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:
The present disclosure relates generally to a system and method for applying a metallic coating. A first metallic coating may be applied to a portion of a total surface of a part and a second metallic coating may be applied to substantially the total surface. The metallic coating may be applied to a vane cluster for use in a turbomachine.
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 is provided for reworking a component. The method includes at least partially filling a cavity in a non-fusion weldable base alloy with a multiple of layers of a multiple of laser powder deposition spots formed of a filler alloy. Each of the multiple of laser powder deposition spots at least partially overlaps at least one of another of the multiple of laser powder deposition spots. The filler alloy may be different than the non-fusion weldable base alloy.
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 laser cladding head (12) comprises a protective housing (18), a focal array (26), a turning mirror (36), and a powder nozzle (34). The housing (18) extends along a primary axis (A P ) from a proximal end (20) to a distal end (22). The focal array (26) is situated at the proximal end (20) and oriented to receive and focus collimated light (28) in a beam (28) directed substantially along the primary axis (Ap). The turning mirror (30) is situated at the distal end (22) and disposed to redirect the beam (28) in an emission direction, towards a target point (P T ) separated from the turning mirror (30) by a working distance (D T ) of at most a tenth the focal length. The turning mirror (30) is a nonfocal reflective surface indexable to alter an impingement location (P I ) of the beam (28) on the turning mirror (30). The powder nozzle (34) is situated at the distal end (22) and receives and directs weld material towards the target point (P T ) for melting.
Abstract:
A weld clad layer having a substantially equiaxed grain microstructure may be formed by forming a repair area (304) in a substrate (201), by depositing a first layer of laser deposition spots (320) in the repair area (304), and depositing a second layer of laser deposition spots (320) over the first layer of laser deposition spots (320). The first layer of laser deposition spots (320) comprises a first laser deposition spot (320) and a second laser deposition spot (320) adjacent to the first laser deposition spot (320). The first laser deposition spot (320) solidifies prior to deposition of the second laser deposition spot (320). The first layer of laser deposition spots (320) comprises titanium or titanium alloy.
Abstract:
A laser cladding system (10) comprises a cladding head (12) and a gas system (50). The cladding head (12) extends along a primary axis (A P ), and comprises a mirror (30) and a powder nozzle (34) both situated at a distal end (22) of the head (40). The powder nozzle (34) directs weld material at a target point (P T ), and the mirror (30) directs a beam (28) of collimated light at the target point (P T ). The gas system (50) comprises a high-speed gas nozzle (304) and a gas knife (310). The high-speed gas nozzle (304) produces a gas sheath (302) coaxial with the beam (28) in a region between the mirror (30) and target point (P T ), shielding the mirror (30) from debris and backspatter. The gas knife (310) redirects the gas sheath (302) away from the target point (P T ) and redirects debris and molten backspatter away from an interior of the laser cladding head (12).
Abstract:
A method is provided that involves a component (20) including a first fastener aperture (36) that extends through the component (20). During the method, the component (20) is machined to enlarge the first fastener aperture (36) to provide an enlarged aperture (54). The component (20) is friction plug welded to plug the enlarged aperture (54) with friction plug welded material (56). A second fastener aperture (36B) is machined in the friction plug welded material (56), where the second fastener aperture (36B) extends through the component (20).
Abstract:
A method is provided for reworking a component. The method includes at least partially filling a cavity in a non-fusion weldable base alloy with a multiple of layers of a multiple of laser powder deposition spots formed of a filler alloy. Each of the multiple of laser powder deposition spots at least partially overlaps at least one of another of the multiple of laser powder deposition spots. The filler alloy may be different than the non-fusion weldable base alloy.