United Technologies Corporation

United Technologies Company

Peter J Draghi

Peter Wrabel

Norman Pietruska

Ramon M Velez

Brian J Shurman

Walter E Olson

Dale A Simard

Alan David Cetel

Shawn J Gregg

Gordon Miller Reed

Sudhangshu Bose

John P Arrigoni

Edward Marchitto

Wayne K Armstrong

Kurt R Snyder

Robert J Zuber

Michael V Borruso

John R Danielsen

John J Smolinski

Howard S Ducotey, Jr

Clyde R Everett

Timothy P Murphy

Ramon M Valez

Jr Ramon M Velez

An airfoil comprises a substrate, a residual abrasive coating and a supplemental abrasive coating. The substrate extends along a tip section of the airfoil, from a leading edge to a trailing edge. The residual abrasive coating comprises a two-phase abrasive and metal matrix material bonded to the substrate, on the tip section of the airfoil. The supplemental abrasive coating comprises a two-phase abrasive and metal matrix material bonded to the residual abrasive coating and to the substrate adjacent the residual abrasive coating, on the tip section of the airfoil. The supplemental abrasive coating restores the airfoil to a nominal tip height in the tip section.

Abrasive airfoil tip

A method for a repair process includes the steps of subjecting a substrate coated with at least one protective metallic coating to a nitric acid solution and then subjecting the substrate with the at least one protective metallic coating to a hydrochloric acid solution to remove the at least one protective metallic coating from the substrate. The substrate includes about 5 wt %-15 wt % chromium, about 2 wt %-8 wt % cobalt, about 2 wt %-6 wt % tungsten, about 0.5 wt %-2.5 wt % titanium, about 8 wt %-16 wt % tantalum, about 2 wt %-8 wt % aluminum, hafnium in an amount no greater than 1 wt %, and a remainder of nickel.

Method for a repair process

A method for repairing defects in a gas turbine component that comprises a substrate and an existing coating on the substrate. The article includes cooling holes having a predetermined air flow requirement and an outer shaped portion and an inner metering portion. The method comprises removing the existing coating and recoating the surface of the article with a nonoriginal coating. After the nonoriginal coating is applied onto the component, the cooling holes that meet a predetermined inspection criteria are reworked to remove the excess nonoriginal coating deposited in the outer shaped portion of the cooling holes. The reworking is done by receiving an electrode, having only a shaped portion with a preselected shape, in the outer shaped portion of the cooling holes thus restoring the cooling holes to the predetermined air flow requirement.

Method for repairing an apertured gas turbine component

Foreign material is dislodged from a hard to reach region of an object by passing a rigid elongated tubular guide in close proximity to the hard to reach region. The upper tip of the guide is bent so that it can be directed at the hard to reach region and a wire is passed through the guide into the hard to reach region. The lower portion of the wire that extends outwardly from the bottom of the guide and the wire is rotated at a speed sufficient to dislodge unwanted foreign material from the hard to reach region.

Rotary probe for cleaning an internal cavity

The present invention relates to a method and a device for cleaning internal passageways within a component, such as a component to be used in an engine. The device for cleaning the internal passageway includes a first probe having a longitudinal axis and at least one nozzle oriented at an angle, preferably perpendicular, to the longitudinal axis. In a preferred embodiment, the first probe has two nozzles, both oriented perpendicular to the longitudinal axis, and offset 180 degrees from each other. The device further includes a second probe having a longitudinal axis and a nozzle in a tip end, which nozzle is oriented along the longitudinal axis. Preferably, the first and second probes are connected to a common manifold.

Apparatus and method for cleaning airfoil internal cavities

The present invention relates to a method for repairing turbine engine components, such as vanes and blades, which have airfoils. The method broadly comprises removing oxidation debris from portions of the component by blending areas exhibiting thermal barrier coating spall and/or oxidation damage, removing a ceramic insulating layer from the component, and blending surfaces of the component where nicks, dents, and/or cracks are located. If the component has a depleted aluminum zone, the depleted zone is either removed or replenished. Further, a tip portion of the component, if damaged, is restored and tip abrasives are applied to restore the component's cutting ability. Thereafter, a ceramic coating is applied to the component.

Method for repairing turbine engine components

A method for preparing a protectively coated, apertured article to be recoated reduces the likelihood that the apertures will become constricted as a consequence of subsequent recoating. The invention, described in the context of a gas turbine engine blade (,) having transpiration cooling passages (,), includes the step of diffusing an auxiliary coating (,) into an existing coating (,) and into the exposed substrate material (,) at the periphery of the passages to form a diffusion zone (,). The blade is then subjected to a stripping agent so that the diffusion zone (,) any undiffused existing coating, and any undiffused auxiliary coating are removed. The method causes a compensatory enlargement of the mouth (,) of each passage so that excess coating that accumulates in the passage mouths during subsequent recoating does not restrict the flow capacity of the passages.

Apertured article preconditioned for recoating

The invention includes a low activity localized aluminide coating for a metallic article made by positioning a coating material, preferably in the form of a tape, on a portion of the article. The coating material comprises a binder, a halide activator, an aluminum source, and an inert ceramic material. The coating material and the article are heated in an inert atmosphere between about 1800.degree. F. (982.degree. C.) and about 2050.degree. F. (1121.degree. C.) for between about four and about seven hours thereby producing a low activity localized aluminide coating having an outward diffusion aluminide coating microstructure characterized by two distinct zones, an inner diffusion zone and an outer zone including between about 20-28 percent, by weight, aluminum.

Low activity localized aluminide coating

A method for preparing a protectively coated, apertured article to be recoated reduces the likelihood that the apertures will become constricted as a consequence of subsequent recoating. The invention, described in the context of a gas turbine engine blade (12) having transpiration cooling passages (34), includes the step of diffusing an auxiliary coating (52) into an existing coating (28) and into the exposed substrate material (26) at the periphery of the passages to form a diffusion zone (54). The blade is then subjected to a stripping agent so that the diffusion zone (54) any undiffused existing coating, and any undiffused auxiliary coating are removed. The method causes a compensatory enlargement of the mouth (44) of each passage so that excess coating that accumulates in the passage mouths during subsequent recoating does not restrict the flow capacity of the passages.

Method for preparing an apertured article to be recoated

A gas turbine engine component coated with a thermal barrier coating that includes a metallic bond coat and a ceramic top coat is repaired by removing the ceramic top coat from an engine-run gas turbine engine component and inspecting the component. A metallic flash coat is applied to at least a portion of the component. A ceramic top coat is then applied over predetermined portions of the component, including the portion to which the metallic flash coat was applied.

Repair of gas turbine engine component coated with a thermal barrier

A repair coating for superalloy articles, such as gas turbine engine components, includes a volatile organic carrier or water-based carrier, a fluxing agent, a thickening agent, balance a filler mix. The filler mix consists of at least two distinct particulate components. The mix includes a first particulate component having a composition which approximates that of the article being repaired. The mix also includes a second particulate component having a composition approximating that of the article and a melting point depressant, such as boron. This melting point depressant is substantially in excess of that in the article and sufficient to provide melting of a portion of the mix at a processing temperature below the melting temperature of the article. The above filler mix is blended with the other constituents to form the repair coating which is applied to an article. A series of heating/cooling cycles is performed to ensure that the repair cooling properly melts, wets, and bonds to the article and that the melting point depressant diffuses into the article.

Method of repairing surface and near surface defects in superalloy

A process for closing cooling holes of an airfoil includes the steps of providing an airfoil having a plurality of cooling holes, closing desired holes of said plurality of cooling holes by applying an ultraviolet curable material over the holes.

Process for precisely closing off cooling holes of an airfoil

A cleaning method for gas turbine engine airfoils includes a step of immersing an ultrasonic agitator, such as a welding horn, into a tank with a cleaning solution and a step of directing the ultrasonic agitator onto the portion of the airfoil having the crust layer. A subsequent step of high pressure water jet spray removes the crust debris. The cleaning method of the present invention significantly increases the power density of the ultrasonic cleaning.

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Simsbury, CT, United States of America

Peter J Draghi