Siemens Energy, Inc.

Mikro Systems, Inc.

Dhafer Jouini

Ahmed Kamel

Gerald Joseph Bruck

Gary Brian Merrill

Michael P Appleby

Kazim Ozbaysal

Bernd Burbaum

John R Paulus

Jill Klinger

Daniel J Ryan

David G Maire

Iain Alasdair Fraser

Gabriel Victor Orsinger

Daniel Ellgass

Systems () and methods () for additively manufacturing or repairing a component from a base material (). The system may include a laser metal deposition (LMD) system () operably connected to a means for cooling () the base material during laser processing of additive materials deposited in a melt pool on the base material. The LMD system includes a laser energy source () configured to direct laser energy towards the base material to form the melt pool thereon and to processes the deposited additive materials to form layers on the base material upon solidification. The means for cooling may be configured to cool the base material to within a cooling temperature range during the LMD process, which results in, e.g., a cooling/freezing effect. This cooling effect shortens the solidification period during laser processing and allows for weld heat to be released from the base material.

Laser metal deposition of high gamma prime superalloys with cooling effect

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.

Gas turbine engine component with performance feature

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 ().

Functional based repair of superalloy components

A process and apparatus for solid freeform fabrication and repair of components on existing bodies (such as turbine blades), the innovative process and apparatus as well as the resultant product having the following advantages: a) Can build on existing 3-D surfaces. Not limited to horizontal flat surfaces, b) Usable for metals that are difficult to weld. c) Robust process that is adaptable to new damage modes. d) No shielding of the melt pool by inert gas is needed. e) Wide range of powder sizes.

Forming a secondary structure directly onto a turbine blade

A superalloy component such as a gas turbine engine blade () having a ceramic thermal barrier coating () is repaired using a textured repair foil (). A degraded region of the thermal barrier coating is removed () and the underlying superalloy material surface is prepared () for re-coating. The repair foil is includes a layer of boron-free braze material () and a layer of superalloy material () having a textured surface (). The foil is brazed () to the prepared surface during a solution heat treatment effective to homogenize the braze (). A new area of thermal barrier coating () is applied over the foil with a bond that is enhanced by the texturing of the foil surface.

Component repair using brazed surface textured superalloy foil

A method, including: detecting in a nondestructive manner a marker () that is fully submerged in a substrate () to obtain spatial information about the marker; detecting in a nondestructive manner the marker after a period of time to obtain a change in the spatial information; and using the change in the spatial information to determine a change in a dimension () of the substrate. The method may be used to measure creep in a gas turbine engine component.

Nondestructive detection of dimensional changes in a substrate using subsurface markers

A method of repairing a superalloy component () wherein a section () of the component containing a plurality of service-induced cracks () is removed, then a replacement section () of superalloy material is installed with a structural braze joint () containing no boron or silicon. The replacement section may have a textured surface (() to enhance bonding with an overlying thermal barrier coating (). The replacement section may be pre-formed to standardized dimensions in expectation of a typical service-induced crack pattern, and the removed section excavated accordingly. The interface between the replacement section and the component may be shaped to provide a mechanical interlock there between.

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Orlando, FL, United States of America

Dhafer Jouini