Abstract:
A method of reworking an aerospace component includes removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity. The cavity is then at least partially filled with a multiple of layers of discrete laser powder deposition spots of a filler alloy. A cast component for a gas turbine engine includes a cast component non-fusion weldable base alloy with a cavity filled with a multiple of layers of laser powder deposition spots of a filler alloy. The filler alloy may be different than the non-fusion weldable base alloy. A layer of non-fusion weldable base alloy is at least partially within the cavity and over the filler alloy.
Abstract:
A method of repairing defects in a casting formed from non-weldable or difficult-to-weld alloys is disclosed. The method includes removing the defect from the casting thereby forming a cavity in the casting, placing a filler material in the cavity and fusion welding the filler material in the cavity. The fusion welding produces surface cracks on the casting and sub-surface cracks in the casting. The method then includes brazing at least some of the surface cracks on the casting and processing the casting with a hot isostatic pressure (HIP) process to close at least some of the sub-surface cracks in the casting.
Abstract:
A method of forming a hybrid component having an axis of rotation includes forming a first substrate having a first interface surface and a first average grain size, forming a second substrate having a second interface surface and a second average grain size different from the first average grain size, and inertia welding the first and second substrates at a junction of the first and second interface surfaces to form a solid-state joint between the first and second substrates.
Abstract:
A method of forming a hybrid component (10) having an axis of rotation (18) includes forming a first substrate (20) having a first average grain size, forming a second substrate (22) having a second average grain size different from the first average grain size, positioning an interlayer (24) on one of the first and second substrates (20, 22), positioning a portion of the first substrate (20) adjacent a portion of the second substrate (22) such that the interlayer (24) extends between the portion of the first substrate (20) and the portion of the second substrate (22), heating the first and second substrates (20, 22) and the interlayer (24) at a temperature below the melting points of the first and second substrates (20, 22) to melt the interlayer (24), and isothermally solidifying the interlayer (24) to form a solid-state joint (26) between the portions of the first and second substrates (20, 22).
Abstract:
A method of reworking or repairing a component includes removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity that results in a through hole; sealing the through hole with a backing; and at least partially filling the cavity with a multiple of layers of a multiple of laser powder deposition spots, each of the multiple of laser powder deposition spots formed of a filler alloy, a first layer of the multiple of layers includes a perimeter of the multiple of laser powder deposition spots that overlap a wall of the cavity and the backing.
Abstract:
A method for coating a part according to an aspect of the disclosure includes the step binding a metallic powder (100) to a section (98) of the part. The metallic powder (100) is then energized which at least partially melts and resolidifies the metallic powder (100) to form a first metallic coating (102). After the first layer of metallic coating (102) is formed a second layer of metallic coating (110) is deposited on substantially all of the part.