 , wherein the metallic substrate comprises a superalloy.3. The method of claim 2 , wherein the metallic substrate is selected from the group consisting of turbine blades and turbine vanes.4. The method of claim 1 , wherein the brazing alloy comprises filler metal selected from the group consisting of nickel claim 1 , iron claim 1 , and cobalt base alloy and elements selected from the group consisting of phosphorous (P) claim 1 , boron (B) claim 1 , silicon (Si) claim 1 , germanium (Ge) claim 1 , sulfur (S) claim 1 , selenium (Se) claim 1 , carbon (C) claim 1 , tellurium (Te) and manganese (Mn).5. The method of claim 4 , wherein the metallic substrate is selected from the group ...

PACK HEAT TREATMENT FOR MATERIAL ENHANCEMENT

A system and method of restoring material properties is disclosed. A subject material may have one or more of its material properties restored by contacting a packed bed of a reactive material contained within a container with the subject material in which material properties are desired to be restored. The packed bed and the subject material may be heated to restore the material properties. The packed bed may be formed from boron, silicon or other appropriate materials. An inert atmosphere system may have an argon injection system or a helium injection system in communication with the container. A deoxidizing system may be in communication with the container for creating a vacuum within the container or injecting hydrogen into the container. 1. A material treatment system , comprising:a packed bed of a reactive material contained within a container; anda heating system for applying heat to the container to heat the packed bed of reactive material.2. The material treatment system of claim 1 , wherein the packed bed is formed from the group consisting of boron and silicon.3. The material treatment system of claim 1 , further comprising an inert atmosphere system having an argon injection system in communication with the container for injecting argon into the container.4. The material treatment system of claim 1 , further comprising an inert atmosphere system having a helium injection system in communication with the container for injecting helium into the container.5. The material treatment system of claim 1 , further comprising a deoxidizing system in communication with the container for creating a vacuum within the container.6. The material treatment system of claim 1 , further comprising a deoxidizing system in communication with the container for injecting hydrogen into the container.7. The material treatment system of claim 1 , wherein the heating system for applying heat to the container to heat the packed bed of reactive material comprises at least one ...

EVALUATING A PROCESS EFFECT OF SURFACE PRESENTATION ANGLE

An apparatus () and method for evaluating an effect of a surface presentation angle (A). The apparatus supports a plurality of samples () separated by support plates () between end plates () in a shish kebab arrangement. A groove () is formed on each side of each support plate for receiving an edge of each respective sample at a different angle relative to an axis of impingement (). A clamping mechanism () holds the end plates, support plates and samples together in the fixed orientation exposing each sample surface at a different presentation angle, yet at the same distance from a process end effector (). The sample impingement surfaces are exposed to the process, and the effect of the different surface presentation angles is determined from the samples. Process variables to counter the effects of surface presentation angle may be identified and controlled. 1. An apparatus for evaluating an effect of a surface presentation angle , the apparatus comprising:opposed end plates and a support plate disposed there between;a first groove formed on a first side of the support plate for receiving an edge of a first sample therein at a first angle relative to an axis of impingement; anda second groove formed on a second side of the support plate opposed the first side for receiving an edge of a second sample therein at a second angle, different than the first angle, relative to the axis of impingement; anda clamping mechanism for urging the end plates together with the support plate and first and second samples disposed there between during a process to hold the samples at their respective different angles relative to the axis of impingement such that a surface presentation angle of the first sample is different than a surface presentation angle of the second sample.2. The apparatus of claim 1 , wherein relative movement between the apparatus and the axis of impingement defines a line of impingement along each sample; and further comprising:the first and second grooves being ...

REPAIR OF DIRECTIONALLY SOLIDIFIED ALLOYS

A method for epitaxial addition of repair material onto a process surface () of a directionally solidified component (). The component is positioned in a fluidized bed () to drift particles of a repair material over the process surface as laser energy () is rastered across the surface to melt the particles and to fuse repair material onto the entire surface simultaneously. The component is moved downward () in the bed in a direction parallel to the grain orientation in the component as material is added to the surface, thereby providing continuous epitaxial addition of material to the surface without recrystallization. 1. A method for epitaxial additional of repair material to a surface of a directionally solidified substrate material , the method comprising:mobilizing a continuous supply of particles of repair material onto an entire process surface of the substrate material;applying energy across the entire process surface in a manner effective to melt and fuse the repair material epitaxially onto the entire process surface simultaneously such that a solidification process interface of the fused particles progresses in a direction parallel to a grain orientation direction of the substrate material; andproviding relative motion between the continuous supply of repair material particles, a source of the energy, and the substrate material effective to maintain conditions for the continuous epitaxial addition of the repair material at the solidification process interface until a desired thickness of the repair material is added.2. The method of claim 1 , wherein the step of mobilizing a continuous supply of repair material particles comprises disposing the substrate material in a fluidized bed of the repair material particles.3. The method of claim 2 , further comprising using an inert gas as a mobilizing fluid in the fluidized bed.4. The method of claim 1 , wherein the step of mobilizing a continuous supply of repair material particles comprises applying the repair ...

STUD WELDING REPAIR OF SUPERALLOY COMPONENTS

Superalloy components are joined or repaired by mating a recess formed in one component substrate with a corresponding projection formed in another component along a contact surface and welding them together with a stud welding apparatus. A mating superalloy repair stud is formed with a stud projection whose profile conforms to the substrate recess profile along a corresponding contact surface. Both the stud and substrate are coupled to a stud welding apparatus, with the stud projection and substrate recess oriented in an opposed spaced relationship with a gap there between. The stud welding apparatus passes current between the stud projection and recess and forms an arc there between, to melt their respective opposed surfaces. The melted stud projection and substrate recess opposed surfaces are pressed into contact with each other with the stud welding apparatus, forming a weld there between. 1. A joined superalloy component comprising:a superalloy substrate defining a recess having a recess profile;a mating superalloy stud having a stud projection captured within the substrate recess, with a projection profile conforming with the substrate profile along a contact surface within the recess; and inserting the stud and substrate in a stud welding apparatus;', 'orienting the stud projection and substrate recess in an opposed spaced relationship with a gap there between;', 'passing current between the stud projection and recess and forming an arc there between with the stud welding apparatus;', 'melting the opposed stud projection and substrate recess opposed surfaces; and', 'pressing the melted stud projection and substrate recess opposed surfaces into contact with each other and forming a weld there between., 'the substrate and stud affixed to each other along the contact surface by the process of stud welding by2. The component of claim 1 , wherein the stud welding apparatus passes current with apparatus selected from the group consisting of a direct current power ...

ELECTROSLAG AND ELECTROGAS REPAIR OF SUPERALLOY COMPONENTS

Superalloy component castings, such as turbine blades and vanes, are fabricated or repaired by an electroslag or electrogas welding process that at least partially replicates the crystal structure of the original cast substrate in a cast-in-place substrate extension. The process re-melts the base substrate surface and grows it with new molten filler material. As the base substrate and the filler material solidify, the newly formed “re-cast” component has a directionally solidified uniaxial substrate extension portion that at least in part replicates the crystalline structure of the base substrate. The “re-cast” component can be fabricated with a unified single crystal structure, including the extension portion. In other applications, a substrate extension can replicate a directionally solidified uniaxial crystal structure of an original base substrate casting. Polycrystalline substrate base structures can be re-cast with a substrate extension that replicates base substrate crystals that are most parallel to the uniaxial casting direction. 1. A superalloy component comprising a base substrate casting having a first crystal structure and a cast-in-place directionally solidified uniaxial substrate extension bonded to the base substrate , the substrate extension having a second crystal structure that is at least a partially replicated extension of the first crystal structure.2. The component of claim 1 , further comprising the base substrate having a directionally solidified uniaxial first crystal structure claim 1 , with the substrate extension second crystal structure being a replicated extension of the first crystal structure.3. The component of claim 2 , wherein the first and second crystal structures comprise a unified single crystal structure.4. The component of claim 1 , wherein the base substrate first crystal structure comprises a polycrystalline structure and the second crystal structure replicates crystals in the substrate that are most parallel to the ...

AUTOMATED SUPERALLOY LASER CLADDING WITH 3D IMAGING WELD PATH CONTROL

Superalloy components, such as service-degraded turbine blades and vanes, are clad by laser beam welding. The welding/cladding path, including cladding application profile, is determined by prior, preferably real time, non-contact 3D dimensional scanning of the component and comparison of the acquired dimensional scan data with specification dimensional data for the component. A welding path for cladding the scanned component to conform its dimensions to the specification dimensional data is determined. The laser welding apparatus, preferably in cooperation with a cladding filler material distribution apparatus, executes the welding path to apply the desired cladding profile. In some embodiments a post-weld non-contact 3D dimensional scan of the welded component is performed and the post-weld scan dimensional data are compared with the specification dimensional data. Preferably the welding path and/or cladding profile application are modified in a feedback loop with the pre- and/or post-welding 3D dimensional scanning. 1. A system for cladding a turbine component having a substrate and a surface with a filler layer , comprising:a work table apparatus for receipt of a turbine component substrate thereon, having a work table interface;a laser profilometer apparatus for scanning a surface of the turbine component substrate and acquiring component dimensional data, having:a scanning laser generating a scanning laser beam for reflecting optical energy off the turbine component surface;at least one movable scanning mirror intercepting the scanning laser beam, for orienting the scanning laser beam on the substrate surface; anda laser profilometer apparatus drive system interface coupled to the scanning laser and the at least one movable scanning mirror, for causing relative movement there between;a cladding filler material distribution apparatus for introducing filler material on the component substrate;a laser welding apparatus for transferring optical energy to the ...

FLUX-ASSISTED DEVICE ENCAPSULATION

There are provided processes for encapsulating a device on a substrate utilizing a flux material . The incorporation of the flux material substantially reduces oxide formation and porosity in the cladding that encapsulates the encapsulated device 1. A deposition process comprising:disposing a device at least partially within an encapsulating material and a molten flux material on a substrate;cooling the encapsulating material and the molten flux material to form a cladding that encapsulates the device and a slag layer formed over the cladding; andremoving the slag layer to leave behind the cladding that encapsulates the device.2. The process of claim 1 , wherein the disposing is done by:adding the encapsulating material, the device, and the flux material to the substrate; andmelting the encapsulating material and the flux material via an effective amount of energy from an energy source.3. The process of claim 2 , wherein at least a portion of a depth of the substrate is also melted during the melting.4. The process of claim 1 , wherein the energy source comprises a laser energy source claim 1 , and wherein the encapsulating material and the flux material are provided in the form of a member selected from the group consisting of a powder claim 1 , a wire claim 1 , a fabric claim 1 , and a pre-form.5. The process of claim 1 , wherein the substrate and the encapsulating material both comprise a material selected from the group consisting of a superalloy material and a ceramic material.6. The process of claim 1 , wherein the cladding claim 1 , comprises less than 5 vol % of oxides and less than 5 vol. % porosity.7. The method of claim 1 , wherein the device comprises a wire or an instrument configured to monitor a property selected from the group consisting of temperature claim 1 , heat flux claim 1 , strain claim 1 , pressure claim 1 , and a load claim 1 , or comprises a device configured to alter the substrate by at least one of heating claim 1 , cooling claim 1 , or ...

Slag free flux for additive manufacturing

A flux ( 55 ) for superalloy laser welding and additive processing ( 20, 50 ), including constituents which decompose when heated in a laser induced plasma or to a melt temperature of the superalloy ( 42 ), creating one or more gases ( 46 ) that blanket the melt to protect it from air, while producing not more than 5 wt. % of slag relative to the weight of the flux. Embodiments may further include compounds providing one or more functions of surface cleaning, scavenging of impurities in the melt, and elemental additions to the superalloy.

LASER CORRECTION OF METAL DEFORMATION

Apparatus (A-C) and a method for determining and correcting a deformation in an article (). An energy beam () such as a laser beam is directed to an area (A-C) to reverse () an existing deformation or to control deformation during additive fabrication (). Two sectionally curved areas of a deformation (A/C, ) may be heated simultaneously to flatten a bulge between them. An existing or developing deformation may be determined by surface scanning () and/or a deformation may be determined predictively to pro-actively correct and prevent it while building or rebuilding a portion of the article by additive fabrication. 1. A method comprising:determining a deformation comprising a departure from a specified shape of a surface of a metal article;directing a first energy beam to a first sectionally curved area of the determined deformation of the metal surface as seen in a sectional view thereof; andcontrolling the first energy beam to correct the deformation by a compensating thermal effect in a thickness of the metal article that reduces a curvature of the first curved area.2. The method of claim 1 , further comprising directing the first energy beam to scan the first sectionally curved area in a series of sets of concentric tracks claim 1 , each set overlapping an adjacent set.3. The method of claim 1 , wherein the deformation comprises an existing bulge in the surface claim 1 , and further comprising directing the first energy beam to follow a series of raster scan tracks along and parallel to a periphery of the bulge.4. The method of claim 3 , wherein the series of raster scan tracks heats opposite sides of the periphery effectively simultaneously.5. The method of claim 1 , wherein the deformation comprises an existing bulge in the surface claim 1 , and further comprising directing the first energy beam to scan opposite sides of a periphery of the bulge to plastically straighten the periphery and flatten the bulge.6. The method of claim 1 , wherein the deformation ...

OPTIMIZATION OF MELT POOL SHAPE IN A JOINING PROCESS

There is provided a process for welding that includes applying a first amount of energy 118 and a second amount of energy 122 to a substrate 105 effective to provide a melt pool 100 comprising a curvilinear and/or curviplanar solid/liquid interface 103 about at least a trailing edge region 106 and within a depth (D) of the melt pool 100.

METHOD FOR FORMING THREE-DIMENSIONAL ANCHORING STRUCTURES

A method for texturing a surface to form anchoring structures for a coating. The method includes: traversing an energy beam () along a path () on a solid substrate surface () to cause a melt pool () to move along the path; controlling power and motion parameters of the energy beam effective to establish a wave front () in the melt pool; and terminating the energy beam at an end () of the path when the wave front contains sufficient energy to create a protrusion () of material above the surface at the end of the path as the melt pool solidifies. 1. A method , comprising:traversing an energy beam along a path on a solid substrate surface to cause a melt pool to move along the path;controlling power and motion parameters of the energy beam effective to establish a wave front in the melt pool; andterminating the energy beam at an end of the path when the wave front contains sufficient energy to create a protrusion of material above the surface at the end of the path as the melt pool solidifies.2. The method of claim 1 , further comprising forming the protrusion over adjacent unmelted solid substrate claim 1 , and solidifying the protrusion over the adjacent unmelted solid substrate.3. The method of claim 1 , further comprising moving the energy beam across the solid substrate surface in only one direction of travel along a straight line claim 1 , and forming a divot in the solid substrate surface during the traversal that is elongated in the direction of travel of the energy beam.4. The method of claim 1 , further comprising maintaining a constant power output of the energy beam during the traversal.5. The method of claim 1 , further comprising positioning the energy beam so that it points into a direction of travel of the energy beam.6. The method of claim 1 , further comprising providing an additional mechanical push to the melt pool to help form the protrusion.7. The method of claim 6 , wherein the additional mechanical push comprises an assist gas configured to push ...

Method for forming three-dimensional anchoring structures on a surface

A method including: forming a melt pool ( 16 ) on a solid surface ( 12 ); applying an energy beam ( 10 ) to melt solid material ( 18 ) adjacent the melt pool; controlling the energy beam such that the melting of the solid material adjacent the melt pool creates a wave front ( 22 ) in the melt pool effective to form a protrusion ( 20 ) of material upon solidification.

APPARATUS FOR PRODUCTION OF FILLER PACKETS FOR SOLID FREEFORM FABRICATION

A hopper () holds a metal and flux powder (). A filler tube () conveys the powder from the hopper. Compressed gas () is injected into the powder to fluidize and convey the powder through the filler tube. The hopper may be vibrated () to prevent clumping. A gas permeable envelope () surrounds the filler tube and is filled with powder as it moves off the end of the filler tube. The gas escapes from the permeable envelope. Feed mechanisms () may feed gas permeable sheets () over opposite sides of the filler tube. A seaming device (A-B, A-B) may seam the sheets along their edges to form the gas permeable envelope surrounding the filler tube. Closing () and cutting () machines close and cut the envelope, forming a packet () containing the powder. 1. An apparatus for production of a filler packet for additive manufacturing , the apparatus comprising:a hopper for holding a metal powder;a gas permeable envelope that is impermeable by the powder;a filler tube from the hopper inserted into the gas permeable envelope; anda gas source that provides a compressed gas to the hopper;wherein the powder flows from the hopper through the filler tube with the compressed gas, and the compressed gas escapes the envelope while the powder is retained by the envelope.2. The apparatus of claim 1 , further comprising a vibration device on the hopper that fluidizes the powder.3. The apparatus of claim 1 , further comprising a feed mechanism that draws the envelope distally over the filler tube and away from an open end of the filler tube as the envelope fills with the powder.4. The apparatus of claim 3 , wherein the envelope is formed from a gas permeable tube of sheet material surrounding the filler tube claim 3 , and further comprising a cutting and closure machine that closes a first end of the envelope before a filling thereof claim 3 , closes a second end of the envelope after the filling thereof claim 3 , and cuts the second end of the envelope away from the tube of sheet material.5. The ...

FLUX FOR LASER WELDING

Flux compositions adapted for use in laser welding, repair and additive manufacturing applications. Flux compositions contain 5 to 60 percent by weight of an optically transmissive constituent, 10 to 70 percent by weight of a viscosity/fluidity enhancer, 0 to 40 percent by weight of a shielding agent, 5 to 30 percent by weight of a scavenging agent, and 0 to 7 percent by weight of a vectoring agent, in which the percentages are relative to a total weight of the flux composition. Also disclosed are processes involving melting of a superalloy material in the presence of a disclosed flux composition to form a melt pool covered by a layer of molten slag, and allowing the melt pool and the molten slag to cool and solidify to form a superalloy layer covered by a layer of solid slag. 1. A flux composition , comprising:5 to 85 percent by weight of a metal oxide, a metal silicate, or both;10 to 70 percent by weight of a metal fluoride; and1 to 30 percent by weight of a metal carbonate, relative to a total weight of the composition, wherein:the flux composition does not contain substantial amounts of iron; and{'sub': 2', '2', '2, 'the flux composition does not contain substantial amounts of LiO, NaO or KO.'}2. The composition of claim 1 , comprising:{'sub': 2', '2', '2', '2', '5', '2', '2, '15 to 30% by weight of at least one selected from the group consisting of CaO, CaF, MgO, MnO, MnO, NbO, NbO, NbO, ZrOand TiO,'}relative to a total weight of the composition.3. The composition of claim 1 , comprising:5 percent or less by weight of at least one selected from the group consisting of titanium, a titanium alloy, titanium oxide, titanite, aluminum, an aluminum alloy, aluminum carbonate, dawsonite, a nickel titanium alloy, zirconium and a zirconium alloy,relative to a total weight of the composition.4. The composition of claim 1 , comprising at least two metal carbonates.5. The composition of claim 1 , comprising CaCO claim 1 , MgCOand MnCO.6. The composition of claim 1 , ...

Flux sheet for laser processing of metal components

A flux sheet ( 20 A) and method of using the flux sheet to restore a surface ( 24 ) of a metal substrate ( 26 ). A laser beam ( 32 ) is directed onto the flux sheet to melt it and the surface, then allowed to cool and solidify to produce a restored surface. The flux sheet may be formulated to optically transmit at least 40% of electromagnetic energy from a laser onto the substrate surface. The flux sheet contains a flux composition that may include: a metal oxide, a metal silicate, or both; a metal fluoride; and a metal carbonate. The flux composition may limit the content of certain elements and compounds such as Fe, Li 2 O, Na 2 O and K 2 O. The flux composition may include constituents providing air shielding, contaminant scavenging, viscosity/fluidity enhancement, and optical transmission of laser energy through the flux sheet.

METHOD FOR CREATING A TEXTURED BOND COAT SURFACE

A method for forming a textured bond coat surface () for a thermal barrier coating system () of a gas turbine component (). The method includes selectively melting portions of a layer of alloy particles () with a patterned energy beam () to form successive layers of alloy material (″) until a desired surface geometric feature () is achieved. The energy beam pattern may be indexed between layers to form a protruding undercut () in the geometric feature. The patterned energy beam may be formed by directing laser energy from a diode laser () through a cartridge filter (). Particles of a flux material () may be melted along with the alloy particles to form a protective layer of slag () over the melted and cooling alloy material.

FUNCTIONALLY GRADED THERMAL BARRIER COATING SYSTEM

A functionally graded thermal barrier coating () formed as a plurality of layers () of materials deposited by a powder deposition process wherein the composition of the various layers changes across a thickness of the coating. A composition gradient may exist within a single layer () due to the buoyancy of ceramic particles () within a melt pool () of bond coat material (). The powder deposition process includes powdered flux material () which melts to form a protective layer of slag () during the deposition process. 1. A method comprising:depositing powder comprising particles of a bond coat material and particles of a flux material onto a substrate;melting the powder with an energy beam to form a layer of melted bond coat material covered by a layer of slag on the substrate;allowing the melted bond coat material to cool and solidify under the layer of slag to form a coating on the substrate; andremoving the layer of slag.2. The method of claim 1 , further comprising depositing the powder as a layer of the bond coat material particles on the substrate and a layer of the flux material particles on the layer of the bond coat material particles.3. The method of claim 2 , further comprising depositing the layer of bond coat material particles to be no more than 1 mm thick and the layer of flux material particles to be at least 3 mm thick.4. The method of claim 2 , further comprising depositing the layer of bond coat material particles to be 1-4 mm thick and the layer of flux material particles to be at least 5 mm thick.5. The method of claim 1 , further comprising:{'claim-ref': {'@idref': 'CLM-00001', 'claim 1'}, 'repeating the steps of a plurality of times to build the coating to a desired thickness in a plurality of layers;'}including particles of an additional material in the powder for at least some of the layers of the coating; andchanging a ratio of the particles of the additional material to particles of the bond coat material between at least some of the layers ...

REPAIR OF A SUBSTRATE WITH COMPONENT SUPPORTED FILLER

In a method of repairing a component substrate (), especially a substrate () composed of a superalloy such as a nickel based superalloy, a portion of the substrate () at a distressed region () to be repaired is removed forming a repair opening () through the substrate (). The repair opening () is adjacent to an internal cavity () of the component (). The cavity () is filled with a filler material () such as a powdered metal alloy having a composition corresponding to that of the substrate (). Heat is then applied to the filler material () and across the repair opening () to melt the filler material, which is allowed to cool to form a repair deposit () fused to the substrate () and across the opening (). Any un-consumed filler material () is subsequently removed from the cavity (). 1. A method of repairing a distressed region of a substrate of a component with a filler material supported within the component , comprising:providing a component for repair wherein the component has a distressed region on an external substrate adjacent to an internal cavity of the component;forming a repair opening at the distressed region and through the external substrate;supporting a filler material in the repair opening;applying heat across the filler material in the repair opening to melt the filler material in the repair opening;allowing the melted filler material in the repair opening to cool and solidify to form a repair deposit across the repair opening; and,removing any unconsumed filler material from the internal cavity of the component through an opening in the component in fluid communication with the internal cavity.2. The method of claim 1 , further comprising controlling the heat across to repair opening such that a sufficient amount of filler material is melted and when cooled the repair deposit has a thickness corresponding to a thickness of the substrate.3. The method of claim 1 , wherein the substrate is composed of a metal alloy and the filler material is composed of ...

LASER MELT PARTICLE INJECTION HARDFACING

A method for hardfacing a surface including: depositing a powder () having alloy particles onto a surface () of a substrate (); rastering a laser beam () across the surface to melt the powder and to form a weld pool () having a width (); directing particles () of a material exhibiting a different property than the substrate into the weld pool in a spray pattern having a width less than the width of the weld pool; and establishing the rastering and directing steps such that material circulation within the weld pool is effective to distribute the particles in the weld pool into a pattern having a width greater than the width of the spray pattern prior to re-solidification of the weld pool. 1. A method comprising:depositing a powder comprising alloy particles onto a surface of a substrate;rastering a laser beam across the surface to melt the powder and to form a weld pool comprising a width;directing particles of a material exhibiting a different property than the substrate into the weld pool in a spray pattern having a width less than the width of the weld pool; andestablishing the rastering and directing steps such that material circulation within the weld pool is effective to distribute the directed particles in the weld pool into a pattern having a width greater than the width of the spray pattern prior to re-solidification of the weld pool.2. The method of claim 1 , wherein the substrate comprises a superalloy material claim 1 , and further comprising:selecting the powder to comprise alloy particles comprising at least one superalloy material and particles comprising a flux material, wherein melted flux material circulating upward in the weld pool forms a protective slag; andremoving the protective slag upon solidification to reveal the directed particles embedded in re-solidified superalloy material.3. The method of claim 2 , further comprising establishing the rastering and directing steps such that the relative widths of the spray pattern and the weld pool are ...

BUILDING AND REPAIR OF HOLLOW COMPONENTS

A method of building or repair of a hollow superalloy component () by forming an opening () in a wall () of the component; filling a cavity (B, ) behind the opening with a fugitive support material () to support a filler powder () across the opening; traversing an energy beam () across the filler powder to form a deposit () that spans and closes the opening; in which the deposit is fused to the edges () of the opening. The filler powder includes at least metal, and may further include flux. The support material may include filler powder, a solid (), a foam () insert, a flux powder () and/or other ceramic powder (). Supporting powder may have a mesh size smaller than that of the filler powder. 1. A method comprising:disposing a supporting element in a cavity of a component below an opening in a wall of the component;supporting a filler material comprising a metal powder on the supporting element across the opening;applying heat to the filler material to melt it across the opening;allowing the melted filler material to solidify to form a metal deposit across the opening; and,removing the supporting element and any unconsumed filler material.2. The method of claim 1 , further comprising disposing the supporting element in a cavity of a superalloy gas turbine blade wherein the opening is at a tip of the blade claim 1 , and wherein the metal deposit forms a blade tip cap.3. The method of claim 2 , further comprising forming a radially extending squealer ridge around a periphery of the tip cap by additive welding.4. The method of claim 1 , further comprising removing a distressed portion of the wall to form the opening across which the deposit forms a repair.5. The method of claim 1 , wherein the wall is made of a superalloy material claim 1 , and the filler material comprises constituents of the superalloy and a flux material.6. The method of claim 1 , wherein the wall is made of a superalloy material claim 1 , the metal powder comprises a first subset of constituents of ...

LASER ADDITIVE MANUFACTURE OF THREE-DIMENSIONAL COMPONENTS CONTAINING MULTIPLE MATERIALS FORMED AS INTEGRATED SYSTEMS

Methods for laser additive manufacture are disclosed in which a plurality of powder layers ( and ) are delivered onto a working surface (A) to form a multi-powder deposit containing at least two adjacent powders layers in contact, and then applying a first laser energy () to a first powder layer () and a second laser energy () to a second powder layer () to form a section plane of a multi-material component. The multi-powder deposit may include a flux composition that provides at least one protective feature. The shapes, intensities and trajectories of the first and second laser energies may be independently controlled such that their widths are less than or equal to widths of the first and second powder layers, their intensities are tailored to the compositions of the powder layers, and their scan paths define the final shape of the multi-material component. 1. A method , comprising:delivering a plurality of powder layers onto a working surface to form a multi-powder deposit comprising at least two adjacent powder layers; andconcurrently applying a first laser energy of a first intensity to a first powder layer and a second laser energy of a second laser intensity to a second powder layer to form a section plane of a multi-material component in which shapes and contents of the section plane are defined at least in part by respective shapes and contents of the plurality of powder layers,wherein a flux composition contained in the multi-powder deposit forms at least one slag layer covering at least a portion of the section plane.2. The method of claim 1 , further comprising:repeating the delivering and applying steps for successive section planes to fabricate the multi-material component.3. The method of claim 1 , wherein:the first powder layer comprises a metal powder, and the second powder layer comprises a ceramic powder;the first laser energy is directed to follow a first scan path parallel to a perimeter of the first powder layer, causing the metal powder to ...

METHODS AND PREFORMS TO MASK HOLES AND SUPPORT OPEN-SUBSTRATE CAVITIES DURING LASER CLADDING

This invention relates to methods in which a protective material () is introduced into a metallic component, or is used to block a hole () in the metallic component, a filler material () is pre-placed or directed to an external surface of the metallic component, the filler material is heated with at least one energy beam () to melt or sinter a metal powder () contained in the filler material to form a cladding layer (), and the protective material is removed from the metallic component, such that the protective material contains, or generates upon being heated, a protective substance. The present invention also relates to preforms () containing an upper section () containing a powdered metal () and a flux (), and a lower section () containing a protective material (), such that the protective material contains, or generates upon being heated, a protective substance. 1. A method , comprising:introducing a protective material into an opening in a metallic component, such that a filler material pre-placed or directed to an external surface of the metallic component is supported by the protective material;heating the filler material with at least one energy beam to melt a metal powder contained in the filler material, thereby forming a melt pool supported by the protective material;allowing the melt pool to cool and solidify to form a metal layer fused to the external surface; andremoving the protective material from the metallic component,wherein the protective material contains, or generates upon being heated during the heating of the filler material, a protective substance.2. The method of claim 1 , wherein the protective material comprises a flux material.3. The method of claim 1 , wherein the protective material comprises at least one of:an inorganic compound selected from the group consisting of a metal oxide, a metal carbonate, a metal halide, a metal silicate, a metal borate, a metal fluoride, a metal fluoroborate, and mixtures thereof, andan organic compound ...

GAS TURBINE ENGINE COMPONENT WITH PERFORMANCE FEATURE

A gas turbine engine component (), including: a surface () subject to loss caused by a wear instrument during operation of the component in a gas turbine engine and a performance feature () associated with the surface. The surface and the performance feature interact in a manner that changes with the loss such that a change in performance of the gas turbine engine resulting from the loss is mitigated. 1. A gas turbine engine component , comprising:a surface subject to loss caused by a wear instrument during operation of the component in a gas turbine engine; anda performance feature associated with the surface;wherein the surface and the performance feature interact in a manner that changes with the loss such that a change in performance of the gas turbine engine resulting from the loss is mitigated.2. The gas turbine engine component of claim 1 , further comprising a plurality of performance features associated with the surface that are distributed in a pattern and that vary in at least one of population density claim 1 , depth of a top of the performance feature below the surface claim 1 , and a diameter of the performance feature.3. The gas turbine engine component of claim 1 , wherein the performance feature presents a contour to the wear instrument claim 1 , and wherein the contour changes with further loss.4. The gas turbine engine component of claim 1 , wherein the component comprises a component material claim 1 , and wherein the performance feature comprises a performance feature material that is less susceptible to loss due to the wear instrument than a material of the component material.5. The gas turbine engine component of claim 4 , wherein the wear instrument comprises a flow of hot gases and the interaction comprises anchoring a separation location where the flow of hot gases separates from the gas turbine engine component.6. The gas turbine engine component of claim 4 , wherein the wear instrument comprises a flow of hot gases and the interaction ...

GAS TURBINE ENGINE COMPONENT WITH PERFORMANCE FEATURE

A gas turbine engine component (), including: a surface () subject to loss caused by a wear instrument during operation of the component in a gas turbine engine and a performance feature () associated with the surface. The surface and the performance feature interact in a manner that changes with the loss such that a change in performance of the gas turbine engine resulting from the loss is mitigated. 1. A gas turbine engine component , comprising:a surface subject to loss caused by a wear instrument during operation of the component in a gas turbine engine; anda performance feature associated with the surface;wherein the surface and the performance feature interact in a manner that changes with the loss such that a change in performance of the gas turbine engine resulting from the loss is mitigated.2. The gas turbine engine component of claim 1 , wherein before any loss the performance feature is set apart from the surface.311. The gas turbine engine component of claim claim 1 , wherein the performance feature comprises a flowable material that is released upon exposure and which flows onto the surface upon the exposure claim 1 , wherein the gas turbine engine component comprises a seal element claim 1 , wherein the wear instrument comprises a sealing surface of an adjacent component claim 1 , wherein the interaction comprises physical contact between the seal element and the sealing surface claim 1 , and wherein the flowable material comprises a sealant.411. The gas turbine engine component of claim claim 1 , wherein the performance feature comprises a flowable material that is released upon exposure and which flows onto the surface upon the exposure claim 1 , wherein the gas turbine engine component comprises a bearing claim 1 , wherein the wear instrument comprises a bearing surface of an adjacent component claim 1 , wherein the interaction comprises physical contact between the bearing and the bearing surface claim 1 , and wherein the flowable material ...

METHOD OF LASER PROCESSING OF VOLATILE ALLOYS

The present invention relates to flux compositions and methods for laser processing volatile alloys. A flux composition contains a metal oxide, a metal silicate, or both; a shielding agent which forms at least one gas upon heating; and a plasma-generating agent, but not a metal fluoride. A process involves applying an energy beam () to a flux composition () such that the flux composition reacts to form a plasma () and a shielding gas (). An amount of energy applied to the flux composition is controlled to convert the flux composition into a molten slag blanket () in the presence of the shielding gas without completely melting an alloy material () situated below the flux composition. The molten slag blanket then heats the alloy material by thermal conduction in the presence of the shielding gas to form a pressurized melt pool () of the alloy material, which cool and solidifies. 1. A flux composition , comprising:a metal oxide, a metal silicate, or both;a shielding agent which decomposes upon heating to form at least carbon monoxide, carbon dioxide, or a mixture thereof; anda plasma-generating agent,wherein the flux composition does not comprise a metal fluoride.2. The flux composition of claim 1 , comprising:{'sub': 2', '3', '2', '2', '3', '2', '2', '2', '3', '2', '3', '2', '2', '2', '2', '3', '2', '3', '2', '2', '3', '2', '3, 'at least one selected from the group consisting of AlO, SiO, ScO, TiO, VO, CrO, YO, ZrO, NbO, HfO, LaO, CeO, CeO, NaSiOand KSiO;'}a metal carbonate; and{'sub': 2', '2', '2, 'at least one selected from the group consisting of LiO, NaO and MgO,'}wherein the flux composition does not comprise a fluoride-containing compound.3. The flux composition of claim 1 , comprising:{'sub': 2', '3', '2', '3', '2', '3', '2', '2', '2', '3', '2', '3', '2, 'at least one selected from the group consisting of ScO, CrO, YO, ZrO, HfO, LaO, CeOand CeO;'}{'sub': 3', '2', '3', '3', '3', '2', '3', '2', '3', '3', '3', '3', '2', '3', '3, 'at least one selected from the ...

METHOD FOR BUILDING A GAS TURBINE ENGINE COMPONENT

A method, including: providing a layer of powder material () on a substrate (); and traversing an energy beam () across the layer of powder material to form a cladding layer (), wherein the cladding layer forms a layer of an airfoil. The traversing step includes: starting a first path () and a second path () of traversal of the energy beam from a common initiation point (); forming a portion () of a first side wall () of the cladding layer and a first rib section () by traversing the energy beam along the first path and concurrently forming a portion () of a second side wall () of the cladding layer by traversing the energy beam along the second path; and creating not more than one initiation point () for each rib section () in the cladding layer. 1. A method , comprising:providing a layer of powder material on a substrate; and starting a first path and a second path of traversal of the energy beam from a common initiation point;', 'forming a portion of a first side wall of the cladding layer and a first rib section by traversing the energy beam along the first path and concurrently forming a portion of a second side wall of the cladding layer by traversing the energy beam along the second path; and', 'creating not more than one initiation point for each rib section in the cladding layer., 'traversing an energy beam across the layer of powder material to form a cladding layer, wherein the cladding layer forms a layer of an airfoil, the traversing comprising2. The method of claim 1 , wherein the substrate comprises a blade platform claim 1 , the method further comprising depositing a first cladding layer onto the blade platform.3. The method of claim 1 , further comprising removing at least a portion of an airfoil from an existing component claim 1 , thereby forming the substrate.4. The method of claim 3 , further comprising:forming the first rib section as part of the first path by widening the energy beam to span at least from the first side wall to the second side ...

METHOD FOR BUILDING A GAS TURBINE ENGINE COMPONENT

A method, including: providing a layer of powder material () on a substrate () having protruding rib material (); and traversing an energy beam () across the layer of powder material to form a cladding layer () around and bonded to the protruding rib material, wherein the cladding layer defines a layer of an airfoil skin (). 1. A method , comprising:providing a layer of powder material on a hollow substrate comprising pressure side skin, suction side skin, a rib connecting the pressure side skin to the suction side skin, and protruding rib material protruding from the rib and past the suction and pressure side skins; andtraversing an energy beam across the layer of powder material to form a cladding layer around and bonded to the protruding rib material, wherein the cladding layer defines a layer of an airfoil skin.2. The method of claim 1 , further comprising removing at least a portion of airfoil skin from an existing component while leaving underlying rib material to form the substrate.3. The method of claim 1 , further comprising tapering the protruding rib material toward an end of a component comprising the airfoil skin and traversing the energy beam to extend the cladding layer to a tapered side surface of the protruding rib material.4. The method of claim 3 , further comprising selecting an angle of taper to permit line of site access to the layer of powder material on both sides of the rib material by a single energy beam source disposed above the end of the rib material.5. The method of claim 4 , further comprising selecting the angle of taper to permit an angle of incidence between the energy beam and the tapered side surface.6. The method of claim 1 , wherein the protruding rib material is not tapered toward an end of a component comprising the airfoil skin.7. The method of claim 1 , further comprising traversing the energy beam to form a first melt pool that forms a first side of the cladding layer and a second melt pool that concurrently forms a second ...

METHOD FOR REPAIRING A GAS TURBINE ENGINE BLADE TIP

A method, including: replacing an original blade shelf () of a gas turbine engine blade () with a new blade shelf () that is located closer to a base () of the blade than the original blade shelf; adding mass to the blade until a mass of the blade with the new blade shelf is greater than a mass of the blade with the original blade shelf in order to maintain a same contribution by the blade with the new blade shelf as a contribution by the blade with the original blade shelf to a dynamic balance of a rotor arrangement. 1. A method , comprising:replacing an original blade shelf of a gas turbine engine blade with a new blade shelf that is located closer to a base of the blade than the original blade shelf;adding mass to the blade until a mass of the blade with the new blade shelf is greater than a mass of the blade with the original blade shelf; andmaintaining a same contribution by the blade with the new blade shelf as a contribution by the blade with the original blade shelf to a dynamic balance of a rotor arrangement.2. The method of claim 1 , further comprising welding a pre-cast new blade shelf to the blade.3. The method of claim 1 , further comprising forming the new blade shelf through an additive manufacturing process.4. The method of claim 3 , further comprising traversing an energy beam across a powder material comprising a superalloy powder and a powder flux to form a layer of the blade during the additive manufacturing process.5. The method of claim 1 , further comprising replacing an original squealer with a new squealer claim 1 , and adding the mass to the new squealer of the blade.6. The method of claim 5 , further comprising tapering the new squealer to match a same interface size as an original squealer interface size.7. The method of claim 1 , further comprising replacing an original squealer with a new squealer claim 1 , and forming the new squealer with a different material than a material that formed the original squealer.8. The method of claim 1 , ...

COATINGS FOR HIGH TEMPERATURE COMPONENTS

A method for forming a coating on a substrate is provided. To an assembly including a substrate a porous matrix on the substrate and an impregnating material on or within the porous matrix the method includes applying an amount of energy from an energy source effective to melt the impregnating material and a portion of the substrate. In this way, the impregnating material impregnates the porous matrix The method further includes cooling the assembly to provide a coating comprising the porous matrix integrated with the substrate 1. A method of coating a substrate comprising:to an assembly comprising a substrate, a porous matrix on the substrate, and an impregnating material on or within the porous matrix, applying an amount of energy from an energy source effective to melt the impregnating material and a portion of the substrate such that the impregnating material impregnates the porous matrix; andcooling the assembly to provide a coating comprising the impregnated porous matrix integrated with the substrate.2. The method of claim 1 , wherein the substrate and the impregnating material comprise a composition selected from the group consisting of a superalloy material claim 1 , titanium aluminide claim 1 , a cermet material claim 1 , and a ceramic material.3. The method of claim 1 , further comprising forming the assembly via:disposing the porous matrix on the substrate; anddisposing the impregnating material on or within the porous matrix.4. The method of claim 1 , wherein the porous matrix comprises a metal oxide selected from the group consisting of alumina claim 1 , antimony (III) oxide claim 1 , boria claim 1 , chromium oxide claim 1 , cobalt oxide claim 1 , copper oxide claim 1 , europium oxide claim 1 , iron oxide claim 1 , nickel oxide claim 1 , silica claim 1 , tin oxide claim 1 , titanium oxide claim 1 , yttrium oxide claim 1 , zinc oxide claim 1 , zirconium oxide claim 1 , and combinations thereof.5. The method of claim 1 , wherein the porous matrix ...

Method for automated superalloy laser cladding with 3d imaging weld path control

Superalloy components, such as service-degraded turbine blades and vanes, are clad by laser beam welding. The welding/cladding path, including cladding application profile, is determined by prior, preferably real time, non-contact 3D dimensional scanning of the component and comparison of the acquired dimensional scan data with specification dimensional data for the component. A welding path for cladding the scanned component to conform its dimensions to the specification dimensional data is determined The laser welding apparatus, preferably in cooperation with a cladding filler material distribution apparatus, executes the welding path to apply the desired cladding profile. In some embodiments a post-weld non-contact 3D dimensional scan of the welded component is performed and the post-weld scan dimensional data are compared with the specification dimensional data. Preferably the welding path and/or cladding profile application are modified in a feedback loop with the pre- and/or post-welding 3D dimensional scanning.

HYBRID MECHANICAL-THERMAL PROCESS FOR COATING REMOVAL

A method of removing a coating () from a substrate () by applying both vibratory mechanical energy () and an energy beam () to the coating. Localized combination of thermally and mechanically induced stressed in the coating result in the formation of cracks () in the coating. 1. A method for removing a coating from a substrate , the method comprising introducing vibratory mechanical energy into the substrate while directing an energy beam onto the coating in a manner effective to fracture the coating.2. The method of claim 1 , further comprising:controlling the vibratory mechanical energy to form a standing wave in the substrate;directing the energy beam into a trough of the standing wave to heat a portion of the coating; andcontrolling the vibratory mechanical energy to move the standing wave such that the heated portion of the coating is on a crest of the moved standing wave.3. The method of claim 1 , further comprising:controlling the vibratory mechanical energy to form a standing wave in the substrate;directing the energy beam onto a crest of the standing wave to heat a portion of the coating; andcontrolling the vibratory mechanical energy to move the standing wave such that the heated portion of the coating is in a valley of the moved standing wave.4. The method of claim 1 , further comprising detecting a location of a wave in the substrate created by the vibratory mechanical energy and controlling the energy beam in response to the detected location of the standing wave.5. The method of claim 1 , further comprising controlling the vibratory mechanical energy effective to induce a wave to move across the substrate.6. The method of claim 5 , further comprising controlling the energy beam responsive to a path of the wave moving across the substrate.7. The method of claim 1 , further comprising selecting parameters of the energy beam such that a sufficient portion of the beam energy is absorbed by the coating to raise a temperature of the coating to above a ...

Method of Tight Crack Braze Repair Using Acoustics

A method for braze repair of tight cracks in a superalloy component is provided. The method includes directing energy, e.g., from an acoustic energy source, towards surfaces of the tight crack to break up one or more contaminants, corrosion products, or oxides at the surface. The directed energy may cause opposed walls of the tight crack to vibrate to break up the oxides, and to generate a modest heat for allowing infiltration of the tight crack with a braze material. The braze material is then melted at a melt temperature of the braze material but below the melt temperature of the component. The braze material is then solidified to repair the tight crack.

METHOD FOR FORMING THREE-DIMENSIONAL ANCHORING STRUCTURES ON A SURFACE

A method for forming three-dimensional anchoring structures on a surface is provided. This may result in a thermal barrier coating system exhibiting enhanced adherence for its constituent coatings. The method involves applying a laser beam () to a surface () of a solid material () to form a liquefied bed () on the surface of the solid material, then applying a pulse of laser energy () to a portion of the liquefied bed to cause a disturbance, such as a splash () or a wave () of liquefied material outside the liquefied bed. A three-dimensional anchoring structure () may thus be formed on the surface upon solidification of the splash or wave of liquefied material. 1. A method comprising:applying a laser beam to a surface of a solid material to form a liquefied bed on the surface of the solid material;applying a pulse of laser energy to at least a portion of the liquefied bed to cause a splash of liquefied material outside the liquefied bed; andforming on the surface of the solid material a three-dimensional anchoring structure upon solidification of the splash of liquefied material.2. The method of claim 1 , wherein the three-dimensional anchoring structure comprises at least one hook.3. The method of claim 1 , wherein the three-dimensional anchoring structure comprises at least one wave.4. The method of claim 1 , wherein the applying of the laser beam to the surface of the solid material comprises a scanning by the laser beam over the surface of the solid material.5. The method of claim 1 , wherein the applying of the pulse of laser energy to the portion of the liquefied bed is performed subsequent to the applying of the laser beam to the surface of the solid material.6. The method of claim 1 , wherein the applying of the pulse of laser energy to the portion of the liquefied bed is performed during the applying of the laser beam to the surface of the solid material.7. The method of claim 1 , wherein the applying of the pulse of laser energy comprises focusing the ...

ARTICULATING BUILD PLATFORM FOR LASER ADDITIVE MANUFACTURING

An additive manufacturing apparatus () including: a container () configured to bound a bed of powdered metal material; a fluidization arrangement () configured to fluidize the bed of powered material; an articulation mechanism () disposed within the container and configured to support and to rotate a component () about at least one horizontal axis; and an energy beam () configured to selectively scan portions () of a surface of the bed of powdered metal material to melt or sinter the selectively scanned portions onto the component. 1. An additive manufacturing apparatus comprising:a container configured to bound a bed of powdered metal material;a fluidization arrangement configured to fluidize the bed of powered material;an articulation mechanism disposed within the container and configured to support and to rotate a component about at least one horizontal axis; andan energy beam arrangement configured to selectively scan portions of a surface of the bed of powdered metal material to melt or sinter the selectively scanned portions onto the component.2. The additive manufacturing apparatus of claim 1 , wherein the container comprises a bottom that is vertically adjustable claim 1 , and wherein the articulation mechanism is secured to the bottom.3. The additive manufacturing apparatus of claim 2 , wherein the articulation mechanism comprises a platform on which the component rests claim 2 , and a joint assembly secured to the platform and to the bottom.4. The additive manufacturing apparatus of claim 1 , wherein the container comprises a bottom claim 1 , and wherein the articulation mechanism is configured to move vertically relative to the bottom.5. The additive manufacturing apparatus of claim 1 , wherein the articulation mechanism is configured to rotate the component about all horizontal axes.6. The additive manufacturing apparatus of claim 1 , wherein the articulation mechanism is further configured to move the component horizontally.7. The additive manufacturing ...

METHODS FOR REMOVING TRAMP ELEMENTS FROM ALLOY SUBSTRATES

Methods are disclosed for cleaning a near surface region of an alloy substrate () in the presence of a flux material (). A flux material is melted on the surface of the alloy substrate to a temperature sufficient to permit a reaction of the flux material with at least one tramp element present within the alloy substrate. The alloy substrate may remain solid, but diffusion of the tramp element is facilitated by an elevated temperature of the substrate. Fluxes disclosed may include a metal oxalate and/or other compounds capable of forming tramp element containing compounds by reaction with the alloy substrate to be cleaned, wherein the compounds formed have a ΔHlower than −100 kcal/g-mol at 25° C. 1. A method comprising:depositing a flux material on a surface of an alloy substrate;melting the flux material and heating a near surface region of the alloy substrate independent of any coating process to permit a reaction of the flux material with a tramp element from within the near surface region to form a reaction product; andremoving the reaction product from the near surface region.2. The method of claim 1 , wherein the alloy substrate below the melted flux material remains solid.3. The method of claim 1 , wherein the near surface region is between only 10 and 40 micrometers deep.4. The method of claim 1 , wherein the flux material comprises aluminum or an aluminum containing compound.5. The method of claim 1 , wherein the flux material comprises a constituent which forms a reaction product compound with a ΔHlower than −100 kcal/g-mol at 25° C.6. The method of claim 1 , wherein the flux material comprises a metal oxalate.7. The method of claim 1 , wherein the flux material comprisesaluminum carbonate; andat least one of the group of a metal oxide, a non-aluminum metal carbonate, a metal halide, a metalloid oxide, and a metal carbide.8. The method of claim 1 , further comprising:cleaning the surface of the substrate of any unmelted flux material and slag; andapplying a ...

FLUX AND PROCESS FOR REPAIR OF SINGLE CRYSTAL ALLOYS

A flux material that provides a heat outflow control layer of slag () on a melt pool () that suppresses lateral heat outflow () and facilitates uniaxial heat outflow (A-D) from the melt pool at a rate that causes unidirectional crystallization in the melt pool to match a crystal direction () of a substrate (). The slag may be insulative, and may flow to form a greater slag thickness (T T) at the sides of the melt pool than at the middle (T). The flux may contain constituents that warm the sides of the melt pool by exothermic reaction. The flux may be used in combination with insulating elements (A-B, A-B, ) placed on the substrate surface beside the melt pool and/or with supplemental heating of the sides of the weld. 1. A flux useful during the deposition of a layer of an alloy material onto a surface of a substrate having a unidirectional crystalline structure by the melting and re-solidification of the alloy material on the surface in the presence of the flux , the flux characterized by a composition that facilitates solidification of the alloy material as a crystalline extension of the substrate by minimizing lateral heat outflow and facilitating uniaxial heat outflow from a melt pool of the alloy material.2. The flux of claim 1 , wherein the flux is constituted to create a thermally insulating slag of a predetermined viscosity claim 1 , at a liquid temperature of the melt pool claim 1 , effective to cause the slag to form a heat outflow control geometry on a free surface of the melt pool as seen in a cross section through the melt pool claim 1 , wherein the heat outflow control geometry comprises a first thickness of the slag over a center of the melt pool claim 1 , and a second thickness of the slag of at least twice the first thickness above a side of the melt pool.34. The flux of claim 2 , wherein the heat outflow control geometry further comprises a third lateral thickness of at least times the first thickness around all sides of the melt pool as measured ...

LASER CLADDING SYSTEM FILLER MATERIAL DISTRIBUTION APPARATUS

Laser cladding filler material is introduced in a pattern on a on a substrate by a filler distribution apparatus having a linear or polygonal array of dispensing apertures for uniform distribution in advance of or during a laser beam transferring optical energy to the substrate. The distribution apparatus includes a housing (or assembly of coupled housings) that defines the distribution aperture array and an internal chamber in communication with the apertures that is adapted for retention of filler material. A mechanical feed mechanism, such as an auger, is adapted for feeding filler material from the internal chamber through the distribution apertures. A feed mechanism drive system is coupled to the mechanical feed mechanism, adapted for selectively varying filler material feed rate. The distribution aperture array may be selectively reconfigured to vary selectively the filler material distribution pattern. 1. Apparatus for laser cladding filler material distribution , comprising:a modular housing having an external surface defining a distribution aperture and an internal chamber in communication with the distribution aperture adapted for retention of filler material therein, the modular housing adapted for selective combination with other modular housings for selective assembly of varying distribution aperture arrays;a mechanical feed mechanism adapted for feeding filler material from the internal chamber through the distribution aperture; anda drive system, coupled to the mechanical feed mechanism, adapted for selectively varying filler material feed rate.2. The apparatus of comprising:a plurality of modular housings oriented in a distribution aperture array;a mounting structure coupling the modular housings into the distribution aperture array; andthe drive system selectively varying filler material feed rate through each aperture in the aperture array.3. The apparatus of claim 2 , the mechanical feed mechanism comprising an auger.4. The apparatus of claim 1 , ...

FORMATION AND REPAIR OF OXIDE DISPERSION STRENGTHENED ALLOYS BY ALLOY MELTING WITH OXIDE INJECTION

Melting energy exemplified by an arc () is delivered to a metal alloy material (), forming a melt pool (). A metal oxide material () is delivered () to the melt pool and dispersed therein. The melting energy and oxide deliveries are controlled () to melt the alloy material, but not to melt at least most of the metal oxide material. The deliveries may be controlled so that the melting energy does not intercept the metal oxide delivery. The melting energy may be controlled to create a temperature of the melt pool that does not reach the melting point of the metal oxide. Deliveries of the melting energy and the oxide may alternate so they do not overlap in time. A cold metal transfer apparatus () and process () may be used for example in combination with an oxide particle pulse delivery device (). 1. A process for forming an oxide strengthened alloy , comprising:applying a first energy to a metal alloy material, creating a melt pool thereof; andinjecting a metal oxide into the melt pool, wherein the metal oxide comprises particles with a higher melting point than the metal alloy material;wherein at least most of the metal oxide is not directly intercepted by the first energy; andwherein solidification of the melt pool forms a deposit of the metal alloy material with the metal oxide dispersed therein.2. The process of claim 1 , further comprising separating the injecting of the metal oxide into the melt pool from the applying of the first energy by at least one of time and space sufficiently to prevent complete melting of at least most of the metal oxide.3. The process of claim 1 , wherein the applying of the first energy and the injecting of the metal oxide overlap each other in space at mutually exclusive times such that the metal oxide is not directly intercepted by the first energy.4. The process of claim 1 , wherein an area of the first energy at a surface of the melt pool is at least 40% overlapped by an area of the oxide injection at the surface of the melt pool ...

ADDITIVE MANUFACTURING USING CAST STRIP SUPERALLOY MATERIAL

A method of additive manufacturing, including: placing a layer () of strip-cast superalloy sheet material over a subcomponent () leaving a gap () between the layer and the subcomponent; and creating a weldment () to the layer. Shrinkage in the layer caused by the weldment is accommodated by a decrease in the gap with reduced shrinkage stress in the weldment. The layer may be formed of more than one piece (), and the weldment may join the pieces together with or without joining the layer to the subcomponent. The gap may again grow due to differential thermal expansion when the resulting component is placed into service, thereby functioning as a passively regulated cooling channel. 1. A method of manufacturing a superalloy component , the method comprising:placing a layer comprising strip-cast superalloy sheet material on a subcomponent,leaving a gap between at least a portion of the layer and the subcomponent; andforming a weld in the layer to form the superalloy component, wherein shrinkage in the layer caused by forming the weld decreases the gap, thereby mitigating weld shrinkage stress in the weld.2. The method of claim 1 , wherein the layer comprises plural pieces claim 1 , the method further comprising welding the pieces together claim 1 , wherein shrinkage in the layer caused by welding the pieces together decreases the gap.3. The method of claim 2 , further comprising butt welding respective edges of the plural pieces together claim 2 , and presetting the plural pieces at an angle with respect to each other prior to the butt welding to establish the gap to accommodate shrinkage caused by the butt weld.4. The method of claim 1 , further comprising welding the layer to the subcomponent during the step of forming the weld.5. The method of claim 1 , further comprising forming the weld proximate a recess in the subcomponent such that a resulting weldment does not join the layer to the subcomponent.6. The method of claim 1 , wherein at least a portion of the gap ...

Laser cladding with programmed beam size adjustment

A method for heating an irregularly shaped target surface ( 28, 36 ) with an energy beam ( 12, 48 ) with a controlled power density as the beam progresses across the surface in order to control a cladding process. In one embodiment, widths (y) of respective rectangular diode laser beam images ( 22, 24, 26 ) are controlled in response to a local width of a gas turbine blade tip ( 20 ), and a power level of the diode laser is linearly controlled in response to the width of the respective image in order to maintain an essentially constant power density across the blade tip. In another embodiment, the width and power level of a continuous laser beam image ( 34 ) are controlled in response to changes in the local surface shape in order to produce a predetermined power density as the image is swept across the surface.

LASER DEPOSITION AND REPAIR OF REACTIVE METALS

Laser processing of reactive metals. One repair process involves laser melting a titanium alloy filler material () in the presence of a flux composition () to form a titanium alloy cladding () bonded to a surface of a titanium-containing component (). A laser beam () may be applied to a flux composition () covering a powdered filler material () such that the laser beam simultaneously melts the flux composition and the powdered filler material to form a melt pool () which solidifies into a resulting alloy layer () covered by a slag layer (). A laser beam () may heat a flux composition () such that an amount of energy applied to the flux composition is controlled so that a molten slag blanket () heats and melts a powdered filler material () by thermal conduction in the presence of a shielding gas (). 1. A method , comprising laser melting a titanium alloy filler material in the presence of a flux composition under an atmosphere comprising greater than 10 ppm of oxygen , to form a titanium alloy cladding bonded to a surface of a titanium-containing component.2. The method of claim 1 , wherein:{'sub': 2', '2', '2', '3', '2', '2', '2', '2', '3', '3', '3', '3', '3', '2', '3', '3', '3', '2', '2', '2', '2', '2', '3', '2', '2', '3', '2', '3', '2', '2', '2', '3', '2', '2', '2', '2', '2', '2', '2', '2', '2', '2', '2', '2', '2', '3', '2', '2', '4', '3', '3', '3', '2', '2', '4', '2', '2', '2', '2', '3', '3', '3', '3', '4', '4', '2', '4', '4', '4', '4', '5', '5', '3', '5', '3', '3', '2', '2', '2', '2', '2', '2', '2', '3', '2', '3', '3', '3', '2', '2', '2', '4', '3', '3', '3', '2', '2', '2', '4', '4', '5', '5', '4', '6', '3', '5', '3', '2', '2', '3', '3', '3', '3', '3', '3', '3', '3', '3', '4', '3, 'the flux composition comprises at least one selected from the group consisting of LiF, LiCl, LiBr, LiI, NaF, NaCl, NaBr, MgF, MgCl, MgBr, AlF, KCl, KF, KBr, CaF, CaF, CaBr, CaCl, CaI, ScBr, ScCl, ScF, ScI, TiF, VCl, VCl, CrCl, CrBr, CrCl, CrF, MnCl, MnBr, MnF, MnF, MnI, FeBr, FeBr, ...

Filler mesh for laser cladding

A coating arrangement ( 16 ), including: a layer ( 18 ) of bond coat material ( 20 ); and a light-transmissive thermal barrier coating (TBC) mesh ( 28 ) having a TBC material ( 24 ) and secured in position relative to the layer of bond coat material. The coating arrangement may be positioned over a superalloy substrate material ( 12 ) and melted with a laser beam ( 62 ) to metallurgically bond the thermal barrier coating onto the substrate.

LASER METALWORKING OF REFLECTIVE METALS USING FLUX

Methods for laser processing of reflective metals. A reflective metal () is heated by applying a laser beam () to a layer of flux () in contact with the reflective metal, in which the flux is a powdered flux composition. The laser beam () may be applied to a powdered flux composition () such that thermal energy absorbed from the laser beam is transferred to a reflective-metal filler material () situated on a support material (), and the powdered flux composition and the reflective-metal filler material melt to form a melt pool () which solidifies to form a metal layer () covered by a slag layer (). 1. A method , comprising heating a reflective metal by applying a laser beam to a layer of flux in contact with the reflective metal , wherein the flux is a powdered flux composition.2. The method of claim 1 , wherein a thickness of the layer of flux ranges from about 1 mm to about 10 mm.3. The method of claim 1 , wherein a particle size of the powdered flux composition ranges from about 0.005 mm to about 5 mm in diameter.4. The method of claim 1 , wherein a frequency of the laser beam is greater than 1 μm.5. The method of claim 1 , wherein the reflective metal is selected from the group consisting of copper claim 1 , aluminum and silver.6. The method of claim 1 , wherein the reflective metal is in the form of a powdered filler material.7. The method of claim 1 , wherein the powdered flux composition comprises at least one of:(i) a metal oxide;(ii) a metal halide;(iii) an oxometallate; and(iv) a metal carbonate.8. The method of claim 1 , wherein the powdered flux composition comprises at least one of:{'sub': 2', '2', '3', '6', '2', '3', '2', '2', '3', '2', '2', '3', '2', '3', '2', '4', '2', '5', '2', '3', '3', '2', '2', '3', '3', '4', '2', '3', '3', '4', '3', '4', '2', '3', '2', '2', '3', '2', '2', '3', '2', '2', '3', '2', '2', '2', '5', '3', '2', '2', '2', '3', '2', '2', '2', '3', '2', '2', '3', '2', '3', '2', '2', '2', '5', '2', '3', '3', '2', '7', '2', '2', '3', '2', ' ...

LASER PRE-PROCESSING TO STABILIZE HIGH-TEMPERATURE COATINGS AND SURFACES

Laser pre-processing to stabilize high-temperature coatings and surfaces. One method involves melting a surface of a metal substrate () with an energy beam () to form a melt pool (), allowing the melt pool to cool and solidify into a melt-processed alloy layer () bonded to the metal substrate, and coating the melt-processed alloy layer with a protective alloy layer () to form a coated substrate. A flux composition () may also be deposited onto the surface of the metal substrate, such that the melt processing also forms a slag layer () at least partially covering the melt-processed alloy layer. A protective material () containing a carbon source may also be deposited onto the surface of the metal substrate, such that the melt processing forms a carbon-enriched melt-processed alloy layer () having a higher proportion of carbon than the metal substrate. 1. A coating method , comprising:melting a surface of a superalloy substrate with an energy beam to form a melt pool;allowing the melt pool to cool and solidify into a melt-processed superalloy layer bonded to the superalloy substrate; andcoating the melt-processed superalloy layer with a protective alloy layer, to form a coated substrate.2. The method of claim 2 , further comprising:before the melting, depositing a flux composition onto the surface of the superalloy substrate, such that the melting of the surface also melts the flux composition and the cooling of the melt pool also forms a slag layer at least partially covering the melt-processed superalloy layer; andbefore the coating, removing the slag layer at least partially covering the melt-processed superalloy layer.3. The method of claim 2 , wherein the flux composition comprises at least one selected from the group consisting of a metal oxide claim 2 , a metal halide claim 2 , an oxometallate claim 2 , a metal carbonate claim 2 , a hydrocarbon claim 2 , an allotrope of carbon claim 2 , a carbohydrate claim 2 , a natural oil claim 2 , a synthetic oil claim 2 , ...

Method of Weld Cladding Over Openings

A method including spanning a relatively larger opening () with a support structure () to divide the larger opening into a plurality of relatively smaller openings (); placing superalloy powder across the smaller openings and in contact with the support structure; and melting the superalloy powder to form a cladding layer () that spans the opening and is metallurgically bonded to the support structure. 1. A method , comprising:spanning a relatively larger opening with a support structure to divide the relatively larger opening into a plurality of relatively smaller openings;melting alloy filler to form a melt pool traversing across the respective relatively smaller openings while in contact with and supported by the support structure; andallowing the melt pool to cool and to solidify to form a cladding layer that spans the relatively larger opening and is metallurgically bonded with the support structure.2. The method of claim 1 , supporting the support structure with a supporting powder prior to the melting step claim 1 , then removing the supporting powder after the cooling and solidifying step.3. The method of claim 2 , further comprising resting the support structure atop the supporting powder.4. The method of claim 2 , further comprising positioning the support structure in the supporting powder such that the supporting powder extends up beside the support structure.5. The method of claim 2 , wherein the supporting powder comprises one of the group of a) a ceramic that does not melt during the melting step and b) a flux and metal that is partially melted during the melting step.6. The method of claim 5 , wherein the supporting powder comprises a ceramic is selected from a group consisting of alumina claim 5 , zirconia claim 5 , beryllium oxide claim 5 , sapphire claim 5 , silica claim 5 , magnesium oxide claim 5 , boron nitride claim 5 , aluminum nitride claim 5 , silicon nitride claim 5 , silicon carbide claim 5 , aluminum silicate claim 5 , mullite claim 5 , ...

REINFORCED CLADDING

A method for forming a reinforced cladding () on a superalloy substrate () The method includes forming a melt pool () including a superalloy material () and a plurality of discrete carbon reinforcing structures () on the superalloy substrate () via application of energy from an energy source () The method further includes cooling the melt pool () to form a reinforced cladding () comprising the superalloy material () and the carbon reinforcing structures () on the substrate (). 1. A method comprisingforming a melt pool comprising a superalloy material and a plurality of discrete carbon reinforcing structures on a superalloy substrate via application of energy from an energy source, andcooling the melt pool to form a reinforced cladding comprising the superalloy material and the carbon reinforcing structures on the substrate2. The method of claim 1 , wherein the forming a melt pool is done by melting a powder comprising the superalloy material and a powdered flux material via the energy source claim 1 , andintroducing the plurality of discrete carbon reinforcing structures into the melt pool after the melt pool has been established3. The method of claim 2 , wherein the introducing is done after the application of energy from the energy source is stopped claim 2 , but before the melt pool solidifies4. The method of claim 2 , wherein the introducing is done before the application of energy from the energy source is stopped claim 2 , but after the melt pool has been established and before the melt pool solidifies5. The method of claim 2 , wherein the introducing is done by propelling the plurality of carbon reinforcing structures toward the surface by a jet of gas6. The method of claim 1 , wherein the forming a melt pool is done by subjecting a powder comprising the superalloy material claim 1 , a powdered flux material claim 1 , and the plurality of discrete carbon reinforcing structures to energy from the energy source claim 1 , and wherein the cooling produces a ...

METHOD OF FORMING A CLADDING LAYER HAVING AN INTEGRAL CHANNEL

A method including: submerging a ceramic preform () in a layer () of powdered superalloy material (), wherein the preform defines a desired shape of a channel () to be formed in a layer () of superalloy material; melting the powdered superalloy material around the preform without melting the preform; and cooling and re-solidifying the superalloy material around the preform to form the layer of superalloy material with the preform defining the shape of the channel therein. 1. A method comprising:submerging a ceramic preform in a layer of powdered superalloy material, wherein the preform defines a desired shape of a void to be formed in a layer of superalloy material;melting the powdered superalloy material around the preform without melting the preform; andcooling and re-solidifying the melted superalloy material around the preform to form the layer of superalloy material with the preform defining the shape of the void therein.2. The method of claim 1 , wherein the preform comprises a hollow ceramic tube.3. The method of claim 2 , further comprising removing the hollow ceramic tube via a mechanical or thermal shocking process.4. The method of claim 1 , further comprising removing the ceramic preform to expose a surface that defines the void.5. The method of claim 1 , further comprising coating an outer surface of the ceramic preform prior to the submerging and melting steps to facilitate wetting of the preform by the melted superalloy material.6. The method of claim 5 , wherein the outer surface of the preform is coated with at least one of the group consisting of molybdenum-manganese claim 5 , titanium claim 5 , tungsten manganese claim 5 , moly tungsten manganese claim 5 , hafnium claim 5 , chromium claim 5 , zirconium claim 5 , and niobium.7. The method of claim 6 , further comprising plating the coating prior to the submerging and melting steps claim 6 , wherein both the coating and the plating facilitate the wetting of the preform by the melted superalloy ...

BELOW SURFACE LASER PROCESSING OF A FLUIDIZED BED

A system and process of additive manufacturing using a fluidized bed of powdered material () including powdered metal material () and powdered flux material ()′ including heating the powdered material with an energy beam () delivered from a location below a top surface () of the powdered material. The powdered bed is fluidized by introduction of an inert or non-inert gas into a chamber (). As the powdered material is heated, melted and solidified, a layer of slag () forms over a deposited metal () and is then removed so that fluidized powdered settling on a previously deposited area () can be heated, melted and solidified to build up a component (). 1. An additive manufacturing apparatus for making a metal component , comprising:a chamber;a bed of powdered material including powdered metal material; andan energy beam scanning system that includes one or more beam exit portals disposed below a surface of the bed and through which an energy beam is transmitted to selectively scan portions of the powdered material from below the surface of the bed according to a predetermined shape of the component.2. The apparatus of wherein the energy beam scanning system comprises one or more controllers operatively associated with the energy beam and/or the chamber to control relative movement between the energy beam and the component according to the predetermined shape of the component.3. The apparatus of claim 1 , wherein the chamber includes optically transmissive walls and the exit portal is positioned outside of the chamber.4. The apparatus of claim 1 , wherein the exit portal is inside the chamber.5. The apparatus of claim 1 , wherein claim 1 , the energy beam is a laser beam.6. The apparatus of claim 1 , wherein the powdered material comprises powdered flux material and the powdered superalloy material.7. The apparatus of claim 6 , further comprising a source of non-inert gas in fluid communication with an interior of the chamber to fluidize the bed of powdered material.8. ...

WELDING PROCESS AND REDUCED RESTRAINT WELD JOINT

A weld joint () having asymmetric sides and providing reduced restraint of weld metal shrinkage and a reduced propensity for weld centerline cracking. The weld joint may have a first side () formed at an angle (A) of 35-60° relative to the component surface (), and a second side () formed at an angle (A) of 10-35° relative to the surface. The sides may be extended to intersect () without the necessity for a flat bottom surface () as is typical for prior art weld joints (). The inventive weld joint may be formed by moving an end mill tool () into and along the surface with its axis of rotation () being transverse to the surface. 1. An apparatus comprising:a substrate comprising a surface;a weld prep formed into the surface and comprising opposed first and second sides in cross section;the first side disposed at a first angle relative to the surface and the second side disposed at a second angle different than the first angle relative to the surface; andweld metal deposited into the weld prep and joining the first and second sides.2. The apparatus of claim 1 , wherein the first side is disposed at an angle relative to the surface of 35-60° and the second side is disposed at an angle relative to the surface of 10-35°.3. The apparatus of claim 1 , wherein the first side is disposed at an angle relative to the surface of 45° and the second side is disposed at an angle relative to the surface of 15°.4. The apparatus of claim 1 , further comprising the first and second sides extending to intersect at a bottom of the weld prep.5. The apparatus of claim 1 , further comprising the weld prep extending in a longitudinal direction on a curvilinear path along the surface.6. The apparatus of claim 1 , further comprising:the weld prep extending to have a longitudinal length along the surface;the weld prep having a first depth proximate a central portion of the longitudinal length; andthe weld prep tapering to a second depth less than the first depth proximate at least one end of ...

SUPERALLOY MATERIAL DEPOSITION WITH INTERLAYER MATERIAL REMOVAL

A method of depositing a multi-layer cladding () of superalloy material and an apparatus so formed. A first layer of material () is deposited on a substrate () such as by laser cladding of superalloy powder (). The deposited material includes a directionally solidified region () and a topmost equiaxed region (). The topmost region is removed such as by grinding to expose a flat surface () of directionally solidified material. A second layer of material () deposited onto the exposed flat surface will again have a directionally solidified region () and a topmost equiaxed region (). The process is repeated until a desired thickness of cladding material is achieved, the multi-layer cladding having no equiaxed material between its layers throughout its thickness. 1. A method comprising:depositing a layer of material onto a substrate surface; andremoving an equiaxed material portion of the layer of material to expose a surface of directionally solidified material.2. The method of claim 1 , further comprising:depositing a second layer of material onto the surface of directionally solidified material; andremoving an equiaxed material portion of the second layer of material to expose a second surface of directionally solidified material; andreversing a direction of deposition between the two layers.3. The method of claim 1 , further comprising:depositing a layer of powdered material comprising a superalloy material and a flux material onto the substrate surface;melting at least a portion of the layer of powdered material to form the layer of superalloy material on the substrate surface covered by a layer of slag; andremoving the slag and the equiaxed material portion to expose the surface of directionally solidified superalloy material.4. The method of claim 3 , further comprising:depositing the layer of powdered material to have a thickness sufficient so that the layer of superalloy material has a thickness of greater than 2 mm; andremoving a top portion of at least 1 mm ...

Hybrid laser plus submerged arc or electroslag cladding of superalloys

A method for cladding of superalloy materials. A layer of powder ( 14 ) disposed over a superalloy substrate ( 12 ) is heated with an energy beam ( 16 ) to form a layer of superalloy cladding ( 10 ) and an overlying layer of slag ( 18 ). A filler material ( 44 ) of nickel, nickel-chromium or nickel-chromium-cobalt wire or strip is also added to the melt pool to combine with the melted powder via a submerged arc or electroslag heating process to give the superalloy cladding the composition of a desired superalloy material. The layer of powder includes a layer of powdered flux material ( 22 ) over a layer of powdered metal ( 20 ), or the flux and metal powders may be mixed together ( 36 ).

MATERIAL PROCESSING THROUGH OPTICALLY TRANSMISSIVE SLAG

A process for growing a substrate () as a melt pool () solidifies beneath a molten slag layer () An energy beam () is used to melt a powder () or a hollow feed wire () with a powdered alloy core () under the slag layer The slag layer is at least partially transparent () to the energy beam, and it may be partially optically absorbent or translucent to the energy beam to absorb enough energy to remain molten As with a conventional ESW process, the slag layer insulates the molten material and shields it from reaction with air A composition of the powder may be changed across a solidification axis (A) of the resulting component () to provide a functionally graded directionally solidified product. 1. A process comprising directing an energy beam through a molten slag layer that is at least partially transmissive to the energy beam in order to melt a feed material for solidification and deposition onto a substrate under the slag layer2. The process of claim 1 , further comprisingdepositing the feed material and a flux material as powder onto the substrate,traversing the energy beam across the powder to form the molten slag layer and melted feed material, andallowing the melted feed material to solidify onto the substrate under the slag layer behind the traversing energy beam3. The process of claim 1 , wherein the energy beam comprises a laser beam and the slag layer comprises at least one of the group of phosphate glass claim 1 , borosilicate glass claim 1 , silica claim 1 , sapphire claim 1 , magnesium fluoride claim 1 , calcium fluoride claim 1 , barium fluoride claim 1 , zinc selenide claim 1 , silicon claim 1 , germanium and ZBLAN glass4. The process of claim 1 , further comprising providing the feed material into the molten slag layer as a powder claim 1 , wire or strip5. The process of claim 1 , further comprising providing the feed material into the molten slag layer as a cored wire filled with powdered alloy material6. The process of claim 1 , further comprising ...

LOW HEAT FLUX MEDIATED CLADDING OF SUPERALLOYS USING CORED FEED MATERIAL

Methods are disclosed for melting a cored feed material () using a low heat input process. The feed material may be a sheath () consisting essentially of pure nickel, nickel-chromium, or nickel-chromium-cobalt, containing a powdered core material () having a powdered alloy material () and powdered flux material () which, when melted, form a desired superalloy material. Flux materials for use with the methods are disclosed. The process may be a cold metal transfer process wherein the feed material is oscillated at greater than 130 oscillations per second. 1. A method of depositing an alloy , the method comprising:melting a cored feed material to form a melt pool using a heat input of 0.05 to 0.6 kJ/mm; andallowing the melt pool to cool and solidify to form deposited alloy.2. The method of claim 1 , further comprising:melting flux material contained within a core of the feed material to form slag over the melt pool;allowing the melt pool to cool and solidify under and with the slag; andremoving the solidified slag to reveal the deposited alloy.3. The method of claim 2 , further comprising:melting the cored feed material with a cold metal transfer process;wherein the melted flux material and slag are effective to quiet weld pool oscillations.4. The method of claim 3 , wherein the cored feed material is oscillated at greater than 130 oscillations per second5. The method of claim 2 , further comprising:selecting the feed material to comprise a sheath containing a powdered core material, the powdered core material comprising a powdered alloy material and a powdered flux material, the sheath consisting essentially of pure nickel, nickel-chromium, or nickel-chromium-cobalt; wherein:the powdered core material comprises constituents that complement the sheath to form the deposited alloy as a desired superalloy material when the sheath and powdered core material are melted together.6. The method of claim 5 , wherein the cored feed material is melted using a cold metal transfer ...

TUNGSTEN SUBMERGED ARC WELDING USING POWDERED FLUX

A tungsten submerged arc welding process wherein a non-consumable electrode () provides an arc () under a protective bed of flux powder (), thereby eliminating the need for an inert cover gas supply. The arc melts a feed material in the form of alloy powder () or filler wire () along with a surface of a substrate () to form a layer of cladding material () covered by a layer of slag (). The flux and slag function to shape the deposit, to control cooling, to scavenge contaminants and to shield the deposit from reaction with air, thereby facilitating the deposit of previously unweldable superalloy materials. 1. A method comprising;depositing a layer of powder comprising a powdered flux material onto a surface of a superalloy substrate;forming an arc within the layer of powder between a non-consumable electrode and the substrate;melting at least a portion of the flux material and a superalloy feed material with the arc to form a layer of cladding material covered by a layer of slag on the substrate; andallowing the cladding material to cool and to solidify under the layer of slag.2. The method of claim 1 , further comprising providing the feed material as powdered superalloy feed material within the layer of powder.3. The method of claim 2 , further comprising depositing the layer of powder as a layer of powdered superalloy feed material covered by a layer of the powdered flux material.4. The method of claim 2 , further comprising depositing the layer of powder as a mixed layer of powdered superalloy feed material and the powdered flux material.5. The method of claim 1 , further comprising depositing the layer of powder as a layer of composite particles comprising both superalloy and flux material.6. The method of claim 1 , further comprising providing the feed material in the form of solid or cored filler wire or strip.7. The method of claim 1 , further comprising providing the superalloy feed material to be a material outside a zone of weldability on a graph of ...

Flux assisted laser removal of thermal barrier coating

A method of removing a ceramic thermal barrier coating system ( 18 ). Laser energy ( 20 ) is applied to the thermal barrier coating system in the presence of a flux material ( 22 ) in order to form a melt ( 26 ). Upon removal of the energy, the melt solidifies to from a layer of slag ( 28 ) which is more loosely adhered to the underlying metallic substrate ( 12 ) than the original thermal barrier coating system. The slag is then broken and released from the substrate with a mechanical process such as grit blasting ( 30 ). Sufficient energy may be applied to melt an entire depth of the coating system along with a thin layer ( 34 ) of the substrate, thereby forming a refreshed surface ( 36 ) on the substrate upon resolidification.

BRAZING GAP SPACING APPARATUS AND METHOD

A screen (A-H) of a specified thickness (T) for insertion in a gap () between surfaces of workpieces () to be joined by brazing. The screen thickness determines and maintains the gap thickness during brazing. The screen has a higher melting point than the braze filler material (), is wettable by a melt of the braze filler material, and may have a higher tensile strength than the braze filler material at operating temperatures of the braze joint. The screen may include electrical resistance heating wires () to melt the filler material (). The screen may be covered by the filler material, forming a brazing foil (B). The screen may include electrically conductive insulated wires () connected to a sensor () such as a thermocouple or strain gauge to monitor a condition of the braze joint during subsequent operation. 1. A brazing apparatus comprising:a screen comprising an array of wires at least partially inserted between two opposed surfaces to be joined by brazing, wherein a thickness of the screen maintains a predetermined gap size between the two opposed surfaces, and wherein the screen comprises multiple intersections of wires that have a first melting point;a brazing filler material having a second melting point and positioned between the two opposed surfaces to define a brazed joint, wherein the second melting point is lower than the first melting point; andan electrical circuit arranged to include at least one of the wires of the screen and operable in response to the flow of an electrical current to heat the screen.2. The brazing apparatus of claim 1 , wherein the array of wires is made of materials selected from the group consisting of rhenium claim 1 , tantalum and refractory alloys.3. The brazing apparatus of claim 1 , wherein each of the multiple intersections comprises a crossing of two of the wires that overlap and are in physical contact with each other at the crossing claim 1 , and wherein said predetermined gap size is the sum of the thicknesses of the ...

FUNCTIONAL BASED REPAIR OF SUPERALLOY COMPONENTS

A method of repairing or manufacturing a superalloy component () by depositing a plurality of layers () of additive superalloy material having a property that is different than an underlying original superalloy material (). The property that is changed between the original material and the additive material may be material composition, grain structure, principal grain axis, grain boundary strengthener, and/or porosity, for example. A region () of the component formed of the additive material will exhibit an improved performance when compared to the original material, such as a greater resistance to cracking (). 1. A method comprising:simultaneously melting powdered alloy material and powdered flux material on a surface of an original superalloy material to form a melt pool comprising a layer of slag covering an additive superalloy material,cooling and solidifying the melt pool; andremoving the layer of slag to reveal a surface of the additive superalloy material;wherein the steps of melting and cooling and solidifying are performed such that the additive superalloy material has a property that is different from a counterpart property of the original superalloy material2. The method of claim 1 , further comprising selecting the powdered alloy material and the powdered flux material such that a composition of the additive superalloy material is different from a composition of the original superalloy material.3. The method of claim 1 , further comprising controlling a direction of solidification during the step of cooling and solidifying such that a grain structure of the additive superalloy material is different from a grain structure of the original superalloy material4. The method of claim 1 , wherein the original superalloy material comprises a directionally solidified material claim 1 , and further comprising controlling a direction of solidification during the step of cooling and solidifying such that a principal grain axis of the additive superalloy material is ...

RASTERED LASER MELTING OF A CURVED SURFACE PATH WITH UNIFORM POWER DENSITY DISTRIBUTION

A method of progressing a melt front () around a curved progression path () via a pattern (LP) of transverse laser scan lines (S-S) of differing lengths. Multiple area bands (B-B) conceptually divide a width of the curved path. The multiple transverse scan lines distribute the laser power among the bands with a predetermined uniformity that provides relatively consistent power density across the melt front. The scan lines may extend from a less curved side () of the curved path, through a band (B or B) of largest area, toward a more curved side () of the path. At least one of the scan lines (S, S) may cross all bands. Other scan lines are shorter and extend by varying distances into the inner bands (B-B or B-B), normalizing the power density across the bands. 1. A method comprising:scanning a laser beam along a series of scan lines on a material surface;progressing the scan lines in a curved path, wherein each scan line is transverse to the curved path;forming a pattern of a plurality of the scan lines of differing lengths that delivers a power of the beam across a plurality of area bands dividing a width of the curved path;wherein an area density of the power delivered to each band varies by less than 35% between each two of the bands along a length of the pattern.2. The method of claim 1 , wherein a first side of the curved path has greater curvature than a second side claim 1 , and further comprising forming the scan lines wherein the beam reaches the second side on each scan line of the pattern claim 1 , and does not reach the first side on some scan lines of the pattern.3. The method of claim 1 , further comprising forming the scan line pattern wherein a total scan time in the pattern is apportioned among the bands according to an area percentage of each band relative to a total area of the pattern.4. The method of claim 1 , wherein a first side of the curved path has greater curvature than a second side claim 1 , the bands have successively greater respective ...

MECHANICAL REPAIR OF DAMAGED AIRFOIL STRUCTURE

A process is provided for repairing an airfoil structure adapted for use in a gas turbine engine comprising: providing an airfoil structure having a section with a defect; removing airfoil structure material comprising the section with the defect such that a through hole is created; providing a replacement element; providing interlocking structure; positioning the replacement element relative to the through hole; and securing the replacement element to the airfoil structure via the interlocking structure such that the through hole is covered. 1. A process for repairing an airfoil structure adapted for use in a gas turbine engine comprising:providing an airfoil structure having a section with a defect;removing airfoil structure material comprising said section with the defect such that a through hole is created;providing a replacement element;providing interlocking structure;positioned said replacement element relative to said through hole; andsecuring said replacement element to said airfoil structure via said interlocking structure such that said through hole is covered.2. The process as set out in claim 1 , wherein said removing comprises forming a through hole comprising a first outer section and a second inner section claim 1 , said first section having a diameter greater than said second section.3. The process as set out in claim 2 , wherein said replacement element comprises a first outer portion and a second inner portion claim 2 , said first portion having a diameter slightly less than said diameter of said through hole first section and said second portion having a diameter slightly less than said diameter of said through hole second section claim 2 , wherein said first outer portion is received in said through hole first section and said second portion is received in said through hole second section.4. The process as set out in claim 3 , wherein said interlocking structure comprises threads on said replacement element and a section of said airfoil ...

METHOD AND APPARATUS FOR COOLING SUPERALLOY TURBINE COMPONENTS DURING COMPONENT WELDING

Superalloy components, such as steam and gas turbine blades or vanes, are cooled during welding fabrication or repair, so as to reduce likelihood of weld metal and weld heat affected zone cracking during weld solidification and during post weld heat treatment. More particularly the invention relates to cooling superalloy steam and gas turbine components, such as turbine blades or vanes during weld repair. A heat sink apparatus includes a heat sink having a first surface adapted for abutting orientation with a turbine component second surface; and a non-gaseous, conformable, heat conductive material adapted for conforming contact with both surfaces. The heat conductive material fills gaps between the heat sink and turbine component abutting surfaces, and facilitates enhanced conductive heat transfer, in order to minimize negative heat effects from welding. The apparatus may be incorporated in a cooling system that varies heat sink cooling capacity in response to sensed component temperature. 1. A heat sink apparatus for cooling a superalloy turbine component during component welding , comprising:a heat sink having a first surface adapted for abutting orientation with a turbine component second surface; anda non-gaseous, conformable, heat conductive material adapted for conforming contact with both surfaces by abutting the heat sink and turbine component.2. The apparatus of claim 1 , the heat conductive material comprising an elastomer.3. The apparatus of claim 2 , the heat conductive material comprising a metallic-filled elastomer.4. The apparatus of claim 2 , the heat conductive material comprising a ceramic-filled elastomer.5. The apparatus of claim 2 , the heat conductive material comprising an acrylic elastomer.6. The apparatus of claim 2 , the heat conductive material comprising a heat curable elastomer.7. The apparatus of claim 1 , the heat conductive material comprising grease.8. The apparatus of claim 1 , the heat conductive material comprising fluid confined ...

OPTIMIZATION OF MELT POOL SHAPE IN A JOINING PROCESS

A process of welding a superalloy is provided. The process includes applying a first amount of energy to a substrate comprised of the superalloy to form a melt pool along a length of the substrate and in a weld direction. The process also comprises advancing the melt pool in the weld direction along the length via the first amount of energy, the melt pool having a width transverse to the weld direction. Further, the process includes applying a second amount of energy to the substrate that extends outside the width of the melt pool at a trailing edge of the melt pool, which second amount of energy causes, relative to a process without application of the second amount of energy: broadening of the width of the melt pool at the trailing edge of the melt pool as the melt pool advances in the weld direction; and reducing segregation of artifacts and stress concentration along a centerline of the width. 1. A process of welding a superalloy comprising:applying a first amount of energy to a substrate comprised of the superalloy to form a melt pool along a length of the substrate and in a weld direction;advancing the melt pool in the weld direction along the length via the first amount of energy, the melt pool having a width transverse to the weld direction; and broadening of the width of the melt pool at the trailing edge of the melt pool as the melt pool advances in the weld direction; and', 'reducing segregation of artifacts and stress concentration along a centerline of the width., 'applying a second amount of energy to the substrate that extends outside the width of the melt pool at a trailing edge of the melt pool, which second amount of energy causes, relative to a process without application of the second amount of energy2. The process of claim 1 , wherein the first amount of energy and the second amount of energy are applied respectively by different energy sources.3. The process of claim 1 , wherein the first amount of energy and the second amount of energy are ...

APPARATUS FOR LASER PROCESSING OF HIDDEN SURFACES

A laser emitter () emits a laser beam () through optics () that focus the beam, and a beam deflection device () redirects the beam. An elongated probe () receives the beam at a proximal end () and has a remote mirror () that reflects the beam toward a hidden surface () to be processed by scanning of the beam. A programmable controller () controls focusing and deflection of the beam to move the focal point and spot of incidence () in three dimensions, causing the spot to traverse the hidden surface. The probe may optionally have translation () and rotation () actuators and a remote mirror pivot actuator () controlled by the controller. The probe may be L-shaped (A, B) to reach around an intervening structure (). An autofocus mechanism () may be provided to focus the beam during scanning or verify focus profiles before scanning. 1. Apparatus for laser processing of a hidden surface , comprising:a laser emitter that emits a laser beam;focusing optics that focus the beam;a beam deflection device that redirects the beam under program control;a probe that receives the beam at a proximal end thereof;a mirror at a distal end of the probe that reflects the beam toward a hidden surface; anda controller that controls focusing and redirection of the beam to move a spot of incidence of the beam in three dimensions, causing the spot of incidence to traverse the hidden surface in a programmed scan pattern.2. The apparatus of claim 1 , further comprising an actuator that moves the probe under program control of the controller.3. The apparatus of claim 1 , wherein the probe comprises a tube with a laser-transparent window at the proximal end and a beam exit aperture at the distal end claim 1 , and further comprising a purge gas supplied to the tube that exits the exit aperture.4. The apparatus of claim 1 , wherein the probe comprises a tube with a first laser-transparent window sealing the proximal end claim 1 , a beam exit aperture at the distal end claim 1 , a second laser- ...

MATERIAL DEPOSITION USING POWDER AND FOIL

The loss of aluminum content during the laser () deposition of superalloy powders () is accommodated by melting pure aluminum foil () with the superalloy powder to increase a concentration of aluminum in the melt pool () so that the resulting layer of deposited material () has a desired elemental composition Foils, screens or strips of any material may be melted with powders to achieve any desired cladding composition, including a graded composition across a thickness of a clad layer (). 1. A method of material deposition comprisingdisposing both powdered metal and metal foil over a substrate surface,melting the powdered metal and metal foil with an energy beam to form a melt pool, andallowing the melt pool to solidify to form a layer of deposited material on the substrate surface.2. The method of claim 1 , further comprisingdisposing powdered flux material with the powdered metal and metal foil over the substrate surface;melting the powdered flux material with the powdered metal and metal foil to form a layer of slag on the melt pool, andallowing the layer of slag to solidify with the melt pool; andremoving the layer of slag to reveal the layer of deposited material3. The method of claim 2 , wherein the powdered metal comprises a superalloy material claim 2 , the metal foil comprises an elemental constituent of the superalloy material claim 2 , and the energy beam comprises a laser beam.4. The method of claim 3 , further comprising disposing the powdered metal and metal foil over the substrate surface as a package.5. The method of claim 1 , further comprising positioning the metal foil onto the substrate surface and then depositing the powdered metal over the metal foil6. The method of claim 1 , further comprising disposing the metal foil within a layer of the powdered metal over the substrate surface.7. The method of claim 1 , further comprising disposing the metal foil over a layer of the powdered metal on the substrate surface.8. The method of claim 2 , further ...

METHOD FOR PROCESSING A PART WITH AN ENERGY BEAM

A method for processing a part () with an energy beam A mask () is arranged between a source of the energy beam and the part. The mask is configured with a beam-transmissive portion () in correspondence with mutually opposed portions () of the part. Simultaneously heating the mutually opposed portions of the part is performed with energy beamlets passing through the beam-transmissive portions of the mask This simultaneous heating is configured to keep a thermally-induced distortion of the part within a predefined tolerance. Scanning of the mask with the energy beam may be performed without precisely tracking the mutually opposed portions of the part, thereby avoiding a need for complicated numerical programming for tracking a relatively complex geometry defined by the mutually opposed portions of the part 1. A method for processing a part with an energy beam , the method comprising:arranging a mask between a source of the energy beam and the part;configuring the mask with a beam-transmissive portion in correspondence with mutually opposed portions of the part; andsimultaneously heating the mutually opposed portions of the part with energy beamlets passing through the beam-transmissive portion of the mask, wherein the simultaneous heating is configured to keep a thermally-induced distortion of the part within a predefined tolerance.2. The method of claim 1 , further comprising forming the energy beamlets passing through the beam-transmissive portion of the mask from an area energy beam having a fixed width3. The method of claim 2 , wherein the fixed width of the area energy beam is chosen to encompass at least a maximum width of a profile defined by the beam-transmissive portion in correspondence with the mutually opposed portions of the part.4. The method of claim 1 , further comprising forming the energy beamlets passing through the beam-transmissive portion of the mask from at least one point energy beam rastered along a width dimension of the mask claim 1 , and ...

METHOD FOR PROCESSING A PART WITH AN ENERGY BEAM

A method of processing a component () with an energy beam () comprises simultaneously scanning and heating a first portion () and second adjacent portion () of the component with an energy beam () At a point or area of divergence of the portions of the component, the energy beam is controlled to repeatedly move back and forth between the portions of the component. This simultaneous heating of adjacent portions () of the component is configured to keep a thermally-induced distortion of the component within a predefined tolerance. This dual-path processing may be performed on a bed of fluidized powdered material including a powdered metal material and a powdered flux material. 1. A process comprising:providing a powdered metal material to develop adjacent metal substrates; andsimultaneously selectively scanning and heating the powdered metal material with an energy beam along a first beam path and an adjacent second beam path to develop two adjacent substrates wherein the simultaneous heating is configured to keep a thermally-induced distortion of the one or both of the substrates within a predefined tolerance.2. The process of wherein the step of scanning and heating the powdered metal material comprises controlling the energy beam to move repeatedly from one beam path to the other beam path to scan and heat the powdered metal material along the respective beam paths.3. The process of wherein the process further comprises initially scanning the powdered metal material with the energy beam wherein the energy beam has a width dimension to cover both beam paths and then controlling the energy beam to move repeatedly from one beam path to the other beam path beginning at a point of divergence of the beam paths to scan and heat the powdered metal material along both beam paths.4. The process of further comprising decreasing the width dimension of the energy beam when the energy beam is controlled to move repeatedly from one beam path to the other beam path5. The process ...

ADHESION OF COATINGS USING ADHESIVE BONDING COMPOSITIONS

A multi-layer article () disclosed herein contains a metallic substrate (), a protective layer (), and an adhesive bonding layer () including an oxygen-containing compound that bonds the adhesive bonding layer to the metallic substrate, the protective layer, or both. A method for forming the multi-layer article includes the steps of heating a protective bonding composition () to form a molten material () in contact with a metal-containing surface (), allowing the molten material to cool and solidify into the adhesion bonding layer () affixed to the metal-containing surface, depositing a ceramic material () onto the adhesive bonding layer, and heating the ceramic material to form the protective layer () affixed to the adhesive bonding layer. 1. A multi-layer article , comprising:a metallic substrate;a protective layer; andan adhesive bonding layer comprising an oxygen-containing compound that bonds the adhesive bonding layer to the metallic substrate, the protective layer, or both.2. The article of claim 1 , further comprising a plurality of anchors bonded to the adhesive bonding layer and to at least one of the metallic substrate and the protective layer claim 1 ,wherein:the anchors comprise the oxygen-containing compound; anda structure of the anchors is effective to adhere the metallic substrate, the protective layer, or both, to the adhesive bonding layer by forming inter-layer linkages such that one portion of the anchors is attached to the adhesive bonding layer and another portion of the anchors is attached to the metallic substrate or to the protective layer.3. The article of claim 1 , comprising:a superalloy substrate;a MCrAlY bond coat layer bonded to a surface of the superalloy substrate;the adhesive bonding layer bonded to a surface of the MCrAlY bond coat layer; anda ceramic thermal barrier layer bonded to a surface of the adhesive bonding layer.4. The article of claim 1 , comprising:a superalloy substrate;the adhesive bonding layer bonded to a surface ...

Method of inducing porous structures in laser-deposited coatings

A layer of a powdered material ( 4 ) is heated with an energy beam ( 10 ) such that at least one gas-generating agent ( 8 ) reacts to form at least one gaseous substance ( 14 ) to produce a void-containing coating ( 16 ) adhered to the surface of a substrate ( 2 ). The powdered material may contain a metallic material, a ceramic material, or both, and may also contain at least one of a flux material ( 32 ) containing the gas-generating agent and an exothermic agent ( 64 ). The heating may occur using a laser beam and may induce a melting or sintering of the powdered material to produce the void-containing coating. A gas turbine engine component exhibiting improved thermal and mechanical properties may be formed to include the void-containing coating, which may take the form of a bond coating, a thermal barrier coating, or both.

METHOD TO FORM DISPERSION STRENGTHENED ALLOYS

A method for forming a dispersion strengthened alloy. An alloy material () is melted with a heat source () to form a melt pool () in the presence of a flux material (), and strengthening particles () are directed into the melt pool such that the particles are dispersed within the melt pool. Upon solidification, a dispersion strengthened alloy () is formed as a layer or weld joint bonded to an underlying substrate or as an object contained in a removal support. 1. A method comprising:melting an alloy material with a heat source to form a melt pool in the presence of a flux material;directing strengthening particles into the melt pool, such that the strengthening particles are dispersed within the melt pool; andallowing the melt pool to cool and solidify to form a dispersion strengthened alloy at least partially covered by a slag layer.2. The method of claim 1 , further comprising depositing a powdered filler material comprising the alloy material onto adjacent surfaces of at least two juxtaposed metal substrates claim 1 , such that the dispersion strengthened alloy forms a dispersion strengthened weld joint fusing the at least two juxtaposed metal substrates.3. The method of claim 2 , wherein the at least two juxtaposed metal substrates are dispersion strengthened alloy substrates.4. The method of claim 1 , further comprising depositing a powdered filler material comprising the alloy material onto a surface of a metallic substrate claim 1 , such that upon cooling of the melt pool the dispersion strengthened alloy is bonded to the surface of the metallic substrate.5. The method of claim 4 , wherein:the powdered filler material further comprises the flux material; orthe powdered filler material is covered by a layer of the flux material.6. The method of claim 1 , further comprising:depositing a powdered filler material comprising the alloy material onto a fugitive support material, such that upon cooling of the melt pool the dispersion strengthened alloy solidifies ...

METHOD TO FORM OXIDE DISPERSION STRENGTHENDED (ODS) ALLOYS

Method for forming an oxide dispersion strengthened alloy. An alloy material () is melted with an energy beam () to form a melt pool () in the presence of a flux material (), and particles () of a metal oxide are directed into the melt pool such that the particles are dispersed within the melt pool. Upon solidification, an oxide dispersion strengthened alloy () is formed as a layer bonded to an underlying substrate () or as an object contained on a removable support. 1. A method comprising:melting an alloy material with an energy beam to form a melt pool in the presence of a flux material;directing particles comprising a metal oxide into the melt pool, such that the particles are dispersed within the melt pool; andallowing the melt pool to cool and solidify to form an oxide dispersion strengthened alloy at least partially covered by a slag layer.2. The method of claim 1 , further comprising depositing a powdered filler material comprising the alloy material onto a surface of a metallic substrate claim 1 , such that upon cooling of the melt pool the oxide dispersion strengthened alloy is bonded to the surface of the metallic substrate.3. The method of claim 2 , wherein:the powdered filler material further comprises the flux material; orthe powdered filler material is covered by a layer of the flux material.4. The method of claim 1 , further comprising:depositing a powdered filler material comprising the alloy material onto a fugitive support material, such that upon cooling of the melt pool the oxide dispersion strengthened alloy solidifies upon the fugitive support material; andremoving the fugitive support material to obtain an object comprising the oxide dispersion strengthened alloy.5. The method of claim 4 , wherein:the fugitive support material is a bed comprising an oxide-containing material or a flux material; orthe fugitive support material is a container comprising a refractory material.6. The method of claim 4 , wherein:the powdered filler material further ...

METHODS AND APPARATUS OF WELDING USING ELECTRODES WITH COAXIAL POWDER FEED

A welding method using embodiments of electrodes () with coaxial power feed. The electrode comprises a metal cylinder () defining a hollow core (). The hollow core provides a conduit for delivering core feed materials () therebetween via a delivery means (). The cylinder may be formed of pure metals or extrudable alloys for forming a desired superalloy material composition; while the delivered core feed materials comprise a balance of compositional constituents for forming the desired superalloy material composition. The resulting deposit achieves the desired superalloy composition as a result of at least a combination of the cylinder materials and core feed materials. The electrode may further include a flux coating () surrounding the cylinder. The flux material may also contribute to the desired superalloy composition as a result of the weld operation. 1100. An electrode () comprising:{'b': 105', '110, 'a metal cylinder () defining a weld end and a hollow interior ();'}{'b': 150', '110, 'powdered feed materials () positioned in the hollow interior () and movable with respect to the metal cylinder towards the weld end of the electrode; and'}a delivery assembly operable to move the powdered feed materials with respect to the metal cylinder.2. (canceled)3. The electrode of claim 1 , wherein the material comprises one or more of iron claim 1 , nickel claim 1 , cobalt claim 1 , aluminum claim 1 , titanium.4. The electrode of claim 1 , wherein the material comprises extrudable metal alloy materials including a subset of elements of a composition contributing to define a desired superalloy material composition claim 1 , and wherein the powdered feed materials delivered via the conduit comprises a balance of compositional constituents defining the desired superalloy material composition.5. (canceled)6. The electrode of claim 1 , wherein the delivery assembly includes a carrier gas.7. The electrode of claim 6 , wherein the carrier gas is selected from one or more of argon ...

METHOD AND APPARATUS FOR PREPLACEMENT OF METAL FILLER POWDER AND FLUX POWDER FOR LASER DEPOSITION

Forming respective packets () of filler metal powder () and flux powder () for adjacent placement on a working surface () for laser deposition of the metal. Each packet may be formed of a sacrificial sleeve () or adjacently seamed sheets (A-D), which may include flux fibers such as alumina, zirconia, basalt, or silica. A packet () of flux may be disposed centrally inside a packet () of metal or vice versa. A connected stack () of three packets (A-C, A-C) may be formed by seaming (A-B) four stacked sheets (A-D) around common edges and filling the three resulting spaces between the sheets with a respective vertical sequence of metal/flux/metal or flux/metal/flux powders. Quilting and intermediate stitching may provide for precise control of material distribution and facilitate feeding of material. 1. A method comprising:providing a first packet containing a metal powder;providing a second packet containing a flux powder; andplacing the first and second packets adjacent to each other on a working surface; andconcurrently melting the first and second packets to deposit metal on the surface under a layer of slag.2. The method of claim 1 , further comprising:placing the first packet on the working surface,placing the second packet on the first packet;framing the first and second packets with shoes of a laser blocking material; anddirecting a laser beam onto the second packet, melting the flux powder and the metal powder to form a melt pool between the shoes.3. The method of claim 1 , further comprising disposing the first packet inside the second packet.4. The method of claim 1 , further comprising disposing the second packet inside the first packet.5. The method of claim 1 , further comprising disposing the second packet concentrically inside the first packet.6. The method of claim 1 , further comprising forming the first and second packets and a third packet from a stacked sequence of first claim 1 , second claim 1 , third claim 1 , and fourth sacrificial sheets seamed ...

FILLER CLOTH FOR LASER CLADDING

A preform (A-F) containing metal (A-C, ) and flux (A-C) for depositing a metal layer to a component being repaired or additively manufactured. The metal may be constrained in the preform in a distribution that creates a desired shape of the deposited metal in response to melting of the metal with an energy beam (). The preform may be embodied as woven (D) or unwoven (B, C) cloth containing fibers of the flux, and fibers, particles or foil of the metal. It may contain at least 30 wt % fibers and at least 40% void fraction to enable flexibility and laser penetration. Alternating layers () or flexible sintered sheets (A-C, ) of metal and flux fibers may be bound or laminated to form the preform. A woven preform may be made of alternating or crossing yarns () of metal and flux. 1. A preform for forming a layer of a component comprising:a metal and a flux, wherein the metal is constrained in the preform in a distribution that creates a desired shape of a metal layer of a metal component in response to a melting of the metal with an energy beam.2. The preform of claim 1 , wherein the metal and flux are bound in a predetermined shape that is flexible and conformable to a curved surface.3. The preform of claim 2 , further comprising at least a 40% void fraction.4. The preform of claim 1 , wherein the metal and flux are disposed in the preform in a predetermined proportion that creates a metal layer with a blanket of slag in response to the melting claim 1 , and the preform comprises at least 30 wt% of randomly oriented fibers.5. The preform of claim 4 , wherein the metal is disposed in particles and the flux is disposed in the randomly oriented fibers.6. The preform of claim 1 , wherein the metal is disposed in first strands or yarns of metal fibers claim 1 , the flux is disposed in second strands or yarns of flux fibers claim 1 , and the respective metal and flux strands or yarns are woven in a predetermined proportion that creates a metal layer with a blanket of slag in ...

SUPERALLOY SOLID FREEFORM FABRICATION AND REPAIR WITH PREFORMS OF METAL AND FLUX

A preform (A-U) containing metal () and flux () for forming a metal layer to be added to a component being repaired or additively manufactured. The metal may be constrained in the preform in a distribution that forms a shape of a sectional layer or a surface repair of a component in response to an energy beam () that melts the preform. The preform is placed on a working surface (), which may be a previously formed layer (A-C) in additive manufacturing, or may be an existing component surface () for repair The preform is then melted by the energy beam () to form a new integrated layer (A-F) on the component with an over-layer of slag () that shields and insulates the melt pool () and the solidifying layer The slag is removed, and a subsequent layer may be added. 1. A process comprising:forming a preform comprising a metal and a flux, wherein the metal is distributed in the preform responsive to a desired shape of a metal layer of a metal component;placing the preform on a working surface,directing an energy beam onto the preform to melt the metal, forming the metal layer overlaid by a slag layer; andremoving the slag layer2. The process of claim 1 , further comprising forming the preform as a container enclosing unbound particles of the metal and flux3. The process of claim 2 , further comprising partitioning the container into a plurality of compartments claim 2 , wherein at least a first one of the compartments encloses the unbound particles of the metal and flux.4. The process of claim 3 , further comprising loading at least a second one of the compartments with a non-metallic energy beam blocking material5. The process of claim 3 , further comprising including dry ice in at least one of the compartments.6. The process of claim 1 , further comprising:forming the preform as a container partitioned into a plurality of compartments,loading a first one of the compartments with first particles comprising the metal having a first average particle diameter, andloading a ...

METHOD OF IMPACT WELDING REPAIR OF HOLLOW COMPONENTS

A method of impact welding a flyer to a hollow component is provided. The method includes providing the component made of a first material and including a cavity where a weld site is disposed on a first side of the component. An incompressible material is packed against a second side of the component opposite the first side facing the cavity. A flyer made of a second material is positioned onto the weld site. The flyer is then impact welded to the component. The incompressible material prevents the deformation of the component during the impact welding. A method of impact welding a cover plate to a component is provided as well as a support system for welding repair of hollow components. 1. A method of impact welding a flyer to a hollow component , comprising:providing the component comprising a first material selected from the group consisting of superalloys, stainless steels, and high temperature nickel based alloys, and including a cavity wherein a weld site is disposed on a first side of the component;packing an incompressible material against a second side of the component, the second side is opposite the first side and facing the cavity;positioning a flyer comprising a second material onto the weld site; andimpact welding the flyer to the component,wherein the second material is selected from the group consisting of superalloys, stainless steels, and high temperature nickel based alloys,wherein the incompressible material prevents deformation of the component during the impact welding.2. The method as claimed in claim 1 , comprising preparing the weld site by excavating damaged material.3. The method as claimed in claim 1 , comprising machining the flyer after the impact welding in order for an outer contour of the second material to conform to a desired contour of the component.4. The method as claimed in claim 1 , wherein the impact welding procedure is selected from the group consisting of explosion welding claim 1 , magnetic pulse welding claim 1 , ...

POWDER DEPOSITION PROCESS UTILIZING VIBRATORY MECHANICAL ENERGY

A method for depositing clad material () onto a substrate () by melting a layer of powdered material () using an energy beam (), and also applying vibratory mechanical energy ( and/or ). The vibratory mechanical energy may be applied before, during or after the melting and solidification of the powdered material in order to preheat the powder, to distribute powder over a top surface () of the substrate, to control the formation of dendrites in the clad material as the melt pool () solidifies, to remove slag, and/or to perform stress relief. Simultaneous application of beam energy and vibratory mechanical energy facilitates the continuous deposition of the clad material, including directionally solidified material. 1. A process comprising:distributing a powdered material over a surface of a substrate;melting the powdered material with an energy beam;allowing the melted material to solidify on the substrate; andapplying vibratory mechanical energy to the powdered material in contact with the substrate or to the substrate during at least one of the steps of distributing, melting and allowing to solidify.2. The process of claim 1 , wherein the powdered material is distributed over the surface by the application of the vibratory mechanical energy.3. The process of claim 1 , wherein the powdered material is distributed over the surface in a continuous manner by the application of the vibratory mechanical energy and the steps of melting and allowing to solidify are conducted continuously.4. The process of claim 1 , wherein the vibratory mechanical energy is applied in a manner effective to preheat the powdered material prior to the step of melting.5. The process of claim 1 , wherein the vibratory mechanical energy is applied to the melted material as it solidifies in a manner effective to break dendrites forming during the solidification.6. The process of claim 1 , wherein the vibratory mechanical energy is applied to the solidified material on the substrate in a manner ...

ACOUSTIC MANIPULATION AND LASER PROCESSING OF PARTICLES FOR REPAIR AND MANUFACTURE OF METALLIC COMPONENTS

A disclosed method includes the steps of generating at least one ultrasonic standing wave (′) between at least one set of mutually-opposed ultrasonic transducers (A, B), dispensing metal-containing particles () into a node () located within the ultrasonic standing wave such that the particles are trapped in the node, positioning a surface of a substrate () proximate to the node, melting the particles with an energy beam to form a melt pool () in contact with the surface, and allowing the melt pool to cool and solidify into a metal deposit () bound to the surface. Apparatuses for carrying out such methods are also disclosed. 1. A method , comprising:generating at least one ultrasonic standing wave between at least one set of mutually-opposed ultrasonic transducers;dispensing metal-containing particles into a node located within the at least one ultrasonic standing wave, such that the metal-containing particles are trapped within the node;positioning a surface of a substrate proximate to the node such that the metal-containing particles become or remain trapped within the node;melting the metal-containing particles with an energy beam to form a melt pool in contact with the surface of the substrate; andallowing the melt pool to cool and solidify into a metal deposit bound to the surface of the substrate.2. The method of claim 1 , comprising generating two orthogonally-arranged ultrasonic standing waves with two orthogonally-arranged sets of mutually-opposed ultrasonic transducers.3. The method of claim 1 , wherein a gaseous medium surrounds the trapped metal-containing particles such that the particles are levitated in a three-dimensional space defined in part by an arrangement of the at least one set of mutually-opposed ultrasonic transducers.4. The method of claim 3 , further comprising tuning the at least one set of transducers in order to change a position of the trapped metal-containing particles within the three-dimensional space.5. The method of claim 1 , ...

MATERIAL REPAIR PROCESS USING LASER AND ULTRASOUND

A process for repair of a surface () of a substrate () including the application of an energy beam () and vibratory mechanical energy () to the surface in a region of a discontinuity () in order to form a renewed surface () on the substrate. A powdered flux material () may be disposed over the discontinuity and melted in order to trap and remove contaminants () into a layer of slag (). The vibratory mechanical energy may be applied to dislodge contaminants within the discontinuity, to add friction heat to the discontinuity, to assist in the flotation of the slag, to remove solidified slag, and/or to provide stress relief of the renewed surface. 1. A process for repair of a surface of a substrate , the process comprising:imparting mechanical vibratory energy to the surface in a region of a discontinuity;melting a portion of the surface including the discontinuity with an energy beam to form a melt pool; andallowing the melt pool to solidify to form a renewed surface on the substrate without the discontinuity.2. The process of claim 1 , wherein the mechanical vibratory energy is imparted to the surface at least prior to the step of melting.3. The process of claim 1 , wherein the mechanical vibratory energy is imparted to the surface at least during the step of melting.4. The process of claim 1 , wherein the mechanical vibratory energy is imparted to the surface at least after the step of melting.5. The process of claim 1 , further comprising imparting the mechanical vibratory energy as ultrasonic energy and melting the portion of the surface with a laser beam.6. The process of claim 1 , further comprising:depositing flux onto the surface over the discontinuity;melting the flux during the step of melting a portion of the surface, the melted flux forming a layer of slag over the melt pool; andremoving the layer of slag to reveal the renewed surface.7. The process of claim 6 , further comprising applying the flux as a paste or liquid effective to infiltrate the ...

MOBILE REPAIR AND MANUFACTURING APPARATUS AND METHOD FOR GAS TURBINE ENGINE MAINTENANCE

Refurbishment of hot gas path components of gas turbine engines can now be performed locally in lieu of the traditional use of a specialized fixed regional repair facility. A mobile manufacturing platform () is provided with the capability to inspect and to repair ceramic coated superalloy alloy components, including the ability to perform flux assisted laser processing () of powdered materials. The mobile platform may include a powder mixing capability () for custom on-site mixing of proprietary powder compositions from a standardized powder inventory (). A communications element () conveys the proprietary powder compositions from a remote home office location (). Superalloy components can now be repaired () or fabricated () on-site by qualified technicians rather than certified welders. The mobile platform may be self-powered by a vehicle hybrid power unit or a renewable energy source. 1. A method comprising:providing a mobile manufacturing platform comprising a laser processing element;transporting the mobile manufacturing platform to proximate a location of a gas turbine engine to be serviced;transferring a service run hot gas path component removed from the gas turbine engine to the mobile manufacturing platform;inspecting the service run component and determining a necessary repair or alternatively a need for the service run component to be scrapped and replaced with a replacement component;repairing a superalloy material portion of the service run component, or alternatively fabricating the replacement component comprising superalloy material, with the laser processing element using a flux assisted process; andinstalling the repaired component, or alternatively the replacement component, into the gas turbine engine.2. The method of claim 1 , further comprising mixing a powder mixture appropriate for the repairing or fabricating step in a powder mixing element of the mobile manufacturing platform.3. The method of claim 2 , further comprising providing ...