Recent Progress in Turbine Blade and Compressor Blisk Regeneration

Aschenbruck, Jens; Adamczuk, Rafael R.; Seume, Joerg R.

doi:10.1016/j.procir.2014.07.016

Cited by 47 publications

(19 citation statements)

References 17 publications

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“…Friction welding is a traditional method that is often used for joining and repair within the aerospace industry. It is considered a solid-state joining method that produces high integrity welds by frictional heat being generated through the movement of one component relative to the one it is being joined to under a force [ 3 , 4 ]. However, new generation nickel-based superalloys have been specifically designed with increased volume fraction of the second phase strengthening precipitate gamma prime (γ′) (>40%) to meet the high temperature requirements of the engine [ 5 ].…”

Section: Introductionmentioning

confidence: 99%

Powder Interlayer Bonding of Nickel-Based Superalloys with Dissimilar Chemistries

et al. 2021

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Novel joining methods are crucial for the aerospace industry to repair components damaged in the high stress, high cycle environment of the jet turbine engine. Powder interlayer bonding (PIB) is a novel joining technique that is being explored for use in the aerospace industry. PIB involves the use of a powder interlayer between two faying surfaces alongside a localised temperature gradient and compressive force to produce one joined workpiece. The use of a localised temperature gradient not only reduces the heat affected zone (HAZ) but also reduces the energy requirements for the process as only a small area of the component needs to be elevated in temperature. Nickel-based superalloys are commonly used in the gas turbine engine due to their superior mechanical properties that are maintained even under the most elevated temperatures experienced in the jet turbine engine. It is therefore essential these alloys can be easily repaired. Conventional joining methods such as friction welding have proved difficult for new generation nickel-based superalloys; therefore, there is much interest in PIB as an alternative repair technology. This study shows the potential of PIB to join dissimilar nickel-based superalloys: bonds with very little porosity were observed after only a short processing time.

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Section: Introductionmentioning

confidence: 99%

Powder Interlayer Bonding of Nickel-Based Superalloys with Dissimilar Chemistries

et al. 2021

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“…Novel joining techniques are of high importance in the aerospace industry, as 8% of operating costs for airline operators are for engine maintenance and repair [3]. Powder Interlayer Bonding (PIB) is of interest as a potential technique for the joining and repair of aerospace alloys.…”

Section: Introductionmentioning

confidence: 99%

The Effect of Processing Variables on Powder Interlayer Bonding in Nickel-Based Superalloys

et al. 2020

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Powder Interlayer Bonding (PIB) has been considered as a lower-energy joining technology for nickel-based superalloys compared to conventional methods; such as friction welding. Typically; nickel-based superalloys exhibit high energy requirements for joining due to their high operating temperatures. However; PIB utilizes a localized temperature gradient created by an induction current; reducing the energy requirements for the process. PIB is a solid-state joining method that compresses and heats a powder interlayer between two faying surfaces to produce one joined workpiece. It has been successfully used to bond titanium alloys; and the objectives of this work were to explore its application as a joining method for nickel-based superalloys. Initial results showed that joining nickel-based superalloys via PIB is possible; and bondlines with very little porosity were observed. Further analysis showed that these bonded areas had lower porosity than the base material; suggesting PIB could be a successful joining method for difficult-to-join nickel-based superalloys.

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“…(4) The hot-wire technique showed no significant influence on the melting deposition rate and the weld seam geometry as well as the hot-crack formation, i.e., the active intervention in the heat management. (5) The largest influence on the weld seam geometry is addressed to the wire-feeding rate and the pulse energy. (6) Increasing wire-feeding rates lead to decreasing stability of the welding process in terms of discontinuous wire-feeding.…”

Section: Discussionmentioning

confidence: 99%

“…Due to the particularly high material and manufacturing costs, there is a significant economic interest in the repair or overhaul instead of the replacement of operationally stressed components [3]. Laser cladding has developed as a suitable repair strategy [4][5][6]. Laser powder cladding is economically preferred for the repair of large-area damages due to the high deposition rates, e.g., at the leading edge of the turbine blade [7].…”

Section: Introductionmentioning

confidence: 99%

Strategies for Increasing the Productivity of Pulsed Laser Cladding of Hot-Crack Susceptible Nickel-Base Superalloy Inconel 738 LC

Kästner

Neugebauer

Schricker

et al. 2020

JMMP

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A novel repair strategy based on decoupled heat source for increasing the productivity of wire-assisted pulsed laser cladding of the γ’-precipitation strengthening nickel-base superalloys Inconel 738 low carbon (IN 738 LC, base material) and Haynes 282 (HS 282, filler material) is presented. The laser beam welding process is supported by the hot-wire technology. The additional energy is utilized to increase the deposition rate of the filler material by increasing feeding rates and well-defining the thermal management in the welding zone. The simultaneous application of laser pulse modulation allows the precise control of the temperature gradients to minimize the hot-crack formation. Accompanying investigations such as high-speed recordings and numerical simulations allow a generalized statement on the influence of the adapted heat management on the resulting weld seam geometry (dilution, aspect ratio and wetting angle) as well as the formation of hot-cracks and lack of fusion between base and filler material. Statistical analysis of the data—the input parameters like laser pulse energy, pulse shape, hot-wire power and wire-feeding rate in conjunction with the objectives like dilution, aspect ratio, wetting angle and hot-cracking behavior—revealed regression functions to predict certain weld seam properties and hence the required input parameters.

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Recent Progress in Turbine Blade and Compressor Blisk Regeneration

Cited by 47 publications

References 17 publications

Powder Interlayer Bonding of Nickel-Based Superalloys with Dissimilar Chemistries

Powder Interlayer Bonding of Nickel-Based Superalloys with Dissimilar Chemistries

The Effect of Processing Variables on Powder Interlayer Bonding in Nickel-Based Superalloys

Strategies for Increasing the Productivity of Pulsed Laser Cladding of Hot-Crack Susceptible Nickel-Base Superalloy Inconel 738 LC

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