Honeywell International Inc.

William F Hehmann

Federico Renteria

Martin Carlin Baker

Yiping Hu

Gary Winchester

Santosh K Das

Donald G Godfrey

Clyde R Taylor

Vincent J Papotto

Richard F Haraz

Mark C Morris

Harry Lester Kington

Richard Bryce Fox

Vincent Chung

Thomas Malcolm Hughes

Wen Guo

Brian G Baughman

Murali N Madhava

George Reimer

Daira Legzdina

In accordance with an exemplary embodiment, a method for repairing a damaged metallic component using additive manufacturing techniques includes separating a damaged portion of the damaged metallic component from an undamaged portion of the damaged metallic component, measuring the undamaged portion to determine the dimensions of the removed damaged portion, fabricating a replacement portion using additive manufacturing techniques in accordance with the determined dimensions of the removed damaged portion, and joining the replacement portion with the undamaged portion of the damaged metallic component to form a repaired metallic component.

Methods for the repair of gas turbine engine components using additive manufacturing techniques

Substantially defect-free titanium aluminide components and methods are provided for manufacturing the same from articles formed by consolidation processes. The method includes providing an intermediate article comprised of a titanium aluminide alloy and formed by a consolidation process. The intermediate article is encapsulated with an aluminum-containing encapsulation layer. The intermediate article is compacted after the encapsulation step. A substantially defect-free titanium aluminide component comprises a compacted three-dimensional article comprised of titanium aluminide and formed by a consolidation process and an aluminum-containing encapsulation layer on at least one surface of the compacted three-dimensional article. The aluminum-containing encapsulation layer comprises an aluminide material, MCrAlY wherein M is cobalt, nickel, or a combination of cobalt and nickel, or TiAlCr.

Methods for manufacturing titanium aluminide components from articles formed by consolidation processes

Methods are provided for repairing a vane assembly, where the vane assembly includes an inner annular housing, an outer annular housing, and a vane extending therebetween. In one embodiment, the method includes removing an identified section of the vane to thereby form a pocket in an inner surface of the outer annular housing, a slot through the inner annular housing, and an edge on the vane, inserting a replacement vane portion with an advanced coating through the formed slot such that a first edge of the replacement vane portion is disposed in the pocket and at least a portion of the first edge is spaced apart from at least a portion of the outer annular housing inner surface, and welding a section of the replacement vane portion to the annular inner annular housing. The repaired vane assembly is also provided.

Repaired vane assemblies and methods of repairing vane assemblies

A mobile support system for a hand-held laser welding wand includes a movable cart, a laser source, a fluid source, and a filler medium supply source. The laser source is mounted on the movable cart and is configured to supply laser light for the hand-held laser welding wand. The fluid source is mounted on the movable cart and is configured to supply cooling fluid for the hand-held laser welding wand. The filler medium supply source is mounted on the movable cart and is configured to supply a filler medium for use by the hand-held laser welding wand. The mobile support system is transportable to areas remote from a work shop environment, and provides stand-alone support for the hand-held laser welding wand.

Mobile hand-held laser welding support system

There is provided a method for depositing a modified MCrAlY coating on a turbine blade tip. The method utilizes laser deposition techniques to provide a metallurgical bond between a turbine blade substrate, such as a superalloy substrate, and the modified MCrAlY composition. Further the modified MCrAlY coating has sufficient thickness such that a post-welding grinding operation to size the turbine blade to a desired dimension will not remove the modified MCrAlY coating entirely. The modified MCrAlY coating thus remains on the finished turbine blade tip after grinding.

Modified MCrAlY coatings on turbine blade tips with improved durability

Methods for repair of single crystal superalloys by laser welding and products thereof have been disclosed. The laser welding process may be hand held or automated. Laser types include: CO, Nd:YAG, diode and fiber lasers. Parameters for operating the laser process are disclosed. Filler materials, which may be either wire or powder superalloys are used to weld at least one portion of a single crystal superalloy substrate.

Methods for repair of single crystal superalloys by laser welding and products thereof

A hand-held laser welding wand includes one or more filler media delivery flow passages. The wand is dimensioned to be grasped with a single hand, thus filler media of various types and forms may be supplied to the weld area on a workpiece using various types of delivery systems and methods, including fully automated, semi-automated, or manually. The filler media may be delivered via the filler media delivery passages or separate from the passages.

Hand-held laser welding wand filler media delivery systems and methods

A hand-held laser welding wand includes internal flow passages through which filler media, gas, and coolant may flow. The wand is dimensioned to be grasped with a single hand, thus filler media of various types and forms, gas, and coolant may be supplied to the hand-held laser welding wand via external systems and delivery devices without substantially impairing operation of the wand.

Hand-held laser welding wand having internal coolant and gas delivery conduits

A method is provided for repairing degraded and/or eroded areas on gas turbine blades and vanes. The method is directed to turbine blades and vanes made of advanced superalloy materials with high elevated-temperature properties. The method uses multiple laser beams to perform steps of preheating the repair area, welding the repair area, and post-welding heating of the repaired area. The method uses an array of two or more lasers to perform the steps of heating, welding, and post-weld heat treatment in nearly simultaneous operation thereby dramatically reducing or eliminating the hot cracking associated with other welding methods used with superalloy materials. The method is further directed to cladding or material buildup of degraded turbine blades where the weld material is the same as the matrix or better superalloy materials.

Multi-laser beam welding high strength superalloys

A diffusion bond mixture paint and method for repairing a single-crystal superalloy article that minimizes the amount of braze alloy applied to the article. The amount of boron and eutectic brittle borides of the wide gap brazing processes is minimized, resulting in a more robust repair. The braze paint includes an alloy powder mixture, a binder, and a carrier to thin the paint.

Diffusion bond mixture for healing single crystal alloys

A powder feed splitter and a machine using a powder feed splitter, to divide a powder flow into two or more streams in a predictable, adjustable, and reliable manner for use in material processing such as welding. A housing encloses an inlet disk having an inlet regulator preferably a disk, having an inlet tube which may be adjustable radially or laterally with respect to the housing. An adjustment mechanism can selectively move the inlet regulator to adjust the powder flow amongst the several powder outlet ports. Funnel-shaped cavities within the housing may have optional gas inlets to enable the introduction of additional gas to the separated powder flow streams. A one-way fit may be present between the interior powder flow splitter and the exterior casing. Smooth interior surfaces through the device prevent turbulence and buildup of powder.

Powder feed splitter for hand-held laser powder fusion welding torch

A novel and inventive hand held powder-fed laser fusion welding torch providing manual flexibility for laser welding with powder-fed material. The hand held laser includes a body, handle, and nozzle assembly. The nozzle may be shrouded by a cover that is slightly spaced apart from the nozzle. The gap between the two may provide space through which inert gas may flow. Laser light from a remote source shines through the nozzle's central aperture. The nozzle aperture may be circumscribed by powder channel outlets aligned upon a working focal point coincident with the laser beam to treat a workpiece. A proximity sensor may enable selective welding torch operation according to the presence of a workpiece.

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Greer, SC, United States of America

William F Hehmann