U.S. patent application number 13/337190 was filed with the patent office on 2012-06-28 for gas turbine engine component material addition process.
Invention is credited to Quinlan Yee Shuck.
Application Number | 20120160443 13/337190 |
Document ID | / |
Family ID | 45476373 |
Filed Date | 2012-06-28 |
United States Patent
Application |
20120160443 |
Kind Code |
A1 |
Shuck; Quinlan Yee |
June 28, 2012 |
GAS TURBINE ENGINE COMPONENT MATERIAL ADDITION PROCESS
Abstract
A material addition process is described that includes coupling
a plate to a gas turbine engine component and adding material to
the plate. In one embodiment the gas turbine engine component can
be processed by removing a portion that is damaged, such as a
portion that includes a crack. A material can be deposited on the
plate and built up in layers to replace the removed portion. The
material can be layered upon the plate such that its thickness
through the layers is smaller than a reach of the layers in a
direction of the layer. The plate can be removed in whole or in
part after a material has been added. In one form the material can
be added by direct laser deposition. In one embodiment a metal
powder is fused using a laser. Excess buildup can be removed to
reveal a net shape article.
Inventors: |
Shuck; Quinlan Yee;
(Indianapolis, IN) |
Family ID: |
45476373 |
Appl. No.: |
13/337190 |
Filed: |
December 26, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61427690 |
Dec 28, 2010 |
|
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|
Current U.S.
Class: |
164/492 ;
164/69.1; 164/80 |
Current CPC
Class: |
B23P 6/045 20130101;
B23K 26/342 20151001; B23K 2103/08 20180801; F05D 2230/31 20130101;
F01D 5/005 20130101; B23K 2101/001 20180801; B23K 35/0244 20130101;
B23K 2101/34 20180801; B23P 6/007 20130101; F05D 2230/80
20130101 |
Class at
Publication: |
164/492 ;
164/69.1; 164/80 |
International
Class: |
B22D 23/06 20060101
B22D023/06 |
Claims
1. A method comprising: coupling a backing plate to a gas turbine
engine component to create a material addition area having
boundaries between the gas turbine engine component and a portion
of the backing plate; conveying a metal powder to be located in the
material addition area of the coupled gas turbine engine component
and backing plate; and forming a plurality of repair layers
throughout the material addition area by fusing the metal powder
with an electromagnetic energy, wherein each of the repair layers
of the plurality of repair layers is offset a different amount from
the backing plate.
2. The method of claim 1, which further includes removing a portion
of a gas turbine engine component to be repaired to reveal a
through-cut and finishing the gas turbine engine component by
eliminating excess material.
3. The method of claim 2, wherein the eliminating includes removing
a portion of the backing plate, wherein a final repaired gas
turbine engine component includes a remaining portion of the
backing plate, and wherein a thickness of the plurality of repair
layers is smaller than a lateral reach of the plurality of repair
layers throughout the material addition area.
4. The method of claim 2, wherein the eliminating includes removing
the backing plate, and wherein the plurality of repair layers is
parallel with the backing plate.
5. The method of claim 4, wherein the gas turbine engine component
is an airfoil member structured to be disposed in a flow path of a
gas turbine engine.
6. The method of claim 1, wherein the fusing includes fusing to the
gas turbine engine component, and wherein the backing plate is a
polycrystalline backing plate.
7. The method of claim 1, which further includes removing a portion
of a gas turbine engine component to be repaired to reveal a
through-cut, wherein the electromagnetic energy is provided with a
laser, and wherein the plurality of repair layers is transverse to
the through-cut of the gas turbine engine component.
8. A method comprising: adding material to a gas turbine engine
component, the adding including: coupling a substrate to the gas
turbine engine component such that the substrate extends beyond the
gas turbine engine component, the substrate forming a base for a
deposit of material to create an extended surface of the gas
turbine engine component; energizing a metal feedstock above the
substrate to create a fused metal coupled with the gas turbine
engine component; as a result of the energizing, creating a first
layer of metal parallel with the substrate, the first layer having
a first thickness; and as a result of the energizing, creating a
second layer of metal parallel with the first layer, the first
layer disposed between the second layer and the substrate, the
second layer having a second thickness.
9. The method of claim 8, which further includes finishing the gas
turbine engine component after the forming to remove material
outside of a net shape, and wherein a length of the first layer is
larger than the first thickness and the length is a distance along
a stack of first layer and second layer parallel with the
substrate.
10. The method of claim 8, wherein the metal feedstock is a metal
powder, and wherein as a result of the creating, forming a stack of
layers having a stack thickness, the thickness smaller than a
length of the stack as it extends to cover an area.
11. The method of claim 10, wherein the energizing includes lasing
the metal feedstock with a laser.
12. The method of claim 8, which further includes removing a
damaged portion of the gas turbine engine component, and wherein
the forming is a repair process of a damaged gas turbine engine
component.
13. The method of claim 8, which further includes removing the
substrate.
14. The method of claim 13, wherein the removing includes removing
a portion of the substrate and leaving another portion coupled to
the gas turbine engine component.
15. A method comprising: coupling a gas turbine engine component
with a sacrificial substrate; directing a feedstock material to a
work area of the gas turbine engine component; fusing the feedstock
material to the gas turbine engine component via an electromagnetic
energy to create a layer of metal; forming a plurality of layers
with the fusing; and removing a portion of the sacrificial
substrate, a remaining portion of the sacrificial substrate forming
part of a refurbished gas turbine engine component.
16. The method of claim 15, which further includes removing a
portion of the gas turbine engine component prior to the forming,
and wherein the plurality of layers are parallel with the
sacrificial substrate.
17. The method of claim 16, wherein the electromagnetic energy is
from a laser.
18. The method of claim 16, wherein the feedstock material is a
powdered metal.
19. The method of claim 15, wherein a thickness of the plurality of
layers is smaller than a width of the plurality of layers.
20. The method of claim 19, wherein the refurbished gas turbine
engine component is a component repaired from a damage inflicted
upon the component.
21. The method of claim 19, wherein the sacrificial substrate is a
polycrystalline substrate.
Description
RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S.
Provisional Patent Application No. 61/427,690 filed Dec. 28, 2010
which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention generally relates to gas turbine
engine components subject to material addition processes, and more
particularly, but not exclusively, to sacrificial substrates used
in material addition processes.
BACKGROUND
[0003] Adding material to a gas turbine engine component remains an
area of interest. Some existing systems have various shortcomings
relative to certain applications. Accordingly, there remains a need
for further contributions in this area of technology.
SUMMARY
[0004] One embodiment of the present invention is a unique gas
turbine engine component subject to a material addition process.
Other embodiments include apparatuses, systems, devices, hardware,
methods, and combinations for adding material to a gas turbine
engine component. Further embodiments, forms, features, aspects,
benefits, and advantages of the present application shall become
apparent from the description and figures provided herewith.
BRIEF DESCRIPTION OF THE FIGURES
[0005] FIG. 1 depicts one embodiment of a gas turbine engine.
[0006] FIG. 2 depicts an embodiment of a gas turbine engine
component.
[0007] FIGS. 3a and 3b depict an embodiment of a damage and removal
from a component.
[0008] FIG. 4 depicts one embodiment of coupling a backer plate to
a component.
[0009] FIG. 5 depicts one embodiment of a material addition to a
component.
[0010] FIG. 6 depicts one embodiment of a final component after
material addition.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0011] For the purposes of promoting an understanding of the
principles of the invention, reference will now be made to the
embodiments illustrated in the drawings and specific language will
be used to describe the same. It will nevertheless be understood
that no limitation of the scope of the invention is thereby
intended. Any alterations and further modifications in the
described embodiments, and any further applications of the
principles of the invention as described herein are contemplated as
would normally occur to one skilled in the art to which the
invention relates.
[0012] With reference to FIG. 1, a gas turbine engine 50 is
depicted having a compressor 52, combustor 54, and turbine 56 and
can be used to provide power to a vehicle such as, but not limited
to, an aircraft. As used herein, the term "aircraft" includes, but
is not limited to, helicopters, airplanes, unmanned space vehicles,
fixed wing vehicles, variable wing vehicles, rotary wing vehicles,
unmanned combat aerial vehicles, tailless aircraft, hover crafts,
and other airborne and/or extraterrestrial (spacecraft) vehicles.
Further, the present inventions are contemplated for utilization in
other applications that may not be coupled with an aircraft such
as, for example, industrial applications, power generation, pumping
sets, naval propulsion, weapon systems, security systems, perimeter
defense/security systems, and the like known to one of ordinary
skill in the art.
[0013] The gas turbine engine 50 operates by receiving a working
fluid and compressing it with the compressor 52. The working fluid
can be air. Upon being compressed the working fluid is mixed with a
fuel and combusted in the combustor 54 before being expanded
through the turbine 56. The gas turbine engine can provide power
through the turbine 56, it can provide propulsive thrust, or a
combination of the two. Though the gas turbine engine 50 is
depicted as a single spool engine, it will be appreciated that in
other embodiments the gas turbine engine can have any number of
spools. The gas turbine engine 50 can take the form of a turbojet,
turbofan, turboprop, or turboshaft and can be a variable cycle
and/or adaptive cycle engine. In short, the gas turbine engine 50
can take on many forms and be used for many purposes.
[0014] Turning now to FIG. 2, one form of a component 58 useful
with the gas turbine engine 50 is shown The component 58 in the
illustrative embodiment is in the form of a turbine blade, but in
other embodiments the component 58 can take on a variety of other
forms whether forming part of a flow path structure or another
portion of the gas turbine engine 50. During some modes of
operation, such as to produce power for a vehicle or while the
component 58 is being manipulated for other purposes, damage to the
component 58 may occur. Such damage can be the result of an impact
with a foreign object, fatigue over multiple operations, and/or
wear from repeated uses, among potential others. The component 58
can be processed and returned to service as will be described
further below. Reference will be made below to the component 58 but
it will be appreciated that the description is not limited to the
embodiment of the component 58 depicted in FIG. 2.
[0015] Turning now to FIGS. 3a-6, one embodiment is shown of a
component 58 during various portions of it being processed to
receive an additional material in light of a damage to the
component. In one form the component is damaged to the extent that
it requires a material addition to place the component back into
service. In another form the component dimensions may not match its
original dimensions at the beginning of its service life because of
a gradual wear over a number of operations. A material operation
such as that described herein can be performed to the component to
return it to, or near, its original outer dimensions.
[0016] FIG. 3a depicts a damage in the form of a crack 60 to the
component 58. A first step in returning the component 58 to service
is to remove the crack 60 from the component 58 by removing a
portion of the component 58 surrounding the crack 60 to create a
workpiece that can be seen in FIG. 3b. The portion removed can take
a variety of shapes and sizes which may be dictated by the
particular type of component, its expected service environment, and
ease of repair, among other possible considerations. Thus, the
shape and location of the material removed from the component 58
shown in FIGS. 3a and 3b are for illustration purposes only.
Furthermore, it will be appreciated that although the illustrated
embodiment depicts removing a portion of the component 58 as a
first step in returning it to service, not all components that are
operated upon according to the present disclosure need to have a
portion removed. The portion of the component 58 that is removed
can be by way of physical removal process such as mechanical
machining/grinding/cutting/etc., to set forth just a few
non-limiting examples. In some forms the portion can be machined
away using processes such as electrical discharge machining. In
other non-limiting forms the portion could be chemically removed.
In short, a variety of techniques, and combination of techniques,
for removing the portion of the component are contemplated
herein.
[0017] FIG. 4 illustrates a backer plate 62 that is coupled to the
component 58 after the portion has been removed as discussed above.
In one form the backer plate 62 is a weld backing plate, but many
other forms are contemplated herein. The backer plate 62 is coupled
to form a bottom so that material can be added in the space to
replace the portion that had been removed. As used herein,
relational terms such as bottom, top, side, right, left, etc., are
used herein for ease of convenience relative to the depictions in
the figures and do not necessarily indicate any particular
orientation of the component 58 during the processes described in
the present application or its installation in a gas turbine engine
50. The backer plate 62 can be affixed using any variety of
techniques such as via mechanical fasteners and the like, chemical
agents such as epoxy, and joining approaches such as brazing, among
any number of potential others. The backer plate 62 can extend any
distance into the component 58 as well as any distance away from
the component 58. To set forth just one non-limiting example, the
backer plate 62 can extend partially to a side of the component
opposite the side having the portion removed just far enough to
form a bottom for the receipt of a material. In another
non-limiting form the backer plate 62 could extend fully to the
opposing side of the component 58 if needed and/or desired.
[0018] The backer plate 62 can have a shape in the form of a mirror
image of a desired final surface of the component 58. For example,
after a material is added to the space above the backer plate 62
and the backer plate 62 subsequently removed, the shape of the
material remaining attached to the gas turbine engine component 58
can have the net shape, or near net shape, of the desired surface
contour. If, for example, the component is in the form of an
airfoil shape and if a material is added to the trailing edge of
the component after that particular portion had been removed, the
shape of the trailing edge after the backer plate 62 is removed can
follow the desired airfoil shape of the component 58.
[0019] The backer plate 62 can be made from any variety of
materials and can have any variety of dimensions. To set forth just
one non-limiting example, the backer plate 62 can be a
polycrystalline backer plate 62. In some forms the backer plate 62
can be reused for multiple material addition operations. In other
forms the backer plate 62 can be removed, either in whole or in
part, from the component 58.
[0020] Turning now to FIG. 5, one embodiment of a layered material
addition process is depicted. The component 58 is shown having a
number of layers 64 of material added in the space formerly
occupied by the portion removed from the component 58. The material
added to the space can result in a net shape, or near net shape
article. The embodiment depicted in FIG. 5 includes a bottom layer
66, middle layer 68, and upper layer 70. In other embodiments of
the component 58, however, any number of material layers can be
added upon the backer plate 62 whether greater in number or fewer
than the number of layers depicted in FIG. 5.
[0021] The layers can be created using any variety of approaches.
In one non-limiting form the layers can be laid down using solid
free form fabrication techniques. One particular non-limiting
approach described more fully below uses direct laser deposition to
fuse a powder and create each of the layers of the material
addition. In one form the powder can be metal. The powder feedstock
can be directed to a general vicinity of a deposition and the laser
can be scanned to fuse the powder and create a consolidated
material. The process can include a full melting or partial melting
of the powder. The powder can be delivered through a variety of
techniques, one non-limiting example of which includes placing
powder above the backing plate 62 by blowing the powder. As the
laser is scanned the material forming the powder is fused in the
general shape according to the scanned path of the laser. In one
form the consolidated material is fused with a nearby fused
material, or can be alternatively and/or additionally fused with a
component that is being worked upon such as the component 58. Any
number of suitable lasers can be used, and in one form the laser is
a carbon dioxide laser. A desired component or material deposit is
created when sequential layers of powder are scanned with the
laser. Any number of layers can be used when adding material to the
component 58.
[0022] The layers 66, 68, and 70 of the material addition can be
created in a variety of manners. In one form the layers can be laid
down using a scanned laser in a variety of build patterns. In one
non-limiting example a layer can be laid down according to
sequential paths of a scanned laser, the first of the paths
adjoining a contour of the gas turbine component. The sequential
paths of the scanned laser can all be in the same direction having
a similar starting side and ending side. Although the immediate
example includes multiple sequential build paths, not all layers
need include multiple paths. Any variety of variations of scanning
patters of the laser are contemplated herein to create any given
layer of the material addition.
[0023] Each of the layers can be laid down using scanned paths that
are different than the paths used in adjacent layers. For example,
a layer closest to the backer plate 62 can be laid down having
paths all aligned in the same general direction, while a layer
above it is laid down having paths aligned in the opposite
direction. Furthermore, any scanned path in one layer can have the
same or opposite direction as an adjacent scanned path in an
adjacent layer. Any variation in scanned paths are contemplated
herein.
[0024] In one form of the present application the layers are laid
down to a desired thickness to cover a desired area of the backer
plate 62. In some forms the desired area may be the entire exposed
area of the backer plate 62. After an initial layer covers the
backer plate 62 in the desired area, another layer is created above
it, again covering either the original desired area or another,
different desired area for that thickness location. In this way a
number of layers can be built up from the backer plate 62. The
layers can have any variety of shapes, sizes, and thicknesses. In
one non-limiting form the layers have the same thicknesses.
[0025] In one non-limiting form the layers are generally in the
shape of a short and wide material addition. For example, the
embodiment of FIG. 5 depicts layers 66, 68, and 70 having a through
layer thickness that is smaller than the extent of the layers as
they extend between portions 72 and 74 of the component 58. For
example, the edge 76 of the material addition layers 64 extends a
greater distance than the through-thickness of the layers 64. The
resulting microstructure of a short and wide layered material
addition can be more isotropic resulting in a tougher and more
ductile material. A lateral reach of the layers 64 can be in any
direction and not just the reach of the edge 76 discussed in FIG.
5. For example, and by ease of convenience only, the thickness of
the layers 64 is smaller than either a width or length of the
layers 64 wherein length is arbitrarily defined along the edge 76.
As used herein, the terms "width" and "length" are used for ease of
convenience according to the illustrated embodiment and may not be
easily identifiable in other embodiments if the material addition
does not have a shape that is generally quadrilateral as in the
illustrated embodiment. It will be appreciated in FIG. 5 that the
thickness of the stack is smaller than the reach of the stack in
width or length. In some forms it could be described that the
thickness is orthogonal to the other directions that the layers 64
extend. In other forms the stack may be curved or have a curvature
and that the thickness is smaller than the distance that the stack
reaches another direction, such as a general direction along the
curve. Thus, the present application discloses a plurality of
layers that are short and wide as opposed to tall and thin.
[0026] After one or more layers have been added or alternatively
after all layers have been added, excess material from the backer
plate 62 and/or from a deposit overbuild can be removed either in
whole or in part from the component 58. FIGS. 5 and 6 illustrate
the removal of the backer plate 62 yielding a component 58 having
the material addition 78. In some forms the entire backer plate 62
is removed from the component 58, but in other forms a portion of
the backer plate 62 may remain integrated with the component 58 as
it is returned to service. The excess material described above can
be removed by way of a physical removal process such as mechanical
machining/grinding/cutting/etc., to set forth just a few
non-limiting examples. In some forms the excess material can be
machined away using processes such as electrical discharge
machining. In other non-limiting forms the excess material could be
chemically removed. In short, a variety of techniques, and
combination of techniques, for removing the portion of the
component are contemplated herein.
[0027] One aspect of the present application provides a method
comprising coupling a backing plate to a gas turbine engine
component to create a material addition area having boundaries
between the gas turbine engine component and a portion of the
backing plate, conveying a metal powder to be located in the
material addition area of the coupled gas turbine engine component
and backing plate, and forming a plurality of repair layers
throughout the material addition area by fusing the metal powder
with an electromagnetic energy, wherein each of the repair layers
of the plurality of repair layers is offset a different amount from
the backing plate.
[0028] One feature of the present application further includes
removing a portion of a gas turbine engine component to be repaired
to reveal a through-cut and finishing the gas turbine engine
component by eliminating excess material.
[0029] Another feature of the present application provides wherein
the eliminating includes removing a portion of the backing plate,
wherein a final repaired gas turbine engine component includes a
remaining portion of the backing plate, and wherein a thickness of
the plurality of repair layers is smaller than a lateral reach of
the plurality of repair layers throughout the material addition
area.
[0030] Yet another feature of the present application provides
wherein the eliminating includes removing the backing plate, and
wherein the plurality of repair layers is parallel with the backing
plate.
[0031] Still another feature of the present application provides
wherein gas turbine engine component is an airfoil member
structured to be disposed in a flow path of a gas turbine
engine.
[0032] Yet still another feature of the present application
provides wherein the fusing includes fusing to the gas turbine
engine component, and wherein the backing plate is a
polycrystalline backing plate.
[0033] A further feature of the present application further
includes removing a portion of a gas turbine engine component to be
repaired to reveal a through-cut, wherein the electromagnetic
energy is provided with a laser, and wherein the plurality of
repair layers is transverse to the through-cut of the gas turbine
engine component.
[0034] Another aspect of the present application provides a method
comprising adding material to a gas turbine engine component, the
adding including coupling a substrate to the gas turbine engine
component such that the substrate extends beyond the gas turbine
engine component, the substrate forming a base for a deposit of
material to create an extended surface of the gas turbine engine
component, energizing a metal feedstock above the substrate to
create a fused metal coupled with the gas turbine engine component,
as a result of the energizing, creating a first layer of metal
parallel with the substrate, the first layer having a first
thickness, and as a result of the energizing, creating a second
layer of metal parallel with the first layer, the first layer
disposed between the second layer and the substrate, the second
layer having a second thickness.
[0035] One feature of the present application further includes
finishing the gas turbine engine component after the forming to
remove material outside of a net shape, and wherein a length of the
first layer is larger than the first thickness and the length is a
distance along a stack of first layer and second layer parallel
with the substrate.
[0036] Another feature of the present application provides wherein
the metal feedstock is a metal powder, and wherein as a result of
the creating, forming a stack of layers having a stack thickness,
the thickness smaller than a length of the stack as it extends to
cover an area.
[0037] Yet another feature of the present application provides
wherein the energizing includes lasing the metal feedstock with a
laser.
[0038] Still another feature of the present application further
includes removing a damaged portion of the gas turbine engine
component, and wherein the forming is a repair process of a damaged
gas turbine engine component.
[0039] Yet still another feature of the present application further
includes removing the substrate.
[0040] A further feature of the present application provides
wherein the removing includes removing a portion of the substrate
and leaving another portion coupled to the gas turbine engine
component.
[0041] Yet another aspect of the present application provides a
method comprising coupling a gas turbine engine component with a
sacrificial substrate, directing a feedstock material to a work
area of the gas turbine engine component, fusing the feedstock
material to the gas turbine engine component via an electromagnetic
energy to create a layer of metal, forming a plurality of layers
with the fusing, and removing a portion of the sacrificial
substrate, a remaining portion of the sacrificial substrate forming
part of a refurbished gas turbine engine component.
[0042] A feature of the present application further includes
removing a portion of the gas turbine engine component prior to the
forming, and wherein the plurality of layers are parallel with the
sacrificial substrate.
[0043] Another feature of the present application provides wherein
the electromagnetic energy is from a laser.
[0044] Yet another feature of the present application provides
wherein the feedstock material is a powdered metal.
[0045] Still another feature of the present application provides
wherein a thickness of the plurality of layers is smaller than a
width of the plurality of layers.
[0046] Yet still another feature of the present application
provides wherein the refurbished gas turbine engine component is a
component repaired from a damage inflicted upon the component.
[0047] A further feature of the present application provides
wherein the sacrificial substrate is a polycrystalline
substrate.
[0048] While the invention has been illustrated and described in
detail in the drawings and foregoing description, the same is to be
considered as illustrative and not restrictive in character, it
being understood that only the preferred embodiments have been
shown and described and that all changes and modifications that
come within the spirit of the inventions are desired to be
protected. It should be understood that while the use of words such
as preferable, preferably, preferred or more preferred utilized in
the description above indicate that the feature so described may be
more desirable, it nonetheless may not be necessary and embodiments
lacking the same may be contemplated as within the scope of the
invention, the scope being defined by the claims that follow. In
reading the claims, it is intended that when words such as "a,"
"an," "at least one," or "at least one portion" are used there is
no intention to limit the claim to only one item unless
specifically stated to the contrary in the claim. When the language
"at least a portion" and/or "a portion" is used the item can
include a portion and/or the entire item unless specifically stated
to the contrary.
* * * * *