A system and method for adaptive welding. In some embodiments, the system includes a weld head, a first weld monitoring camera, and a machine learning system. The machine learning system may be configured, while the weld head forms a weld layer in a groove, to estimate the position of a distal end of a filler wire relative to the groove.
A system and method for weld path generation. In some embodiments, the method includes adding a volume of material, by welding, to a deficient part, the deficient part differing from a nominal part by distortion, and by absent material. The adding of the material may include generating a model of the absent material and adapting the model of the absent material based on the distortion. The volume of material may have a curvature based on a curvature of the absent material.
B23K 9/04 - Welding for other purposes than joining, e.g. built-up welding
G01B 11/25 - Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures by projecting a pattern, e.g. moiré fringes, on the object
A system and method for welding. In some embodiments, the method includes: performing, by an automated welder, a cycle of a weld to fill a gap, the cycle including: a first dwell; a first excursion forming a first excursion bead; a second dwell; and a second excursion, the automated welder forming, during the entire second excursion, a weld pool in contact with the first excursion bead.
B23K 9/12 - Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
B23K 37/06 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for positioning the molten material, e.g. confining it to a desired area
A system and method for in-process weld inspection. In some embodiments, the system includes: a weld head; and a nondestructive weld defect sensing probe, the weld head being configured to move relative to a substrate and to form a weld layer on the substrate, and the nondestructive weld defect sensing probe being configured to move relative to the substrate, at a distance of less than 50 centimeters from the weld head, and to sense defects in the formed weld layer.
B23K 31/12 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to investigating the properties, e.g. the weldability, of materials
G01N 27/90 - Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws using eddy currents
A nickel based active brazing material for high temperature furnace and laser brazing of stainless steels, nickel and cobalt based alloys and superalloys, refractory metals and alloys in vacuum and inert gases for manufacturing and repair of turbine engine components and other articles comprising in weight percentage (wt. %) of (4.5-8.5)% Cr, (4.2-6.5)% Ti, (5.0-9.5)% Zr, (3.0-4.5)% Hf, (0.5-1.6)% Ta, (1.0-3.5)% Al, (0.5-1.7)% Si, (0-12.0)% Fe, (0-0.2)% Mo, (0-0.05)% W, and nickel to balance.
A system and method for adaptive welding. In some embodiments, the system includes a weld head, a first weld monitoring camera, and a machine learning system. The machine learning system may be configured, while the weld head forms a weld layer in a groove, to estimate the position of a distal end of a filler wire relative to the groove.
The high gamma prime (γ′) nickel based welding material for repair and 3D additive manufacturing of turbine engine components containing from 9.0 to 11.0% Cr, from 16.0 to 24.0% Co, from 1.0 to 1.4% Mo, from 5.0 to 5.8% W, from 1.5 to 1.9% Ta, from 4.5 to 5.5 Al %, from 0.1 to 0.3% Hf, up to 0.02% B, from 0.05 to 0.12% C, from 0.2 to 0.8% Fe, from 1.5 to 2.5% Re, and nickel with impurities to balance.
The high gamma prime (y') nickel based welding material for repair and 3D additive manufacturing of turbine engine components containing from 9.0 to 11.0 % Cr, from 16.0 to 24.0 % Co, from 1.0 to 1.4 % Mo, from 5.0 to 5.8 % W, from 1.5 to 1.9 % Ta, from 4.5 to 5.5 Al %, from 0.1 to 0.3 % Hf, up to 0.02 % B, from 0.05 to 0.12 % C, from 0.2 to 0.8 % Fe, from 1.5 to 2.5 % Re, and nickel with impurities to balance.
High gamma prime nickel based welding materials comprising (all in wt. %) from 13.0 to 14.0% Cr, from 30.0 to 32.0% Co, from 0.7 to 0.9% Mo, from 7.0 to 8.0% W, from 0.5 to 6.0% Ta, from 3.8 to 5.5 Al %, up to 0.12% Ti, up to 0.02 Zr %, from 0.4 to 0.8% Hf, up to 0.02% B, from 0.05 to 0.3% C, up to 0.015% Y, up to 0.015% V, from 1.0 to 2.0% Re, and nickel to balance for repair of turbine engine components and other articles manufactured from single crystal materials and other superalloys by manual and automatic gas tungsten arc, plasma arc, laser, and electron beam welding as well as for 3D additive manufacturing.
High gamma prime nickel based welding materials comprising (all in wt. %) from 13.0 to 14.0 % Cr, from 30.0 to 32.0 % Co, from 0.7 to 0.9 % Mo, from 7.0 to 8.0 % W, from 0.5 to 6.0 % Ta, from 3.8 to 5.5 Al %, up to 0.12 % Ti, up to 0.02 Zr %, from 0.4 to 0.8 % Hf, up to 0.02 % B, from 0.05 to 0.3 % C, up to 0.015 % Y, up to 0.015 % V, from 1.0 to 2.0 % Re, and nickel to balance for repair of turbine engine components and other articles manufactured from single crystal materials and other superalloys by manual and automatic gas tungsten arc, plasma arc, laser, and electron beam welding as well as for 3D additive manufacturing.
B23K 9/23 - Arc welding or cutting taking account of the properties of the materials to be welded
B23K 35/22 - Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
B33Y 70/00 - Materials specially adapted for additive manufacturing
C22C 30/00 - Alloys containing less than 50% by weight of each constituent
12.
SYSTEM AND METHOD FOR PREVENTING STUB-OUTS IN GTAW
A system and method for welding. In some embodiments, the system includes a tungsten electrode, an electrode position actuator, and a processing circuit. The processing circuit may be configured to detect contact between the tungsten electrode and a weld puddle, and, in response to detecting contact between the tungsten electrode and the weld puddle, to control the electrode position actuator to move the tungsten electrode out of contact with the weld puddle.
The specification relates to a high gamma prim nickel based superalloy, its use and a method of manufacturing of turbine engine components by welding, 3D additive manufacturing, casting and hot forming, and the superalloy comprises by wt %: from 9.0 to 10.5% Cr, from 16 to 22% Co, from 1.0 to 1.4% Mo, from 5.0 to 5.8% W, from 2.0 to 6.0% Ta, from 1.0 to 4.0% Nb provided that total content of Ta and Nb remains with a range from 3.0 to 7.0%, from 3.0 to 6.5% Al, from 0.2 to 1.5% Hf, from 0.01 to 0.2% C, from 0 to 1.0% Ge, from 0 to 1.0 wt. % Si, from 0 to 0.2 wt. % Y, from 0 to 0.015 wt. % B, from 1.5 to 3.5 wt. % Re, and nickel with impurities to balance.
C22C 19/05 - Alloys based on nickel or cobalt based on nickel with chromium
B33Y 70/00 - Materials specially adapted for additive manufacturing
C22F 1/10 - Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
The specification relates to a high gamma prim nickel based superalloy, its use and a method of manufacturing of turbine engine components by welding, 3D additive manufacturing, casting and hot forming, and the superalloy comprises by wt%: from 9.0 to 10.5 % Cr, from 16 to 22 % Co, from 1.0 to 1.4 % Mo, from 5.0 to 5.8 % W, from 2.0 to 6.0 % Ta, from 1.0 to 4.0% Nb provided that total content of Ta and Nb remains with a range from 3.0 to 7.0%, from 3.0 to 6.5 % Al, from 0.2 to 1.5 % Hf, from 0.01 to 0.2% C, from 0 to 1.0 % Ge, from 0 to 1.0 wt. % Si, from 0 to 0.2 wt. % Y, from 0 to 0.015 wt. % B, from 1.5 to 3.5 wt. % Re, and nickel with impurities to balance.
B22D 25/02 - Special casting characterised by the nature of the product by its peculiarity of shapeSpecial casting characterised by the nature of the product of works of art
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B22F 5/04 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
B33Y 70/00 - Materials specially adapted for additive manufacturing
C22C 19/05 - Alloys based on nickel or cobalt based on nickel with chromium
C22C 30/00 - Alloys containing less than 50% by weight of each constituent
C22F 1/10 - Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
An arc welder with current and voltage control. The welder includes a current control loop for sensing and controlling the arc current. In an operating state, a voltage control loop senses an average arc voltage and controls it to be equal to a setpoint, by sending a current control signal to the current control loop, the current control signal being a constant frequency, variable duty cycle square wave. When starting a weld, the welder operates for an initial time interval in an arc-starting state, in which a constant frequency, constant duty cycle square wave is sent to the current control loop as a current control signal. In some embodiments the weld head position is controlled based on a ratio of the average arc voltage to the average arc current, and the frequency of the current control signal is adjusted to be synchronized with droplet detachment from the feed wire.
The present invention is a composite welding wire for fusion welding of components manufactured of superalloys. The composite weld wire includes a surface layer applied to the core wire in a green condition and bonded to the core wire. The surface layer includes alloying elements selected from among B and Si, the total bulk content of B and Si representing 0.5 to 4.0 wt. % of the composite welding wire. The boron and silicon alloying elements reduce the melting temperature and increase the solidification range of the weld pool, minimizing the incidence of weld cracking compared to welding without the coating. The green condition surface layer is comprised of more than 80 wt. % of the bulk content of the composite welding wire selected from the combination of B and Si.
B23K 35/22 - Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
B23K 35/30 - Selection of soldering or welding materials proper with the principal constituent melting at less than 1550°C
B23K 35/02 - Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
B05D 7/20 - Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to wires
B23K 35/36 - Selection of non-metallic compositions, e.g. coatings, fluxesSelection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
B23K 35/365 - Selection of non-metallic compositions of coating materials either alone or conjoint with selection of soldering or welding materials
C23C 14/28 - Vacuum evaporation by wave energy or particle radiation
C23C 14/02 - Pretreatment of the material to be coated
C23C 16/02 - Pretreatment of the material to be coated
C23C 16/44 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
B05D 1/00 - Processes for applying liquids or other fluent materials
B05D 3/00 - Pretreatment of surfaces to which liquids or other fluent materials are to be appliedAfter-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
B05D 3/02 - Pretreatment of surfaces to which liquids or other fluent materials are to be appliedAfter-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
17.
High gamma prime nickel based superalloy, its use, and method of manufacturing of turbine engine components
The invention is related to a high gamma prim nickel based superalloy, its use and a method of manufacturing of turbine engine components by welding, 3D additive manufacturing, casting and hot forming, and the superalloy comprises 9.0-10.5 wt. % Cr, 20-22 wt. % Co, 1.0-1.4 wt. % Mo, 5.0-5.8 wt. % W, 2.0-6.0 wt. % Ta, 3.0-6.5 wt. % Al, 0.2-0.5 wt. % Hf, 0.01-0.16 wt. % C, 1.5-3.5 wt. % Re, 0-1.0 Ge wt. %, 0-0.2 wt. % Y, 0-1 wt. % Si, 0-0.015 wt. % B and nickel with impurities to balance.
C22C 19/05 - Alloys based on nickel or cobalt based on nickel with chromium
C22F 1/10 - Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
The invention is related to a high gamma prim nickel based superalloy, its use and a method of manufacturing of turbine engine components by welding, 3D additive manufacturing, casting and hot forming, and the superalloy comprises 9.0-10.5 wt. % Cr, 20-22 wt. % Co, 1.0-1.4 wt. % Mo, 5.0-5.8 wt. % W, 2.0-6.0 wt. % Ta, 3.0-6.5 wt. % Al, 0.2-0.5 wt. % Hf, 0.01-0.16 wt. % C, 1.5-3.5 wt. % Re, 0- 1.0 Ge wt. %, 0 - 0.2 wt. % Y, 0- 1 wt. % Si, 0 - 0.015 wt. % B and nickel with impurities to balance.
C22C 19/05 - Alloys based on nickel or cobalt based on nickel with chromium
C22C 19/07 - Alloys based on nickel or cobalt based on cobalt
C22C 30/00 - Alloys containing less than 50% by weight of each constituent
C22F 1/10 - Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
F02C 7/00 - Features, component parts, details or accessories, not provided for in, or of interest apart from, groups Air intakes for jet-propulsion plants
A system and method for controlling the position of a filler wire and/or a laser head, or other heating head, in a welding system. The distal end of the filler wire is gradually moved, e.g., upward, until electrical continuity with the weld pool is lost; the filler wire is then moved back into contact with the weld pool. The heating head may be stationary relative to the weld pool, or it may move, with the distal end of the filler wire, relative to the weld pool.
A system and method for controlling the position of a filler wire and/or a laser head, or other heating head, in a welding system. The distal end of the filler wire is gradually moved, e.g., upward, until electrical continuity with the weld pool is lost; the filler wire is then moved back into contact with the weld pool. The heating head may be stationary relative to the weld pool, or it may move, with the distal end of the filler wire, relative to the weld pool.
The high gamma prime nickel based superalloy, which comprises 10 - 13 wt. % Co, 3 - 10 wt. % Cr, 0.5 - 2 wt. % Mo, 3 - 7 wt. % W, 0.5 - 10 wt. % Re, 5 - 6 wt. % Al, 5 - 7 wt. % Ta, 0.5 - 2 wt. % Hf, 0.01 - 0.15 wt. % C, 0.005 - 0.05 wt. B and 0.01 wt. % Zr, was first describe in the US Patent 4,169,742. Later on the optimized the optimized version of this alloy that comprises 12 wt. % Co, 6.8 wt. % Cr, 1.5 wt. % Mo, 4.9 wt. % W, 2.8 wt. % Re, 6.15 wt. % Al, 6.35 wt. % Ta, 1.5 wt. % Hf, 0.12 wt. % C, 0.015 wt. % B and 0.02 wt. % Zr became well-known as Rene 142 or R142 superalloy that has been widely used as welding material and structural material for a manufacturing of directionally solidified (DS) turbine blades due to unique combination of oxidation resistance and high mechanical properties that were achieved by the optimization of Ta+Al+Cr content coupled with no titanium addition and high aluminum content combined with the special multi step heat treatment, refer to per Earl W. Ross and Kevin S. O'Hara, "Rene 142: A high strength, oxidation resistant DS turbine airfoil alloy", Superalloys 1982, pp. 257 - 265. The optimization of rupture properties of Rene 142 DS as per Earl W. Ross and Kevin were achieve by a homogenization at 2335°F for 2 hours followed by annealing at 2050°F for four hours, primary aging at 1975°F for four hours and secondary aging at 1650°F for four hours (referred to as R142 HT).
B23K 35/22 - Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
The high gamma prime nickel based superalloy, which comprises 10 - 13 wt. % Co, 3 - 10 wt. % Cr, 0.5 - 2 wt. % Mo, 3 - 7 wt. % W, 0.5 - 10 wt. % Re, 5 - 6 wt. % Al, 5 - 7 wt. % Ta, 0.5 - 2 wt. % Hf, 0.01 - 0.15 wt. % C, 0.005 - 0.05 wt. B and 0.01 wt. % Zr, was first describe in the US Patent 4,169,742. Later on the optimized the optimized version of this alloy that comprises 12 wt. % Co, 6.8 wt. % Cr, 1.5 wt. % Mo, 4.9 wt. % W, 2.8 wt. % Re, 6.15 wt. % Al, 6.35 wt. % Ta, 1.5 wt. % Hf, 0.12 wt. % C, 0.015 wt. % B and 0.02 wt. % Zr became well-known as Rene 142 or R142 superalloy that has been widely used as welding material and structural material for a manufacturing of directionally solidified (DS) turbine blades due to unique combination of oxidation resistance and high mechanical properties that were achieved by the optimization of Ta+Al+Cr content coupled with no titanium addition and high aluminum content combined with the special multi step heat treatment, refer to per Earl W. Ross and Kevin S. O'Hara, "Rene 142: A high strength, oxidation resistant DS turbine airfoil alloy", Superalloys 1982, pp. 257 - 265. The optimization of rupture properties of Rene 142 DS as per Earl W. Ross and Kevin were achieve by a homogenization at 2335°F for 2 hours followed by annealing at 2050°F for four hours, primary aging at 1975°F for four hours and secondary aging at 1650°F for four hours (referred to as R142 HT).
C22C 19/05 - Alloys based on nickel or cobalt based on nickel with chromium
B23K 35/22 - Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
Method of repairing and manufacturing of turbine engine components includes application of a transition layer by fusion welding with dissimilar nickel based filler material, preferably comprising from about 0.05 wt. % to about 1.2 wt. % B and other alloying elements, followed by a diffusion and primary aging heat treatment and application of the top oxidation resistance layer using dissimilar nickel based filler materials comprised 3-6 wt. % Al, 0.5-6 wt. % Si, 12-25 wt. % Cr and other alloying elements that enhance strength and oxidation resistance followed by a secondary aging heat treatment and machining of the repaired area to restore geometry of turbine engine components. The inventions also relates to a turbine engine components repaired and manufactured by the method.
C22C 19/05 - Alloys based on nickel or cobalt based on nickel with chromium
C22F 1/10 - Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
B23P 15/02 - Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from one piece
B23K 9/04 - Welding for other purposes than joining, e.g. built-up welding
B23K 9/167 - Arc welding or cutting making use of shielding gas and of a non-consumable electrode
Method of repairing and manufacturing of turbine engine components includes application of a transition layer by fusion welding with dissimilar nickel based filler material, preferably comprising from about 0.05 wt. % to about 1.2 wt. % B and other alloying elements, followed by a diffusion and primary aging heat treatment and application of the top oxidation resistance layer using dissimilar nickel based filler materials comprised 3 - 6 wt. % Al, 0.5 - 6 wt. % Si, 12- 25 wt. % Cr and other alloying elements that enhance strength and oxidation resistance followed by a secondary aging heat treatment and machining cf the repaired area to restore geometry of turbine engine components. The inventions also relates to a turbine engine components repaired and manufactured by the method.
B23K 35/22 - Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
B23P 6/04 - Repairing fractures or cracked metal parts or products, e.g. castings
25.
Ductile boron bearing nickel based welding material
A ductile boron bearing nickel based welding material which includes boron within the range of 0.4-0.6 wt. % B, carbon from a trace amount to 0.04 wt. % C, 17-23 wt. % Cr, 0.35-10 wt. % Mo, 0.1-4.15 wt. % Nb with nickel or iron and impurities to balance for manufacturing of welding and brazing wires, powders and foils used in the repair of various articles made of nickel, cobalt and iron based alloys.
A ductile boron bearing nickel based welding material which includes boron within the range of 0.4 - 0.6 wt. % B, carbon from a trace amount to 0.04 wt. % C, 17 - 23 wt. % Cr, 0.35 - 10 wt. % Mo, 0.1 - 4.15 wt. % Nb with nickel or iron and impurities to balance for manufacturing of welding and brazing wires, powders and foils used in the repair of various articles made of nickel, cobalt and iron based alloys.
A precipitation strengthened nickel based welding material that comprises 5-15 wt. % Co, 5-25 wt. % Cr, 1-6 wt. % Al, 0.05-0.2 wt. % C, 0.015-0.4 wt. % B, 1-3 wt. % Si, chemical elements selected from among tungsten and molybdenum from about 1 to 20 wt. %, chemical elements selected from among titanium, zirconium, hafnium, tantalum and rhenium from about 1 to 18 wt. % and nickel with impurities to balance, wherein the boron content is inversely proportional to silicon content and decreases from about 0.3 wt. % to about 0.015 wt. % when silicon content increases from about 1 wt. % to about 3 wt. % produces sound high strength and high oxidation resistance crack free welds on precipitation strengthened superalloys and single crystal materials.
B23K 35/30 - Selection of soldering or welding materials proper with the principal constituent melting at less than 1550°C
C22F 1/10 - Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
C22C 19/05 - Alloys based on nickel or cobalt based on nickel with chromium
A ductile boron bearing nickel based welding material which includes boron within the range .of 0.4 - 0.6 wt. % B, carbon from a trace amount to 0.04 wt. % C, 17 - 23 wt. % Cr, 0.35 - 10 wt. % Mo, 0.1 - 4.15 wt. % Nb with nickel or iron and impurities to balance for manufacturing of welding and brazing wires, powders and foils used in the repair of various articles made of nickel, cobalt and iron based alloys.
B23K 35/22 - Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
A weldhead assembly is disclosed. The weldhead assembly comprises a welding torch, an AVC subassembly mounted on an oscillation base adapted for movement back and forth across a weld joint, the AVC subassembly adapted for movement of the weldhead closer to and farther from a weld joint, and a motor adapted for driving the movement of the AVC subassembly, the motor mounted on the oscillation base.
A precipitation strengthened nickel based welding material that comprises 5 ¨ 15 wt. % Co. 5 ¨ 25 wt. % Cr, 1 ¨ 6 wt. % Al, 0.05 ¨ 0.2 wt. % C, 0.015 ¨ 0.4 wt. % B, 1 ¨ 3 wt. % Si, chemical elements selected from among tungsten and molybdenum from about 1 to 20 wt. %, chemical elements selected from among titanium, zirconium, hafnium, tantalum and rhenium from about 1 to 18 wt. % and nickel with impurities to balance, wherein the boron content is inversely proportional to silicon content and decreases from about 0.3 wt. % to about 0.015 wt. % when silicon content increases from about 1 wt. % to about 3 wt. % produces sound high strength and high oxidation resistance crack free welds on precipitation strengthened superalloys and single crystal materials.
A precipitation strengthened nickel based welding material that comprises 5 - 15 wt. % Co, 5 - 25 wt. % Cr, 1 - 6 wt. % A1, 0.05 - 0.2 wt. % C, 0.015 - 0.4 wt. % B, 1 - 3 wt. % Si, chemical elements selected from among tungsten and molybdenum from about 1 to 20 wt. %, chemical elements selected from among titanium, zirconium, hafnium, tantalum and rhenium from about 1 to 18 wt. % and nickel with impurities to balance, wherein the boron content is inversely proportional to silicon content and decreases from about 0.3 wt. % to about 0.015 wt. % when silicon content increases from about 1 wt. % to about 3 wt. % produces sound high strength and high oxidation resistance crack free welds on precipitation strengthened superalloys and single crystal materials.
Welding material for welding of superalloys comprising boron with the range of 0.3-0.8 wt. % B, 0.2-0.8 wt. % C, 17-23 wt. % Cr, 0.35-10 wt. % Mo, 0.1-4.15 wt. % Nb with nickel or iron and impurities to balance for weld repair of engine components manufactured of precipitation hardening superalloys with high content of gamma prime phase at an ambient temperature.
Improvement of Inconel 625 as well as other nickel and iron based welding materials is required to increase mechanical properties of welds at a high temperature avoiding at the same time heat affected zone (HAZ) cracking of Inconel 738, GTD111 and other superalloys with high content of .gamma.' phase. Disclosed is a welding material for welding of superalloys containing 0.4 to 0.8 wt.% Boron; 0.2 to 0.8 wt.% Carbon; 20 to 23 wt.% Chromium; 8 to 12 wt.% Molybdenum; 3.15 to 4.14 wt.% Niobium; trace amount to 5 wt.% Iron; trace amount to combined 1.4 wt.% of micro alloying elements (Titanium, Silicon and Manganese); and Nickel with impurities to balance; which can help to produce high strength welds to minimize and eliminate cracking in the HAZ of Inconel 738, GTD 111 and other nickel based superalloys and improve mechanical properties of welds on various nickel and iron based alloys.
09 - Scientific and electric apparatus and instruments
37 - Construction and mining; installation and repair services
42 - Scientific, technological and industrial services, research and design
Goods & Services
Electronic, gas, laser, and plasma welding machines; parts of cutting machines, namely, cutting and grinding heads; linear and rotary actuators Automated welding systems comprised primarily of electronic controllers and position sensors, and also including linear and rotary actuators; automated machining systems comprised primarily of electronic controllers, position sensors, and also including linear and rotary actuators, cutting heads and grinding heads; automated parts loading systems comprised primarily of electronic controllers, part manipulators for remote operation of robotics, position sensors, and also including linear and rotary actuators; automated coating systems comprised primarily of electronic controllers and electronic gas flow controllers, and also including gas, plasma and evaporated coating sources, coating chambers; electric or electronic position sensors; part manipulators for remote robotic positioning of parts for gluing, screwing, welding, staking or snapping together; electronic controllers for controlling gas flow Refurbishment of turbines; repair of metal Mechanical engineering services; engine performance analysis; computer systems analysis; computer software design for others; software authoring; computer software development; metallurgical engineering services; welding engineering services; material testing; laboratory research in the field of metallurgy; chemical analysis; laboratory research and analysis services in the field of industrial machines, namely, welding analysis services; metallurgical analysis; performance monitoring, namely, testing and evaluation of the goods of others to assure compliance with industry standards; laboratory research and analysis services in the field of industrial machines, namely, development of repair methods for others; designing welding systems; designing coating systems; chemical vapor deposition and physical vapor deposition coating services for engines and turbines; product research and development; robotics design and development for others
35.
METHOD OF CLADDING AND FUSION WELDING OF SUPERALLOYS USING COMPOSITE FILLER POWDER
The present concept is a method of cladding and fusion welding of superalloys and includes the steps of firstly application of a composite filler powder that comprises 5- 50% by weight brazing powder which includes melting point depressants, and 50-95% by weight high temperature welding powder, to a superalloy base material. Secondly there is simultaneous heating of the base material and the composite filler powder by a welding heat source that is movable relative to the base material. There is heating to a temperature that will fully melt the brazing powder and at least partially melt the high temperature welding powder and also melt a surface layer of the base material, thereby forming a weld pool. Thirdly upon solidification and cooling of the weld pool, there is coalescence between a weld bead and the base material.
B23K 9/04 - Welding for other purposes than joining, e.g. built-up welding
B23K 26/34 - Laser welding for purposes other than joining
B23K 35/22 - Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
36.
METHOD OF CLADDING AND FUSION WELDING OF SUPERALLOYS USING COMPOSITE FILLER POWDER
The present concept is a method of cladding and fusion welding of superalloys and includes the steps of firstly application of a composite filler powder that comprises 5- 50% by weight brazing powder which includes melting point depressants, and 50-95% by weight high temperature welding powder, to a superalloy base material. Secondly there is simultaneous heating of the base material and the composite filler powder by a welding heat source that is movable relative to the base material. There is heating to a temperature that will fully melt the brazing powder and at least partially melt the high temperature welding powder and also melt a surface layer of the base material, thereby forming a weld pool. Thirdly upon solidification and cooling of the weld pool, there is coalescence between a weld bead and the base material.
B23K 26/34 - Laser welding for purposes other than joining
B23K 35/22 - Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
B23K 9/04 - Welding for other purposes than joining, e.g. built-up welding
37.
A COMPOSITE WELDING WIRE AND METHOD OF MANUFACTURING
The present invention is a composite welding wire for fusion welding of components manufactured of superalloys. The composite weld wire includes an inner core wire and a surface layer applied and bonded to the inner core wire. The surface layer includes alloying elements selected from among B and Si with a total bulk content of B and Si in the composite welding wire of 0.1 to 10 wt. %. Preferably the total bulk content of B is less than 4 wt. % and the surface layer comprises from 5 to 95 wt.% of the alloying elements selected from among B and Si.
B23K 35/22 - Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
B23K 35/40 - Making wire or rods for soldering or welding
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
38.
A COMPOSITE WELDING WIRE AND METHOD OF MANUFACTURING
The present invention is a composite welding wire for fusion welding of components manufactured of superalloys. The composite weld wire includes an inner core wire and a surface layer applied and bonded to the inner core wire. The surface layer includes alloying elements selected from among B and Si with a total bulk content of B and Si in the composite welding wire of 0.1 to 10 wt. %. Preferably the total bulk content of B is less than 4 wt. % and the surface layer comprises from 5 to 95 wt.% of the alloying elements selected from among B and Si.
B23K 35/22 - Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
B23K 35/40 - Making wire or rods for soldering or welding
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
40 - Treatment of materials; recycling, air and water treatment,
Goods & Services
(1) Treatment of materials, namely heat treatment and application of powder metallurgy to metal components used in jet and land based gas turbine engines.
40 - Treatment of materials; recycling, air and water treatment,
Goods & Services
Electro and metal coating, metal treating and casting, hardening of metal and metal products; Heat treatment and coating of metal components of gas turbine engines; Metal treatment
40 - Treatment of materials; recycling, air and water treatment,
Goods & Services
Electro and metal coating, metal treating and casting, hardening of metal and metal products; Heat treatment and coating of metal components of gas turbine engines; Metal treatment
40 - Treatment of materials; recycling, air and water treatment,
Goods & Services
Heat treatment and coating of metal components of gas turbine engines using powder metallurgical techniques; Metal heat treating services by means of powder metallurgy; Metal treating; Treatment of metal
A method for manufacturing an abrasive coating on a gas turbine component, especially on a gas turbine rotor blade tip, comprising at least the following steps: a) providing a gas turbine component, especially a gas turbine rotor blade; b) providing a high temperature melting alloy powder; c) providing abrasive particles; d) providing a low temperature melting alloy powder; e) blending at least said high temperature melting alloy powder and said abrasive particles to provide a mixture; f) applying said low temperature melting alloy powder and said mixture to an area of said gas turbine component, especially to a tip of said turbine rotor blade; g) locally heating said area of said gas turbine component to a temperature above the melting point of said low temperature melting alloy powder but below the melting point of said high temperature melting alloy powder is provided.
B05D 5/06 - Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain multicolour or other optical effects
C23C 24/10 - Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
F01D 5/28 - Selecting particular materialsMeasures against erosion or corrosion
49.
METHOD FOR MANUFACTURING AN ABRASIVE COATING ON A GAS TURBINE COMPONENT
The invention relates to a method for manufacturing an abrasive coating on a gas turbine component, especially on a gas turbine rotor blade tip, comprising at least the following steps: a) providing a gas turbine component, especially a gas turbine rotor blade; b) providing a high temperature melting alloy powder; c) providing abrasive particles; d) providing a low temperature melting alloy powder; e) blending at least said high temperature melting alloy powder and said abrasive particles to provide a mixture; f) applying said low temperature melting alloy powder and said mixture to an area of said gas turbine component, especially to a tip of said turbine rotor blade; g) locally heating said area of said gas turbine component to a temperature above the melting point of said low temperature melting alloy powder but below the melting point of said high temperature melting alloy powder.
C23C 24/00 - Coating starting from inorganic powder
C23C 24/08 - Coating starting from inorganic powder by application of heat or pressure and heat
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
F01D 5/28 - Selecting particular materialsMeasures against erosion or corrosion
50.
METHOD FOR MANUFACTURING AN ABRASIVE COATING ON A GAS TURBINE COMPONENT
The invention relates to a method for manufacturing an abrasive coating on a gas turbine component, especially on a gas turbine rotor blade tip, comprising at least the following steps: a) providing a gas turbine component, especially a gas turbine rotor blade; b) providing a high temperature melting alloy powder; c) providing abrasive particles; d) providing a low temperature melting alloy powder; e) blending at least said high temperature melting alloy powder and said abrasive particles to provide a mixture; f) applying said low temperature melting alloy powder and said mixture to an area of said gas turbine component, especially to a tip of said turbine rotor blade; g) locally heating said area of said gas turbine component to a temperature above the melting point of said low temperature melting alloy powder but below the melting point of said high temperature melting alloy powder.
C23C 24/00 - Coating starting from inorganic powder
C23C 24/08 - Coating starting from inorganic powder by application of heat or pressure and heat
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
F01D 5/28 - Selecting particular materialsMeasures against erosion or corrosion
37 - Construction and mining; installation and repair services
40 - Treatment of materials; recycling, air and water treatment,
42 - Scientific, technological and industrial services, research and design
Goods & Services
(1) Fully automated welding systems, the system being fully integrated machinery; fully automated machining and parts loading systems, the system being fully integrated machinery; fully automated coating systems, the system being fully integrated machinery. (1) Designing and operating integrated automated welding systems to customer specifications; and designing and operating integrated automated coating systems to customer specifications; providing metallurgical engineering services to customer specifications; and providing welding engineering services to customer specifications; providing chemical vapour deposition and physical vapour deposition coating services to customer specifications; providing welding engineering services to customer specifications; repairing of gas turbine components to customer specifications.
09 - Scientific and electric apparatus and instruments
42 - Scientific, technological and industrial services, research and design
Goods & Services
(1) DC gas tungsten arc welding power sources; DC plasma arc welding power sources; variable polarity gas tungsten arc welding power sources; and variable polarity plasma arc welding power sources. (1) Designing and engineering DC gas tungsten arc welding power sources to customer specifications; designing and engineering DC plasma arc welding power sources to customer specifications; designing and engineering variable polarity gas tungsten arc welding power sources to customer specifications; and designing and engineering variable polarity plasma arc welding power sources to customer specifications.
