Siemens Westinghouse Power Corporation

Siemens Energy, Inc.

Siemens Power Generation, Inc.

Brij B Seth

Gregg P Wagner

Michael Anthony Burke

Gary W Swartzbeck

Paul John Zombo

Thomas Walter Zagar

Paula D Freyer

Mohan A Hebbar

Ramesh Subramanian

David B Allen

Kent Goran Hultgren

Allister William James

Dennis C Nagle

David S Segletes

Peter Jon Ditzel

Srikanth Chandrudu Kottilingam

Vinod Philip

Kevin C Sheehan

Carol E Moyer

Stanislaus A David

Gene M Goodwin

Sudarsanum S Babu

Kenneth Kirch Starr

Easo P George

Greg P Wagner

A method of fabricating a Ti-6Al-4V titanium alloy component including solution heat treating a forged Ti-6Al-4V titanium alloy component at a temperature within the alpha+beta two-phase field for the material of the component for a predetermined period of time, and subsequently cooling the component. The component is then age heat treated using an overaging process at a predetermined overaging temperature for a predetermined time, and the component is cooled to room temperature. The overaging temperature is selected to be a higher temperature than an aging heat treatment temperature for effecting a maximum yield strength in the component.

Solution heat treatment and overage heat treatment for titanium components

A method of adding material to a nickel-based superalloy component, such as a gas turbine rotor disk, without damaging the underlying material and without creating an unacceptable level of cracking. The method is advantageously applied in the repair of Alloy 706 turbine rotors having experienced operating failures in the steeple region of the disk. Once the damaged material is removed, replacement nickel-based superalloy material is added using a welding process that protects both the underlying material and the replacement material. The replacement material may be added by welding, with the preheat temperature maintained no lower than 100&#xb0; C. below the aging temperature of the deposited alloy and with the interpass temperature maintained below the solution annealing temperature of the alloy. Alternatively, the replacement material may be preformed and welded to the original material using a friction welding process. In one embodiment, a replacement steeple of directionally solidified or single crystal material is installed onto a disk hub using a linear friction welding technique.

Repair of nickel-based alloy turbine disk

A component () including a substrate material () and a wear alloy coating () applied to the substrate by a cold spray process. Particles of the wear alloy coating material () are directed toward a target surface () of the substrate at a velocity sufficiently high for the particles to deform and to adhere to the target surface. The size and/or composition of the particles may be varied during the cold spray process to produce a coating with a varying property across the depth of the coating. Particles of the wear alloy material may be applied by cold spraying along with particles of a second material such as a lubricant or a ceramic material. For Group 5 hard facing materials, the size and distribution of the embedded carbide nodules may be controlled by controlling the selection of the carbide particles being sprayed. The cold spray process permits a wear alloy coating to be applied proximate a brazed joint or over a directionally stabilized or single crystal material without degrading the underlying material.

Component having wear coating applied by cold spray process

A method for preparing a protective layer () on a surface of the substrate () that requires a bonding temperature (BT) above a detrimental phase transformation temperature range () of the substrate, and then cooling the layer and substrate without cracking the layer or detrimentally transforming the substrate. The protective layer () and the substrate () are cooled from the bonding temperature (BT) to a temperature () above the detrimental phase transformation range () at a first cooling rate () slow enough to avoid cracking the protective layer. Next, the protective layer and the substrate are cooled to a temperature below the detrimental phase transformation range of the substrate at a second cooling rate () fast enough to pass the detrimental phase transformation range before a substantial transformation of the substrate into the detrimental phase can occur.

Crack-free erosion resistant coatings on steels

A method () of fabricating a large component such as a gas turbine or compressor disk () from segregation-prone materials such as Alloy 706 or Alloy 718 when the size of the ingot required is larger than the size that can be predictably formed without segregations using known triple melt processes. A sound inner core ingot () is formed () to a first diameter (D), such as by using a triple melt process including vacuum induction melting (VIM), electroslag remelting (ESR), and vacuum arc remelting (VAR). Material is than added () to the outer surface () of the core ingot to increase its size to a dimension (D) required for the forging operation (). A powder metallurgy or spray deposition process may be used to apply the added material. The added material may have properties that are different than those of the core ingot and may be of graded composition across its depth. This process overcomes ingot size limitations for segregation-prone materials.

Rotating apparatus disk

A method for in-frame repairing of a thermal barrier coating () on a gas turbine component includes cleaning a desired surface portion () of the component without removing the component from the gas turbine. The method also includes roughening the surface portion in-frame, applying a bond coat () to the surface portion in-frame, and applying a ceramic topcoat () to the bond coat, in-frame. A system () for cleaning the surface portion in-frame includes an abrasive media () having a state change characteristic occurring at a temperature lower than an operating temperature of the gas turbine so that the abrasive media changes from a solid state to another state allowing the media to exit the gas turbine during operation. The system also includes an abrasive media sprayer () to direct a spray of the abrasive media at the desired surface portion.

In-frame repairing system of gas turbine components

Method of manufacturing a rotating apparatus disk

A wear alloy coating ( ) applied to a substrate material ( ) by a cold spray process. Particles of the wear alloy coating material ( ) are directed toward a target surface ( ) of the substrate at a velocity sufficiently high for the particles to deform and to adhere to the target surface. The size and composition of the particles may be varied during the cold spray process to produce a coating with a varying property across the depth of the coating. Particles of the wear alloy material may be applied by cold spraying along with particles of a second material such as a lubricant or a ceramic material. For Group 5 hard facing materials, the size and distribution of the embedded carbide nodules may be controlled by controlling the selection of the carbide particles being sprayed. The cold spray process permits a wear alloy coating to be applied proximate a brazed joint or over a directionally stabilized or single crystal material without degrading the underlying material.

Wear and erosion resistant alloys applied by cold spray technique

A device ( ) is made, having a ceramic thermal barrier coating layer ( ) characterized by a microstructure having gaps ( ) with a sintering inhibiting material ( ) disposed on the columns ( ) within the gaps ( ). The sintering resistant material ( ) is stable over the range of operating temperatures of the device ( ), is not soluble with the underlying ceramic layer ( ) and is applied by a process that is not an electron beam physical vapor deposition process.

Thermal barrier coating resistant to sintering

An abrasive coating and a process for forming the abrasive coating by co-depositing hard particles within a matrix material onto a substrate using a cold spray process. The cold sprayed combination of hard particles and matrix material provides a coating that is wear, erosion and oxidation resistant. The abrasive coating may have different compositions across its depth. The hard particles may be deposited at different densities across the thickness of the matrix material. A first layer of the abrasive coating proximate the surface of the substrate may be devoid of hard particles.

Mixed powder deposition of components for wear, erosion and abrasion resistant applications

A fusion weldable superalloy containing 0.005-0.5 wt. % scandium. In one embodiment, the superalloy may have a composition similar to IN-939 alloy, but having added scandium and having only 0.005-0.040 wt. % zirconium. A gas turbine component may be formed by an investment casting of such a scandium-containing superalloy, and may include a fusion weld repaired area. A scandium-containing nickel-based superalloy coated with an MCrAlY bond coat will have improved cyclic oxidation resistance due to the sulfur-gettering effect of the scandium.

Superalloy material with improved weldability

High efficiency, thin-walled turbine components such as turbine blade airfoils comprise a superalloy substrate covered by a thin skin. The thin skin may be bonded to the inner spar structure of a turbine blade airfoil by a transient liquid phase bonding process. The inner spar preferably comprises a cast single crystal nickel base superalloy. The thin skin may comprise a single crystal or polycrystalline nickel base superalloy or the like.

Turbine components comprising thin skins bonded to superalloy substrates

A process ( ) for the repair of a component part ( ) incorporating a cold spray process step ( ) for depositing material particles ( ) to fill a discontinuity ( ) in the part surface ( ) or to create a desired surface geometry ( ) on the part ( ). The cold spray process may be controlled to provide a grit blasting effect prior to depositing the material in order to remove contaminants ( ) from the surface of the part. The material deposited ( ) by the cold spray process may form a joint ( ) between an insert ( ) and the part ( ). The process may be used to repair parts made of directionally solidified (DS) or single crystal (SC) base material ( ) without causing a re-crystallization of the base material. The process may further be used to deposit repair material ( ) over a braze material ( ).

Cold spray repair process

A process ( ) for applying a thermal barrier coating ( ) to a turbine component ( ) including the step ( ) of depositing a bond coating layer ( ) by, directing solid particles using a cold spray process. The layer of bond coating material may have different depths ( ) in different areas of the component ( ), and it may have different compositions ( ) across its depth. The precise control afforded by the cold spray material deposition step allows the surface of the bond coating material layer to be formed with a predetermined surface roughness or with a plurality of micro-ridges ( ) in order to optimize its bond to the overlying ceramic insulating layer ( ).

Thermal barrier coating applied with cold spray technique

A method of consolidating or repairing turbine component parts, such as turbine blades ( ), requires providing a turbine component part ( ), establishing a contact pressure between the opposing surfaces ( ), where, optionally, fine particles may be present between such surfaces ( ), and then generating an electrical field to provide heat, and applying pressure on the opposing surfaces, resulting in high temperature spark plasma sintering to provide a consolidated turbine blade ( ).

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Maitland, FL, United States of America

Brij B Seth