United Technologies Corporation

David A Rutz

Monika D Kinstler

Robert L Memmen

Robert P Schaefer

Daniel A Bales

Norman Pietruska

James J Moor

Igor V Belousov

Edward R Szela

Beth Kwiatkowski Abriles

Bradford A Cowles

Igor S Malashenko

Edward Lee

Michael A Joy

Gregory A Serhiyenko

Evgeniy A Shelkovoy, Legal Representative

Nicole Sullivan

Brian S Tryon

Paul Henry Zajchowski

Thomas DeMichael

Walter E Olson

William M Rose

Donn Blankenship

Sudhangshu Bose

Gary Charles Shubert

Andrew DeBiccari

Billie W Bunting

David R Malley

Edward J Ryan

Timothy P Hasselberg

Kenneth E Taylor

Leonard A Friedrich

Jack W Lee

John H Hughes

Bryan W Manis

Louis E Dardi

Edward J Johnson

Walter F Gustafson

Edward L Johnson

Richard Gerst

Anatoli N Shelkovoy

Donn R Blankenship

Norman A Pietruska

Gary Shubert

Norman A Pietrusca

Jeffrey D Hayes

A repaired article includes a body extending between a first side and a second side. The body has a repair section with an associated thickness between the first side and the second side. The repair section includes regions of plastic deformation distributed through the thickness. A gas turbine engine including the body is also disclosed.

Repair article of a gas turbine engine

A method of hole defect repair includes removing one or more defects at or near a desired hole in a part by removing a portion of the part proximate the desired hole in a series of chain link patterns, and welding a filler material to the part after removing the chain link pattern portion of the part.

Bolt hole repair technique

A method of repairing an article includes removing an undesirable section of the article, attaching a repair section to the article at a location from which the undesirable section has been removed, and mechanically working the repair section to achieve a reduction in a cross-sectional area of the repair section.

Method of repairing an article

A method of repairing a stator assembly of a gas turbine engine includes removing a worn surface of the stator assembly to provide a revealed area, and securing additional material to the stator assembly utilizing gas metal arc welding.

Method for repairing a gas turbine engine component

A method of repairing a damaged coated vane from a turbine module without removing the vane from the module is taught. The method includes locally removing the coating in the vicinity of the damage as well as any underlying damage in the superalloy substrate. A diffusible coating precursor is then applied to the damage site. A heat treating fixture is then mounted on the vane and repair site is heated to up to 2000&#xb0; F. in an inert environment to interdiffuse the coating precursor and the substrate. After the diffusion anneal, the vane is cleaned and the module is returned to service.

Repair of coated turbine vanes installed in module

Repair methods involving conductive heat resistance welding includes repairing a crack of a gas turbine engine component using a conductive heat resistance welding technique and a welding technique other than conductive heat resistance welding.

Repair methods involving conductive heat resistance welding

A method for depositing a first material on a substrate includes providing the substrate in a deposition chamber. A molten body is formed between the substrate and a source of the first material by melting one or more second materials. A flow of the first material is passed through the molten body and from the molten body to the substrate as a vapor flow. An essentially non-expending portion of the molten body comprises an alloy having a melting temperature below a melting temperature of the first material.

Vapor deposition of dissimilar materials

A gas turbine engine blade has a platform. A root depends from the platform and an airfoil extends from the platform. The airfoil has leading and trailing edges and pressure and suction sides. The blade has a substrate having a surface. A compressive stress exists below a first region of the surface. The first region extends over a majority of a streamwise perimeter of the airfoil at a location at a spanwise distance from the tip or more than 50% of a tip-to-platform span. A coating is on the surface including at the location.

Pre-coating burnishing of erosion coated parts

A method for restoring blade dovetails to their original shape comprising the steps of removing damaged material from a blade dovetail at a damage site, physically depositing a metal at the damage site in an amount sufficient to replace the removed damaged material, and machining the blade dovetail to the original shape.

Fan and compressor blade dovetail restoration process

Microspray apparatus and methods involve injecting powdered material into a plasma gas stream. The material comprises first and second component powders. The second powder is a majority by the weight of the powdered material. The first powder acts as a melting point depressant. The first and second powders may have similar compositions but with the first powder including a greater quantity of a melting point depressant element.

Deposition apparatus and methods

Novel materials and methods for repairing/reclassifying superalloy components are described herein. These materials are non-traditional blends of materials having a much higher base material content than traditional repair/reclassification materials. In embodiments used to repair/reclassify nickel-based components, these materials may comprise about 5-18.9 weight percent of a low melting point alloy and about 81.1-95 weight percent of a base material. In embodiments used to repair/reclassify cobalt-based components, these materials may comprise about 15-30 weight percent of a low melting point alloy and about 70-85 weight percent of a base material. These materials can be used to repair surface defects and/or build up worn or eroded areas of a component to meet precise dimensional and metallurgical requirements. These materials create robust repaired components having a dense, isothermally solidified structure having minimal borides and a high re-melt temperature.

Repair and reclassification of superalloy components

The present invention relates to a self cleaning braze paste which is used in the repair of gas turbine engines. The braze paste comprises lithium fluoride in an amount sufficient to act as a flux which allows the braze material to flow into a crack or void in a part to be repaired up to an amount where there is no residual lithium or fluoride in the crack or void, preferably up to about 20% by volume, a gel binder in an amount up to about 15% by volume, and the balance comprising at least one of a nickel braze alloy and a cobalt braze alloy. In a preferred embodiment, the lithium fluoride is present in an amount from about 10% to about 15% by volume. The braze material of the present invention may be applied in a paste form or, alternatively, in a paint or tape form. A method for cleaning and repairing a braze joint is also disclosed. The method broadly comprises the steps of forming a braze material containing lithium fluoride in the above mentioned range, a gel binder in an amount up to about 15% by volume, and the balance comprising at least one of a nickel braze alloy or a cobalt braze alloy, applying the braze material to the braze joint, and heating the braze material to a temperature in the range of from about a temperature sufficient to cause the lithium fluoride to volatize up to about 2300&deg; F. for a time period from about 1.0 minute to about 30.0 minutes.

Self cleaning braze material

An abrasive, wear resistant layer is applied to the tip surface of a superalloy gas turbine blade by high temperature sintering operation which produces a high strength bond between the layer and the blade, minimizes gamma prime phase growth, and prevents recrystallization in the blade. Important features of the invention include removing plastic strain damage from the tip surface prior to the sintering operation, using induction heating techniques to sinter a layer of metal powder particles and ceramic particulates to the blade tip surface, and shielding the airfoil and root portion of the blade from the radiant heating source during the sintering operation while at the same time, conductively removing heat from the blade.

Method for making a turbine blade having a wear resistant layer sintered

A gas turbine engine blade has an abrasive material tip with a fused superalloy matrix and evenly distributed ceramic particulate. The matrix will have a desirable metallurgical structure characterized by fine dendrites and remanants of the original powder metal structure from which it was made. Due to the fusion of the tip, the peripheral edge will tend to be curved. To lessen the effect of thermal strains on such an abrasive tip, a sheath of a superalloy, such as a portion of the turbine blade substrate, extends along the side of the abrasive. The sheath may be present only in the thicker leading edge part of the blade airfoil.

Turbine blade having a fused metal-ceramic tip

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Glastonbury, CT, United States of America

David A Rutz