General Electric Company

Matthew Nicklus Miller

David Edwin Budinger

Warren Davis Grossklaus, Jr

Melvin Robert Jackson

Joshua L Miller

Brian Alan Norton

Brent Ross Tholke

Wayne Ray Grady

James Michael Caldwell

Robert Ingram Ackerman

James Walter Caddell

Marek M Steplewski

James W Caddell, Jr

Cary Michael Kinder

Ian Craig Linscott

James M Caldwell

Brian A Norton

A turbine nozzle may be repaired by severing the inner band from the vanes and outer band, which may then be discarded. A replacement nozzle is cast to include replacement vanes extending between a replacement outer band and an inner web, with the replacement outer band and vanes conforming with the original outer band and vanes. The new web is configured differently than the old inner band and includes a tie bar. The inner band is machined to form vane seats. The web is machined to form plinths atop the tie bar at each of the replacement vanes. The plinths and tie bar are assembled through the vane seats and bonded to the machined inner band to collectively form the repaired turbine nozzle.

Turbine nozzle biform repair

A method for repairing a nickel-base superalloy article, such as a gas turbine stationary flowpath shroud having flowpath cooling holes therein that has previously been in service, includes the steps of providing the nickel-base superalloy article that has previously been in service; and applying a restoration to a surface of the article. The restoration is applied by the steps of providing a restoration nickel-base alloy, wherein the restoration nickel-base alloy preferably has no more than about 15 weight percent chromium and no more than about 0.01 percent yttrium, thereafter applying a restoration coating of the restoration nickel-base alloy to the surface of the article by a hyper-velocity oxyfuel metal spray process or a low-pressure plasma spray process, and thereafter heating the article with the restoration coating applied to the surface thereof to a sufficiently high temperature to diffusion bond the restoration coating to the surface of the article. The article is then returned to service.

Method for HVOF or LPPS restoration coating repair of a nickel-base superalloy article

A method for repairing a stationary turbine nozzle segment having at least one vane disposed between outer and inner structural bands includes providing an engine-run turbine nozzle segment having at least one vane disposed between outer and inner bands, wherein the outer band and the vanes are previously replaced components of the segment and the inner band is an original component of the segment; separating the inner band from the nozzle segment; repairing damage in the outer band and/or the vane; and joining the outer band and the vane to a newly manufactured replacement inner band segment. The replacement inner band segment includes: a structural inner band; and an integral structural collar adapted to receive an inner end of the at least one vane.

Turbine nozzle segment and method of repairing same

A nickel-base superalloy article, such as a gas turbine stationary flowpath shroud that has previously been in service, is repaired by applying a restoration coating to a surface of the article. The restoration coating is applied by providing a precursor mixture, wherein the precursor mixture has no more than about 15 weight percent chromium and no more than about 0.01 percent yttrium, and wherein the precursor mixture includes a higher-melting-point alloy component and a lower-melting-point alloy component. The precursor mixture is applied to the surface of the article, in a form such as a preform of the alloy components. The article with the precursor mixture applied to the surface thereof is heated to a sufficiently high temperature to melt the lower-melting-point alloy component, thereby forming the restoration coating on the surface of the article.

Method for repair of a nickel-base superalloy article using a thermally densified coating

A stationary shroud of a gas turbine engine made of a base metal is repaired by removing any damaged material from a flow-path region of the stationary shroud to leave an initially exposed base-metal flow-path surface; and applying a base-metal restoration overlying the initially exposed flow-path surface. The base-metal restoration is applied by furnishing a source of a structural material that is compatible with the base metal, and depositing the source of the structural material overlying the initially exposed base-metal flow-path surface of the stationary shroud by plasma transferred arc welding to form a repaired base-metal flow-path surface. An environmentally resistant rub coating may be applied overlying the base-metal restoration.

Method of repairing a stationary shroud of a gas turbine engine using plasma transferred arc welding

A method for repairing a turbine nozzle segment having at least one vane disposed between outer and inner bands includes separating the inner band from the nozzle segment, and joining the inner band to a newly manufactured replacement casting having an outer band and at least one vane. The replacement casting includes a mounting platform formed on one end of the vane and a boss formed on the mounting platform. A collar is joined to the inner band and has a slot formed therein. The boss is then inserted into the slot, and the mounting platform is received in a recess formed in the inner band. Joining is completed by joining the boss to the collar and the mounting platform to the inner band. The thickness of the collar is tapered in an axial direction, and a relief is formed in the collar to provide assembly clearance with adjacent components.

Fabricated repair of cast nozzle

Growing community of inventors

Maineville, OH, United States of America

Matthew Nicklus Miller