公开(公告)号：US09085042B2

公开(公告)日：2015-07-21

申请号：US13571754

申请日：2012-08-10

申请人： Gerald J. Bruck

发明人： Gerald J. Bruck

IPC分类号： B23K33/00 ,  B32B15/01 ,  B23K9/20 ,  B23P6/00 ,  F01D5/00

CPC分类号： B23K9/201 ,  B23K2101/001 ,  B23P6/005 ,  F01D5/005 ,  F05D2230/232 ,  Y10T428/12396

摘要： Superalloy components are joined or repaired by mating a recess formed in one component substrate with a corresponding projection formed in another component along a contact surface and welding them together with a stud welding apparatus. A mating superalloy repair stud is formed with a stud projection whose profile conforms to the substrate recess profile along a corresponding contact surface. Both the stud and substrate are coupled to a stud welding apparatus, with the stud projection and substrate recess oriented in an opposed spaced relationship with a gap there between. The stud welding apparatus passes current between the stud projection and recess and forms an arc there between, to melt their respective opposed surfaces. The melted stud projection and substrate recess opposed surfaces are pressed into contact with each other with the stud welding apparatus, forming a weld there between.

摘要翻译： 超合金部件通过将形成在一个部件基板中的凹部与沿着接触表面形成在另一个部件中的相应凸起配合，并用螺柱焊接装置将它们焊接在一起而连接或修复。 配合的超合金修复螺柱形成有一个螺柱凸起，其凸出部分沿相应的接触表面符合衬底凹槽轮廓。 螺柱和衬底都联接到螺柱焊接装置，其中螺柱突起和衬底凹槽与它们之间的间隙相对地间隔开。 螺柱焊接装置在螺柱突起和凹部之间传递电流，并在其间形成弧，以熔化它们各自相对的表面。 熔融的螺柱突起和基板凹部相对表面通过螺柱焊接装置彼此压接，在其间形成焊接。

公开(公告)号：US20150132143A1

公开(公告)日：2015-05-14

申请号：US14076465

申请日：2013-11-11

申请人： Gerald J. Bruck ,  Ahmed Kamel

发明人： Gerald J. Bruck ,  Ahmed Kamel

IPC分类号： B23K31/02

CPC分类号： B23K31/02 ,  B23C3/28 ,  B23C2265/08 ,  B23K26/342 ,  B23K26/60 ,  B23K33/00 ,  B23K2101/001 ,  B23K2103/26 ,  B23P6/007 ,  Y10T403/479

摘要： A weld joint (30) having asymmetric sides and providing reduced restraint of weld metal shrinkage and a reduced propensity for weld centerline cracking. The weld joint may have a first side (38) formed at an angle (A1) of 35-60° relative to the component surface (36), and a second side (40) formed at an angle (A2) of 10-35° relative to the surface. The sides may be extended to intersect (44) without the necessity for a flat bottom surface (20) as is typical for prior art weld joints (10). The inventive weld joint may be formed by moving an end mill tool (60) into and along the surface with its axis of rotation (64) being transverse to the surface.

摘要翻译： 具有不对称侧面的焊接接头（30），并且减少了焊接金属收缩的限制，并减少了焊接中心线开裂的倾向。 焊接接头可以具有相对于部件表面（36）以35-60°的角度（A1）形成的第一侧面（38）和形成为10-35°的角度（A2）的第二侧面（40） °相对于表面。 侧面可以延伸到相交（44），而不需要像现有技术的焊接接头（10）的典型的平坦底面（20）。 本发明的焊接接头可以通过将端铣刀工具（60）移动到表面中并沿着其旋转轴线（64）横向于表面而形成。

公开(公告)号：US20150096963A1

公开(公告)日：2015-04-09

申请号：US14045818

申请日：2013-10-04

申请人： Gerald J. Bruck ,  Ahmed Kamel

发明人： Gerald J. Bruck ,  Ahmed Kamel

IPC分类号： B23K26/00

CPC分类号： B23K26/354 ,  B23K26/0006 ,  B23K26/04 ,  B23K26/0626 ,  B23K26/064 ,  B23K26/0732 ,  B23K26/08 ,  B23K26/342 ,  B23K2101/001 ,  B23K2103/50

摘要： A method for heating an irregularly shaped target surface (28, 36) with an energy beam (12, 48) with a controlled power density as the beam progresses across the surface in order to control a cladding process. In one embodiment, widths (y) of respective rectangular diode laser beam images (22, 24, 26) are controlled in response to a local width of a gas turbine blade tip (20), and a power level of the diode laser is linearly controlled in response to the width of the respective image in order to maintain an essentially constant power density across the blade tip. In another embodiment, the width and power level of a continuous laser beam image (34) are controlled in response to changes in the local surface shape in order to produce a predetermined power density as the image is swept across the surface.

摘要翻译： 一种用于当光束前进穿过表面时具有受控功率密度的能量束（12,48）加热不规则形状的目标表面（28,36）的方法，以便控制包层过程。 在一个实施例中，响应于燃气轮机叶片尖端（20）的局部宽度来控制各个矩形二极管激光束图像（22,24,26）的宽度（y），并且二极管激光器的功率电平是线性的 受控于响应于相应图像的宽度，以便在刀片尖端上保持基本上恒定的功率密度。 在另一个实施例中，响应于局部表面形状的变化来控制连续激光束图像（34）的宽度和功率水平，以便当图像被扫过表面时产生预定的功率密度。

公开(公告)号：US20140259665A1

公开(公告)日：2014-09-18

申请号：US13795984

申请日：2013-03-12

申请人： Gerald J. Bruck

发明人： Gerald J. Bruck

IPC分类号： F01D5/14

CPC分类号： F01D5/14 ,  B23P6/005 ,  F01D5/005 ,  F05D2260/36 ,  Y10T29/49318

摘要： A process is provided for repairing an airfoil structure adapted for use in a gas turbine engine comprising: providing an airfoil structure having a section with a defect; removing airfoil structure material comprising the section with the defect such that a through hole is created; providing a replacement element; providing interlocking structure; positioning the replacement element relative to the through hole; and securing the replacement element to the airfoil structure via the interlocking structure such that the through hole is covered.

摘要翻译： 提供一种用于修理适用于燃气涡轮发动机的翼型结构的方法，包括：提供具有缺陷部分的翼型结构; 去除翼型结构材料，其包括具有缺陷的部分，使得形成通孔; 提供替代元素; 提供互锁结构; 将更换元件相对于通孔定位; 并且通过所述互锁结构将所述更换元件固定到所述翼型结构，使得所述通孔被覆盖。

公开(公告)号：US20140069893A1

公开(公告)日：2014-03-13

申请号：US13936482

申请日：2013-07-08

申请人： Gerald J. Bruck ,  Ahmed Kamel

发明人： Gerald J. Bruck ,  Ahmed Kamel

IPC分类号： B23K26/34

CPC分类号： B23K26/342 ,  B23K26/082 ,  B23K26/34 ,  B23K35/0244 ,  B23K2101/001 ,  B23P6/007 ,  F01D5/28 ,  F01D5/286 ,  F01D5/288

摘要： Superalloy components, such as service-degraded turbine blades and vanes, are clad by laser beam welding. The welding/cladding path, including cladding application profile, is determined by prior, preferably real time, non-contact 3D dimensional scanning of the component and comparison of the acquired dimensional scan data with specification dimensional data for the component. A welding path for cladding the scanned component to conform its dimensions to the specification dimensional data is determined. The laser welding apparatus, preferably in cooperation with a cladding filler material distribution apparatus, executes the welding path to apply the desired cladding profile. In some embodiments a post-weld non-contact 3D dimensional scan of the welded component is performed and the post-weld scan dimensional data are compared with the specification dimensional data. Preferably the welding path and/or cladding profile application are modified in a feedback loop with the pre- and/or post-welding 3D dimensional scanning.

摘要翻译： 超合金部件，如服务劣化的涡轮叶片和叶片，通过激光束焊接包层。 焊接/包层路径，包括覆层应用轮廓，由组件的先前优选实时非接触3D维扫描确定，并将所获取的维度扫描数据与部件的规格尺寸数据进行比较。 确定用于将扫描的部件包围以使其尺寸符合规格尺寸数据的焊接路径。 激光焊接装置，优选地与包层填充材料分配装置协作，执行焊接路径以施加期望的包层分布。 在一些实施例中，执行焊接部件的焊接后非接触3D维度扫描，并将焊接后扫描尺寸数据与规格尺寸数据进行比较。 优选地，焊接路径和/或包层轮廓应用在具有预焊接和/或焊后3D三维扫描的反馈回路中被修改。

公开(公告)号：US08641845B2

公开(公告)日：2014-02-04

申请号：US13005640

申请日：2011-01-13

申请人： Gerald J. Bruck

发明人： Gerald J. Bruck

IPC分类号： B32B41/00

CPC分类号： B23K31/125 ,  B23K1/19 ,  B23K35/0244 ,  B23K35/304 ,  C22C1/02

摘要： A method of determining bonding agent coverage in a joint between a first substrate (10) and a second substrate (12), including: dispersing a marker material (18) throughout a bonding agent (16); melting the bonding agent (16) but not the marker material; solidifying the melted bonding agent (16) to form an actual bond (24) in a joint between the first substrate (10) and the second substrate (12); detecting the marker material (18) in the joint through at least one of the substrates to ascertain an actual bond (24); and comparing the actual bond (24) to an expected bond (28) for the joint to determine the bonding agent coverage.

摘要翻译： 一种确定第一基板（10）和第二基板（12）之间的接合部中的接合剂覆盖的方法，包括：将标记材料（18）分散在整个粘合剂（16）中; 熔化粘合剂（16）而不是标记材料; 在第一基板（10）和第二基板（12）之间的接头中固化熔化的粘合剂（16）以形成实际的接合（24）; 通过所述至少一个所述基底检测所述接头中的所述标记材料（18）以确定实际结合（24）; 并将实际的债券（24）与预期债券（28）进行比较，以确定债券代理人的覆盖范围。

公开(公告)号：US20130232749A1

公开(公告)日：2013-09-12

申请号：US13417401

申请日：2012-03-12

申请人： Gerald J. Bruck ,  Petya M. Georgieva ,  Brandon W. Shinn

发明人： Gerald J. Bruck ,  Petya M. Georgieva ,  Brandon W. Shinn

IPC分类号： B23P6/00

CPC分类号： B23K26/32 ,  B23K9/042 ,  B23K10/027 ,  B23K15/0086 ,  B23K26/342 ,  B23K35/007 ,  B23K35/0244 ,  B23K2101/001 ,  B23K2103/26 ,  B23P6/007 ,  F01D5/005 ,  F05D2230/31 ,  F05D2230/80 ,  Y10T29/49718

摘要： A method of build-up welding including depositing of a weld material on a substrate in a series of weld passes in side-by-side relation to form a first weld layer, wherein substantially all weld passes forming the first weld layer are deposited in a first pass direction. Subsequently, a series of weld passes are deposited in side-by-side relation on the first layer to form a second weld layer, wherein substantially all weld passes forming the second weld layer are deposited in a second pass direction opposite to the first pass direction. Each weld pass of each layer may be deposited at a location where it is restrained on no more than one lateral side extending parallel to the weld pass.

摘要翻译： 一种堆积焊接方法，其包括在一系列焊接通道中以并排关系在基板上沉积焊接材料以形成第一焊接层，其中形成第一焊接层的基本上所有焊接通道沉积在 第一传球方向。 随后，在第一层上并排地沉积一系列焊缝，以形成第二焊接层，其中形成第二焊接层的基本上所有的焊接通道以与第一焊接方向相反的第二传递方向沉积 。 每个层的每个焊道可以在其被限制在不超过平行于焊道的一个横向侧的位置处被沉积。

公开(公告)号：US20130136868A1

公开(公告)日：2013-05-30

申请号：US13755098

申请日：2013-01-31

申请人： Gerald J. Bruck ,  Ahmed Kamel

发明人： Gerald J. Bruck ,  Ahmed Kamel

IPC分类号： B05D3/06

CPC分类号： B05D3/06 ,  B22F3/1055 ,  B22F5/04 ,  B23K9/042 ,  B23K9/044 ,  B23K10/027 ,  B23K15/0093 ,  B23K26/144 ,  B23K26/32 ,  B23K26/322 ,  B23K26/34 ,  B23K26/342 ,  B23K26/402 ,  B23K35/0244 ,  B23K35/0266 ,  B23K35/30 ,  B23K35/3033 ,  B23K35/304 ,  B23K35/36 ,  B23K35/362 ,  B23K2101/001 ,  B23K2101/34 ,  B23K2103/06 ,  B23K2103/08 ,  B23K2103/50 ,  B23P6/007 ,  B23P15/02 ,  B33Y10/00 ,  B33Y30/00 ,  C23C24/10 ,  C23C26/02 ,  F01D5/005 ,  F05D2230/31 ,  Y02P10/295

摘要： An additive manufacturing process (110) wherein a powder (116) including a superalloy material and flux is selectively melted in layers with a laser beam (124) to form a superalloy component (126). The flux performs a cleaning function to react with contaminants to float them to the surface of the melt to form a slag. The flux also provides a shielding function, thereby eliminating the need for an inert cover gas. The powder may be a mixture of alloy and flux particles, or it may be formed of composite alloy/flux particles.

摘要翻译： 一种添加剂制造方法（110），其中包括超合金材料和助熔剂的粉末（116）用激光束（124）选择性地熔化成层以形成超合金部件（126）。 助焊剂执行清洁功能以与污染物反应以将其漂浮到熔体的表面以形成渣。 助焊剂还提供屏蔽功能，从而不需要惰性覆盖气体。 粉末可以是合金和焊剂颗粒的混合物，或者它可以由复合合金/焊剂颗粒形成。

公开(公告)号：US10415390B2

公开(公告)日：2019-09-17

申请号：US13658866

申请日：2012-10-24

申请人： Gerald J. Bruck

发明人： Gerald J. Bruck

IPC分类号： F01D5/00 ,  B23K26/34 ,  B23K26/32 ,  B23K26/342 ,  B23K103/00

摘要： A method for epitaxial addition of repair material onto a process surface (38) of a directionally solidified component (30). The component is positioned in a fluidized bed (34) to drift particles of a repair material over the process surface as laser energy (36) is rastered across the surface to melt the particles and to fuse repair material onto the entire surface simultaneously. The component is moved downward (39) in the bed in a direction parallel to the grain orientation in the component as material is added to the surface, thereby providing continuous epitaxial addition of material to the surface without recrystallization.

公开(公告)号：US20160144448A1

公开(公告)日：2016-05-26

申请号：US14034609

申请日：2013-09-24

申请人： Gerald J. Bruck

发明人： Gerald J. Bruck

IPC分类号： B23K9/18 ,  B23K25/00 ,  B23K9/167

CPC分类号： B23K9/182 ,  B23K9/167 ,  B23K9/23 ,  B23K9/235 ,  B23K25/00 ,  B23K2101/001 ,  B23K2103/02 ,  B23K2103/05 ,  B23K2103/08 ,  B23K2103/18 ,  B23K2103/26

摘要： A tungsten submerged arc welding process wherein a non-consumable electrode (18) provides an arc (16) under a protective bed of flux powder (26), thereby eliminating the need for an inert cover gas supply. The arc melts a feed material in the form of alloy powder (22) or filler wire (40) along with a surface of a substrate (12) to form a layer of cladding material (10, 32) covered by a layer of slag (20, 44). The flux and slag function to shape the deposit, to control cooling, to scavenge contaminants and to shield the deposit from reaction with air, thereby facilitating the deposit of previously unweldable superalloy materials.

摘要翻译： 一种钨埋弧焊接方法，其中非消耗性电极（18）在焊剂粉末（26）的保护床下提供弧（16），从而不需要惰性覆盖气体供应。 电弧与基材（12）的表面一起熔化为合金粉末（22）或填充金属丝（40）形式的进料，以形成由一层炉渣覆盖的包层材料层（10,32） 20，44）。 助熔剂和渣的作用是形成沉积物，控制冷却，清除污染物和屏蔽沉积物与空气反应，从而有助于沉积以前不可焊接的超级合金材料。