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.
B23K 9/095 - Surveillance ou commande automatique des paramètres de soudage
B23K 9/12 - Alimentation automatique en électrodes ou en pièces ou déplacement automatique des électrodes ou des pièces pour le soudage ou le découpage à l'arc en lignes continues ou par points
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 - Soudage pour d'autres buts que l'assemblage de pièces, p. ex. soudage de rechargement
B23P 6/00 - Remise en état ou réparation des objets
G01B 11/25 - Dispositions pour la mesure caractérisées par l'utilisation de techniques optiques pour mesurer des contours ou des courbes en projetant un motif, p. ex. des franges de moiré, sur l'objet
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.
B23P 6/00 - Remise en état ou réparation des objets
B23K 9/04 - Soudage pour d'autres buts que l'assemblage de pièces, p. ex. soudage de rechargement
G01B 11/25 - Dispositions pour la mesure caractérisées par l'utilisation de techniques optiques pour mesurer des contours ou des courbes en projetant un motif, p. ex. des franges de moiré, sur l'objet
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 - Alimentation automatique en électrodes ou en pièces ou déplacement automatique des électrodes ou des pièces pour le soudage ou le découpage à l'arc en lignes continues ou par points
B23K 37/06 - Dispositifs ou procédés auxiliaires non spécialement adaptés à un procédé couvert par un seul des autres groupes principaux de la présente sous-classe pour mettre au bon emplacement les matériaux fondus, p. ex. pour les retenir dans une zone désirée
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 - Procédés relevant de la présente sous-classe, spécialement adaptés à des objets ou des buts particuliers, mais non couverts par un seul des groupes principaux relatifs à la recherche des propriétés, p. ex. de soudabilité, des matériaux
G01N 27/90 - Recherche ou analyse des matériaux par l'emploi de moyens électriques, électrochimiques ou magnétiques en recherchant des variables magnétiques pour rechercher la présence des criques en utilisant les courants de Foucault
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.
B23K 9/095 - Surveillance ou commande automatique des paramètres de soudage
B23K 9/12 - Alimentation automatique en électrodes ou en pièces ou déplacement automatique des électrodes ou des pièces pour le soudage ou le découpage à l'arc en lignes continues ou par points
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.
B23K 9/095 - Surveillance ou commande automatique des paramètres de soudage
B23K 9/12 - Alimentation automatique en électrodes ou en pièces ou déplacement automatique des électrodes ou des pièces pour le soudage ou le découpage à l'arc en lignes continues ou par points
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 - Soudage ou découpage à l'arc tenant compte des propriétés des matériaux à souder
B23K 35/22 - Baguettes, électrodes, matériaux ou environnements utilisés pour le brasage, le soudage ou le découpage caractérisés par la composition ou la nature du matériau
B33Y 70/00 - Matériaux spécialement adaptés à la fabrication additive
C22C 30/00 - Alliages contenant moins de 50% en poids de chaque constituant
13.
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 - Alliages à base de nickel ou de cobalt, seuls ou ensemble à base de nickel avec du chrome
B33Y 70/00 - Matériaux spécialement adaptés à la fabrication additive
C22F 1/10 - Modification de la structure physique des métaux ou alliages non ferreux par traitement thermique ou par travail à chaud ou à froid du nickel ou du cobalt ou de leurs alliages
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 - Coulée particulière caractérisée par la nature du produit par sa formeCoulée particulière caractérisée par la nature du produit d'œuvres d'art
B22F 3/105 - Frittage seul en utilisant un courant électrique, un rayonnement laser ou un plasma
B22F 5/04 - Fabrication de pièces ou d'objets à partir de poudres métalliques caractérisée par la forme particulière du produit à réaliser d'aubes de turbines
B23K 31/02 - Procédés relevant de la présente sous-classe, spécialement adaptés à des objets ou des buts particuliers, mais non couverts par un seul des groupes principaux relatifs au brasage ou au soudage
B33Y 70/00 - Matériaux spécialement adaptés à la fabrication additive
C22C 19/05 - Alliages à base de nickel ou de cobalt, seuls ou ensemble à base de nickel avec du chrome
C22C 30/00 - Alliages contenant moins de 50% en poids de chaque constituant
C22F 1/10 - Modification de la structure physique des métaux ou alliages non ferreux par traitement thermique ou par travail à chaud ou à froid du nickel ou du cobalt ou de leurs alliages
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 - Baguettes, électrodes, matériaux ou environnements utilisés pour le brasage, le soudage ou le découpage caractérisés par la composition ou la nature du matériau
B23K 35/30 - Emploi de matériaux spécifiés pour le soudage ou le brasage dont le principal constituant fond à moins de 1550 C
B23K 35/02 - Baguettes, électrodes, matériaux ou environnements utilisés pour le brasage, le soudage ou le découpage caractérisés par des propriétés mécaniques, p. ex. par la forme
B05D 7/20 - Procédés, autres que le flocage, spécialement adaptés pour appliquer des liquides ou d'autres matériaux fluides, à des surfaces particulières, ou pour appliquer des liquides ou d'autres matériaux fluides particuliers à des fils
B23K 35/36 - Emploi de compositions non métalliques spécifiées, p. ex. comme enrobages, comme fluxEmploi de matériaux de brasage ou de soudage spécifiés associé à l'emploi de compositions non métalliques spécifiées, dans lequel l'emploi des deux matériaux est important
B23K 35/365 - Emploi de compositions non métalliques spécifiées comme enrobages, soit seules, soit liées à l'emploi de matériaux spécifiés pour le brasage ou le soudage
C23C 14/28 - Évaporation sous vide par énergie éléctromagnétique ou par rayonnement corpusculaire
C23C 16/44 - Revêtement chimique par décomposition de composés gazeux, ne laissant pas de produits de réaction du matériau de la surface dans le revêtement, c.-à-d. procédés de dépôt chimique en phase vapeur [CVD] caractérisé par le procédé de revêtement
B05D 1/00 - Procédés pour appliquer des liquides ou d'autres matériaux fluides aux surfaces
B05D 3/00 - Traitement préalable des surfaces sur lesquelles des liquides ou d'autres matériaux fluides doivent être appliquésTraitement ultérieur des revêtements appliqués, p. ex. traitement intermédiaire d'un revêtement déjà appliqué, pour préparer les applications ultérieures de liquides ou d'autres matériaux fluides
B05D 3/02 - Traitement préalable des surfaces sur lesquelles des liquides ou d'autres matériaux fluides doivent être appliquésTraitement ultérieur des revêtements appliqués, p. ex. traitement intermédiaire d'un revêtement déjà appliqué, pour préparer les applications ultérieures de liquides ou d'autres matériaux fluides par cuisson
18.
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 - Alliages à base de nickel ou de cobalt, seuls ou ensemble à base de nickel avec du chrome
C22F 1/10 - Modification de la structure physique des métaux ou alliages non ferreux par traitement thermique ou par travail à chaud ou à froid du nickel ou du cobalt ou de leurs alliages
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 - Alliages à base de nickel ou de cobalt, seuls ou ensemble à base de nickel avec du chrome
C22C 19/07 - Alliages à base de nickel ou de cobalt, seuls ou ensemble à base de cobalt
C22C 30/00 - Alliages contenant moins de 50% en poids de chaque constituant
C22F 1/10 - Modification de la structure physique des métaux ou alliages non ferreux par traitement thermique ou par travail à chaud ou à froid du nickel ou du cobalt ou de leurs alliages
F02C 7/00 - Caractéristiques, parties constitutives, détails ou accessoires non couverts dans, ou d'un intérêt plus général que, les groupes Entrées d'air pour ensembles fonctionnels de propulsion par réaction
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.
B23K 26/02 - Mise en place ou surveillance de la pièce à travailler, p. ex. par rapport au point d'impactAlignement, pointage ou focalisation du faisceau laser
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 - Baguettes, électrodes, matériaux ou environnements utilisés pour le brasage, le soudage ou le découpage caractérisés par la composition ou la nature du matériau
B23P 6/00 - Remise en état ou réparation des objets
C22C 19/05 - Alliages à base de nickel ou de cobalt, seuls ou ensemble à base de nickel avec du chrome
23.
HIGH GAMMA PRIME NICKEL BASED WELDABLE SUPERALLOY AND METHOD OF REPAIRING AND MANUFACTURING OF TURBINE ENGINE COMPONENTS USING THE SAME
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 - Alliages à base de nickel ou de cobalt, seuls ou ensemble à base de nickel avec du chrome
B23K 35/22 - Baguettes, électrodes, matériaux ou environnements utilisés pour le brasage, le soudage ou le découpage caractérisés par la composition ou la nature du matériau
B23P 6/00 - Remise en état ou réparation des objets
24.
Method of repairing and manufacturing of turbine engine components and turbine engine component repaired or manufactured using the same
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.
B23P 6/00 - Remise en état ou réparation des objets
C22C 19/05 - Alliages à base de nickel ou de cobalt, seuls ou ensemble à base de nickel avec du chrome
C22F 1/10 - Modification de la structure physique des métaux ou alliages non ferreux par traitement thermique ou par travail à chaud ou à froid du nickel ou du cobalt ou de leurs alliages
B23P 15/02 - Fabrication d'objets déterminés par des opérations non couvertes par une seule autre sous-classe ou un groupe de la présente sous-classe d'aubes de turbine ou d'organes équivalents, en une seule pièce
B23K 9/04 - Soudage pour d'autres buts que l'assemblage de pièces, p. ex. soudage de rechargement
B23K 9/167 - Soudage ou découpage à l'arc utilisant des gaz de protection et une électrode non consommable
B23K 15/00 - Soudage ou découpage par faisceau d'électrons
B23K 26/34 - Soudage au laser pour des finalités autres que l’assemblage
F01D 5/00 - AubesOrganes de support des aubesDispositifs de chauffage, de protection contre l'échauffement, de refroidissement, ou dispositifs contre les vibrations, portés par les aubes ou les organes de support
B23K 101/00 - Objets fabriqués par brasage, soudage ou découpage
F01D 5/28 - Emploi de matériaux spécifiésMesures contre l'érosion ou la corrosion
25.
METHOD OF REPAIRING AND MANUFACTURING OF TURBINE ENGINE COMPONENTS AND TURBINE ENGINE COMPONENT REPAIRED OR MANUFACTURED USING THE SAME
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 - Baguettes, électrodes, matériaux ou environnements utilisés pour le brasage, le soudage ou le découpage caractérisés par la composition ou la nature du matériau
B23P 6/04 - Réparation de pièces ou de produits métalliques brisés ou fissurés, p. ex. de pièces de fonderie
26.
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.
C22C 19/05 - Alliages à base de nickel ou de cobalt, seuls ou ensemble à base de nickel avec du chrome
B23K 35/30 - Emploi de matériaux spécifiés pour le soudage ou le brasage dont le principal constituant fond à moins de 1550 C
B23K 35/02 - Baguettes, électrodes, matériaux ou environnements utilisés pour le brasage, le soudage ou le découpage caractérisés par des propriétés mécaniques, p. ex. par la forme
27.
A 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 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 - Emploi de matériaux spécifiés pour le soudage ou le brasage dont le principal constituant fond à moins de 1550 C
C22F 1/10 - Modification de la structure physique des métaux ou alliages non ferreux par traitement thermique ou par travail à chaud ou à froid du nickel ou du cobalt ou de leurs alliages
C22C 19/05 - Alliages à base de nickel ou de cobalt, seuls ou ensemble à base de nickel avec du chrome
B23P 6/00 - Remise en état ou réparation des objets
B23K 35/24 - Emploi de matériaux spécifiés pour le soudage ou le brasage
B23K 35/02 - Baguettes, électrodes, matériaux ou environnements utilisés pour le brasage, le soudage ou le découpage caractérisés par des propriétés mécaniques, p. ex. par la forme
29.
LOW CARBON 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.
B23K 35/22 - Baguettes, électrodes, matériaux ou environnements utilisés pour le brasage, le soudage ou le découpage caractérisés par la composition ou la nature du matériau
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.
B23K 35/30 - Emploi de matériaux spécifiés pour le soudage ou le brasage dont le principal constituant fond à moins de 1550 C
B23K 35/02 - Baguettes, électrodes, matériaux ou environnements utilisés pour le brasage, le soudage ou le découpage caractérisés par des propriétés mécaniques, p. ex. par la forme
C22C 19/05 - Alliages à base de nickel ou de cobalt, seuls ou ensemble à base de nickel avec du chrome
C22C 38/22 - Alliages ferreux, p. ex. aciers alliés contenant du chrome et du molybdène ou du tungstène
C22C 38/40 - Alliages ferreux, p. ex. aciers alliés contenant du chrome et du nickel
C22C 38/44 - Alliages ferreux, p. ex. aciers alliés contenant du chrome et du nickel et du molybdène ou du tungstène
C22C 38/54 - Alliages ferreux, p. ex. aciers alliés contenant du chrome et du nickel et du bore
C22C 38/02 - Alliages ferreux, p. ex. aciers alliés contenant du silicium
C22C 38/04 - Alliages ferreux, p. ex. aciers alliés contenant du manganèse
C22C 38/48 - Alliages ferreux, p. ex. aciers alliés contenant du chrome et du nickel et du niobium ou du tantale
C22C 38/50 - Alliages ferreux, p. ex. aciers alliés contenant du chrome et du nickel et du titane ou du zirconium
C22C 38/58 - Alliages ferreux, p. ex. aciers alliés contenant du chrome et du nickel et plus de 1,5% en poids de manganèse
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 - Appareils et instruments scientifiques et électriques
37 - Services de construction; extraction minière; installation et réparation
42 - Services scientifiques, technologiques et industriels, recherche et conception
Produits et 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
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 9/04 - Soudage pour d'autres buts que l'assemblage de pièces, p. ex. soudage de rechargement
B23K 26/34 - Soudage au laser pour des finalités autres que l’assemblage
B23K 35/22 - Baguettes, électrodes, matériaux ou environnements utilisés pour le brasage, le soudage ou le découpage caractérisés par la composition ou la nature du matériau
37.
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 - Soudage au laser pour des finalités autres que l’assemblage
B23K 35/22 - Baguettes, électrodes, matériaux ou environnements utilisés pour le brasage, le soudage ou le découpage caractérisés par la composition ou la nature du matériau
B23K 9/04 - Soudage pour d'autres buts que l'assemblage de pièces, p. ex. soudage de rechargement
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 - Baguettes, électrodes, matériaux ou environnements utilisés pour le brasage, le soudage ou le découpage caractérisés par la composition ou la nature du matériau
B23K 35/40 - Fabrication de fils ou de barres pour le brasage ou le soudage
C23C 30/00 - Revêtement avec des matériaux métalliques, caractérisé uniquement par la composition du matériau métallique, c.-à-d. non caractérisé par le procédé de revêtement
39.
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 - Baguettes, électrodes, matériaux ou environnements utilisés pour le brasage, le soudage ou le découpage caractérisés par la composition ou la nature du matériau
B23K 35/40 - Fabrication de fils ou de barres pour le brasage ou le soudage
C23C 30/00 - Revêtement avec des matériaux métalliques, caractérisé uniquement par la composition du matériau métallique, c.-à-d. non caractérisé par le procédé de revêtement
40 - Traitement de matériaux; recyclage, purification de l'air et traitement de l'eau
Produits et 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 - Traitement de matériaux; recyclage, purification de l'air et traitement de l'eau
Produits et 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 - Traitement de matériaux; recyclage, purification de l'air et traitement de l'eau
Produits et 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 - Traitement de matériaux; recyclage, purification de l'air et traitement de l'eau
Produits et 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 - Procédés pour appliquer des liquides ou d'autres matériaux fluides aux surfaces pour obtenir des effets, finis ou des structures de surface particuliers pour obtenir des effets multicolores ou d'autres effets optiques
C23C 24/10 - Revêtement à partir de poudres inorganiques en utilisant la chaleur ou une pression et la chaleur avec formation d'une phase liquide intermédiaire dans la couche
C23C 30/00 - Revêtement avec des matériaux métalliques, caractérisé uniquement par la composition du matériau métallique, c.-à-d. non caractérisé par le procédé de revêtement
F01D 5/28 - Emploi de matériaux spécifiésMesures contre l'érosion ou la 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 - Revêtement à partir de poudres inorganiques
C23C 24/08 - Revêtement à partir de poudres inorganiques en utilisant la chaleur ou une pression et la chaleur
C23C 30/00 - Revêtement avec des matériaux métalliques, caractérisé uniquement par la composition du matériau métallique, c.-à-d. non caractérisé par le procédé de revêtement
F01D 5/28 - Emploi de matériaux spécifiésMesures contre l'érosion ou la corrosion
51.
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 - Revêtement à partir de poudres inorganiques
C23C 24/08 - Revêtement à partir de poudres inorganiques en utilisant la chaleur ou une pression et la chaleur
C23C 30/00 - Revêtement avec des matériaux métalliques, caractérisé uniquement par la composition du matériau métallique, c.-à-d. non caractérisé par le procédé de revêtement
F01D 5/28 - Emploi de matériaux spécifiésMesures contre l'érosion ou la corrosion
37 - Services de construction; extraction minière; installation et réparation
40 - Traitement de matériaux; recyclage, purification de l'air et traitement de l'eau
42 - Services scientifiques, technologiques et industriels, recherche et conception
Produits et 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 - Appareils et instruments scientifiques et électriques
42 - Services scientifiques, technologiques et industriels, recherche et conception
Produits et 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.
