Abstract:
An improved method and apparatus for laser trepanning a passage through a workpiece, gas turbine engine component or the like includes the method steps of: providing a linearly polarized beam of laser energy; focusing the laser beam on a selected location on the component; moving one of the laser beam or the workpiece relative to one another along a first selected trepanning path and along a second selected trepanning path, which is substantially opposite in direction to the first selected path, to compensate for the linear polarization of the laser beam and to reduce the processing time. The steps of moving one of the laser beam or the workpiece along the first and second trepanning paths are repeated until a passage is cut to a desired depth into the surface of the component or the passage is cut entirely through the component. An apparatus for accomplishing the method of the present invention includes a laser system for generating a linearly polarized beam of laser energy and a manipulator arrangement for moving one of the laser system or the component relative to one another. The apparatus further includes a computer controller which is programmed to move either the laser system or the component along the first and second selected trepanning paths.
Abstract:
The present invention consists in the apparatus for use in welding a first component and a second component together by friction welding, comprising drive means operative to generate reciprocatory movement, a component holder operative to hold said first component, linking means operative to transmit reciprocatory movement from the drive means to the component holder so that in operation said first component performs reciprocatory heat-generating movement, pressure means operative to exert pressure on the component holder so that in operation said first component also performs welding movement, the linking means being such as to accommodate that welding movement during friction welding and the pressure means being such as to accommodate that heat-generating movement during friction welding. The pressure means preferably comprises ram means operative to apply force to a non-reciprocating head which is connected to the component holder through flexible connecting means enabling heat-generating movement of the holder to be accommodated. The connecting means may comprise one or more hinged links but preferably comprises one or more flexible elements. These flexible elements may comprise flexible rods or bars but preferably comprise flexible blades so orientated as to prevent movement of the component holder in a direction transverse to its heat-generating movement. Movement of the head in a direction parallel with the reciprocatory heat-generating movement of the component holder is preferably resisted by guide means which nevertheless permits the head with the component holder to perform welding movement. The guide means is preferably constituted by roller means preloaded to prevent backlash or rattling in use.
Abstract:
A turbine blade spar wall surrounds a coolant plenum of the blade and is cast with an intermediate thickness exceeding its final or design thickness. The outer surface of the spar wall is machined to form a plurality of incomplete holes extending to bottoms located at the final thickness dimension of the spar wall. A pre-formed sheath of porous metal is fit closely around the spar wall outer surface with coolant pores in the sheath communicating with the incomplete holes. A high pressure inert gas is introduced into the coolant plenum concurrently with application of compressive forces to the sheath as both the sheath and the spar wall are raised to a high temperature whereby the sheath is diffusion bonded to the spar wall. The inert gas pressure in the coolant plenum reinforces the spar wall against the compressive forces. The inner surface of the spar wall is then chemically machined to an etch depth dimension which brings the spar wall to its design thickness and simultaneously removes the bottoms of the incomplete holes so that the incomplete holes become complete holes between the coolant plenum and the sheath of porous metal.
Abstract:
A mask particularly useful in the weld repair of air cooled gas turbine blades and vanes contains a mixture of ceramic particles in a liquid carrier. The mask is applied onto the surface of the blade or vane, and into the cooling holes. Following a sintering treatment, an inert, thermally stable, electrically nonconductive ceramic mask is produced, which is easily removed after welding.
Abstract:
A method and an apparatus for welding an impeller by using a TIG process are provided in which one of the blades to be welded to a side plate or shroud plate is disposed so as to form a V-shaped channel with the plate, the channel being oriented to face upwardly, and a torch head supported at the tip of a torch rod is placed above a weld line produced by the intersection of the blade and the plate so as to contact the inner surface of the channel keeping a proper distance between the tip of the tungsten electrode encased within the torch head and the weld line on which a filler wire of suitable length is disposed. The opposite end of the torch rod is mounted on a translating mechanism through an universal joint so the torch head moves along and above the weld line and electric current is supplied between the weld line on which the filler wire is disposed and the electrode while simultaneously supplying an inert gas through the nozzle during the movement of the nozzle, the nozzle keeping in contact with the inner surface of the channel due to gravity. The nozzle has a specific configuration so that the electrode distance is constant from the apex of the channel when the channel is curved or straight.
Abstract:
A refurbished turbine vane or blade. Used turbine vanes and blades are cleaned, annealed and in some cases slotted adjacent their ends, after which any cooling passages are welded closed and all cracks welded over, on both leading and trailing edges. The trailing edge, for a vane or blade having a short chord, is built up by welding along its full length with an alloy wire, after which any slots that were cut adjacent the ends are closed, also by welding. Then the worn surfaces of the vane or blade are built-up by a plasma spray process, using a metal powder with added silica, to a thickness as great as 30 to 40 thousandths of an inch. The built-up vane or blade is then sintered and thereafter surface finished to conform to the original contour of the component when new. Any cooling holes are finally recut, and the vane or blade polished as required and inspected.
Abstract:
A narrow crevice in a Ni-base superalloy article is repaired by first removal of a complex oxide of at least one metal selected from Al and Ti, by treatment of the oxide in the crevice with gaseous active fluoride ions in a non-oxidizing atmosphere at a temperature at which the oxide will react with the fluoride ions under the conditions around the oxide. The crevice is then repaired in a subsequent step such as by filling with metal or pressure bonding.
Abstract:
A refurbished turbine vane and method of producing the same. Used turbine vanes are cleaned, annealed and slotted adjacent their ends, after which the cooling passages are welded closed and all cracks welded over, on both leading and trailing edges. The trailing edge, for a vane having a short chord, is built up by welding along its full length with an alloy wire, after which the slots that were cut adjacent the ends are closed, also by welding. Then the worn surfaces of the vane are built-up by a plasma spray process, using a metal powder with added silica, to a thickness as great as 30 to 40 thousandths of an inch. The built-up vane is then sintered and thereafter surface finished to conform to the original contour of the blade when new. The cooling holes are finally recut, and the vane polished as required and inspected.
Abstract:
A method for applying a cladding to the surface of a body by enclosing the body with a cladding of sheet metal or foil loosely adherent to the body surface in a mass of a non-reactive, nondensifying powder, and compressing the powder at a pressure of greater than about 500 psi and at elevated temperatures up to the melting point of the body or the cladding.
Abstract:
A process for friction or inertia bonding difficult-to-grip parts wherein the parts are mounted within fixtures and a lowmelting-temperature alloy is poured into the fixtures so as to absorb hoop stresses and to prevent relative rotation between the workpiece and the fixture.