公开(公告)号：US20150048058A1

公开(公告)日：2015-02-19

申请号：US13936395

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 ,  F01D5/00 ,  B23K26/00 ,  B23K26/06 ,  B23K26/08 ,  B23K31/12

CPC分类号： B23K26/08 ,  B23K26/032 ,  B23K26/0626 ,  B23K26/32 ,  B23K26/34 ,  B23K26/342 ,  B23K31/125 ,  B23K35/0244 ,  B23K35/0255 ,  B23K35/36 ,  B23K2101/001 ,  B23K2103/26 ,  F01D5/005

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。 确定用于将扫描部件包围以符合规格尺寸数据的焊接路径。优选地，与包层填充材料分配装置配合的激光焊接装置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：US20150033561A1

公开(公告)日：2015-02-05

申请号：US13956521

申请日：2013-08-01

申请人： Gerald J. Bruck ,  Ahmed Kamel

发明人： Gerald J. Bruck ,  Ahmed Kamel

IPC分类号： F01D5/28 ,  B23K26/08 ,  B23K26/34 ,  F01D5/14 ,  B23K26/00

CPC分类号： F01D5/288 ,  B23K26/0006 ,  B23K26/082 ,  B23K26/144 ,  B23K26/342 ,  B23K2101/001 ,  B23K2103/50 ,  C23C24/103 ,  F01D5/147 ,  F05D2230/31 ,  F05D2300/506 ,  Y10T29/49337

摘要： A method for hardfacing a surface including: depositing a powder (68) having alloy particles onto a surface (70) of a substrate (66); rastering a laser beam (60) across the surface to melt the powder and to form a weld pool (78) having a width (64); directing particles (74) of a material exhibiting a different property than the substrate into the weld pool in a spray pattern having a width less than the width of the weld pool; and establishing the rastering and directing steps such that material circulation within the weld pool is effective to distribute the particles in the weld pool into a pattern having a width greater than the width of the spray pattern prior to re-solidification of the weld pool.

摘要翻译： 一种用于表面表面硬化的方法，包括：将具有合金颗粒的粉末（68）沉积到基底（66）的表面（70）上; 在整个表面上扫描激光束（60）以熔化粉末并形成具有宽度（64）的熔池（78）; 将具有与衬底不同的性质的材料的颗粒（74）以具有小于焊池宽度的宽度的喷涂图案引导到熔池中; 并且建立耙子和引导步骤，使得熔池内的材料循环有效地将熔池中的颗粒分布成在熔池重新凝固之前具有大于喷射图案的宽度的宽度的图案。

公开(公告)号：US20140212594A1

公开(公告)日：2014-07-31

申请号：US13755157

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： B23K37/00 ,  B05C21/00

CPC分类号： B23K37/00 ,  B05C21/00 ,  B22F3/1055 ,  B22F2003/1056 ,  B29C64/153 ,  B29C64/35 ,  B29C67/0077 ,  B29C67/0096 ,  C21B3/04 ,  Y02P10/295 ,  Y02W30/542

摘要： An apparatus (20, 21) and method (80) operable to: feed (82) a granulated feedstock (26) into a chamber (22); apply (84) a melting or sintering energy (28) in programmable scans (30) producing a material deposit (32) overlaid with slag (34) in the chamber (22); position (86) a slag removal device (40, 52) such that its cutting surface (35) is coincident with a top surface (33) of the material deposit; cut or break the slag free (88) from the material deposit with the slag removal device; separate (92) the removed slag from a reusable portion of the granulated feedstock in a separator (42); and feed (94) the reusable portion of the granulated feedstock to the top surface of the material deposit for repeating (96) the above operations.

摘要翻译： 一种装置（20,21）和方法（80），其可操作以：将颗粒状原料（26）进料（82）进入腔室（22）中; 在可编程扫描（30）中施加（84）熔化或烧结能量（28），产生在所述室（22）中与渣（34）重叠的材料沉积物（32）; 位置（86）除渣装置（40,52），使得其切割表面（35）与材料沉积物的顶表面（33）重合; 切割或破碎无渣（88）与物料沉积物与除渣装置; 在分离器（42）中将去除的矿渣（92）从造粒原料的可重复使用部分分离（92）; 并将造粒原料的可重复使用部分（94）进料（94）到材料沉积物的顶表面，以重复（96）上述操作。

公开(公告)号：US20140209571A1

公开(公告)日：2014-07-31

申请号：US13755145

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： B23K25/00

CPC分类号： B23K25/005 ,  B23P6/007 ,  F01D5/005 ,  F05D2230/13

摘要： A method for cladding of superalloy materials. A layer of powder (14) disposed over a superalloy substrate (12) is heated with an energy beam (16) to form a layer of superalloy cladding (10) and an overlying layer of slag (18). A filler material (44) of nickel, nickel-chromium or nickel-chromium-cobalt wire or strip is also added to the melt pool to combine with the melted powder via a submerged arc or electroslag heating process to give the superalloy cladding the composition of a desired superalloy material. The layer of powder includes a layer of powdered flux material (22) over a layer of powdered metal (20), or the flux and metal powders may be mixed together (36).

摘要翻译： 一种用于包覆超合金材料的方法。 设置在超合金基底（12）上方的一层粉末（14）用能量束（16）加热以形成一层超合金包覆层（10）和上层的熔渣（18）。 还将镍，镍铬或镍铬钴钴线或条带的填充材料（44）加入到熔池中，以通过浸没电弧或电渣加热工艺与熔融粉末组合以使超合金包层成为 所需的超合金材料。 粉末层包括粉末状金属层（20）上的粉末焊剂材料层（22），或者熔剂和金属粉末可以混合在一起（36）。

公开(公告)号：US20140044991A1

公开(公告)日：2014-02-13

申请号：US13571708

申请日：2012-08-10

申请人： Gerald J. Bruck

发明人： Gerald J. Bruck

IPC分类号： B22D27/02 ,  F01D5/14 ,  B22D25/06 ,  B32B15/01

CPC分类号： B22D19/10 ,  B23K9/038 ,  B23K9/042 ,  B23K25/005 ,  B23K2101/001 ,  B23P6/007 ,  F01D5/005 ,  F05D2230/80 ,  F05D2300/175 ,  Y10T428/12986

摘要： Superalloy component castings, such as turbine blades and vanes, are fabricated or repaired by an electroslag or electrogas welding process that at least partially replicates the crystal structure of the original cast substrate in a cast-in-place substrate extension. The process re-melts the base substrate surface and grows it with new molten filler material. As the base substrate and the filler material solidify, the newly formed “re-cast” component has a directionally solidified uniaxial substrate extension portion that at least in part replicates the crystalline structure of the base substrate. The “re-cast” component can be fabricated with a unified single crystal structure, including the extension portion. In other applications, a substrate extension can replicate a directionally solidified uniaxial crystal structure of an original base substrate casting. Polycrystalline substrate base structures can be re-cast with a substrate extension that replicates base substrate crystals that are most parallel to the uniaxial casting direction.

摘要翻译： 超合金部件铸件（例如涡轮机叶片和叶片）通过电渣或电动气焊接工艺制造或修理，该方法至少部分地复制了现浇衬底延伸部中的原始铸造衬底的晶体结构。 该工艺重新熔化基底表面，并用新的熔融填料生长。 当基底和填料固化时，新形成的“重铸”组件具有至少部分地复制基底衬底的晶体结构的定向凝固的单轴衬底延伸部分。 “重铸”部件可以用统一的单晶结构制造，包括延伸部分。 在其他应用中，基底延伸可以复制原始基底基底铸造的定向凝固的单轴晶体结构。 多晶基材基体结构可以用基板延伸部进行再铸造，所述基板延伸部分复制最平行于单轴铸造方向的基底晶体。

公开(公告)号：US20130115477A1

公开(公告)日：2013-05-09

申请号：US13352475

申请日：2012-01-18

申请人： Gerald J. Bruck

发明人： Gerald J. Bruck

IPC分类号： B32B7/04 ,  B23H1/00 ,  B32B3/30

CPC分类号： B23K1/0004 ,  B23K1/0018 ,  B23K11/00 ,  B23K11/002 ,  B23K11/004 ,  B23K11/14 ,  B23K2101/001 ,  B23K2101/08 ,  B23P6/005 ,  F01D5/005 ,  Y10T428/12451

摘要： Superalloy components are joined by mating a recess formed in one component with a corresponding projection formed in another component along a contact surface. The components are compressed along the contact surface and resistance heat brazed to each other. Current is passed between the components at a selected flow rate and application time until brazing alloy melting occurs along the contact surface, and they are mutually affixed to each other. When repairing a damaged surface portion of a superalloy material component, the damaged portion is removed to form an excavated recess. A repair splice is formed, preferably of a same material with similar mechanical structural properties, having a mating projection with profile conforming to the corresponding recess profile. The splice and substrate are resistance heat brazed under compression pressure until brazing alloy melting occurs along the contact surface, so that they are mutually affixed.

摘要翻译： 超合金部件通过将形成在一个部件中的凹部与沿着接触表面形成在另一部件中的相应突起配合而接合。 这些部件沿着接触表面被压缩，并且电阻热量相互钎焊。 电流以选定的流速和施加时间在组分之间通过，直到沿着接触表面发生钎焊合金熔化，并且它们彼此相互固定。 当修复超合金材料部件的损坏的表面部分时，损坏的部分被移除以形成挖掘的凹部。 形成具有类似机械结构特性的相同材料的修补接头，其具有符合相应凹槽轮廓的轮廓的配合凸起。 接头和衬底是在压缩压力下钎焊的电阻热，直到沿着接触表面发生钎焊合金熔化，使得它们相互贴合。

公开(公告)号：US20120223057A1

公开(公告)日：2012-09-06

申请号：US13038682

申请日：2011-03-02

申请人： Lucian Iordache ,  Ovidiu Timotin ,  Chris E. Schumacher ,  Patrick Schumacher ,  Gerald J. Bruck

发明人： Lucian Iordache ,  Ovidiu Timotin ,  Chris E. Schumacher ,  Patrick Schumacher ,  Gerald J. Bruck

IPC分类号： B23K9/16

CPC分类号： B23K9/167 ,  B23K35/0261 ,  B23K35/222 ,  B23K35/3033 ,  B23K35/3046 ,  B23K2101/001 ,  F01D5/28

摘要： A method of applying a weld using a gas tungsten arc welding procedure. A filler element is provided to a welding location. The filler element includes a first material used during formation of a weld, and a second material that is capable of producing a slag upon melting thereof. A welding arc provides heat that melts portions of first and second components and the filler element proximate to the welding location to form a weld pool. The second material melts and forms a slag, which flows to an outer surface of the weld pool and shields the weld pool from exposure to reactive elements in the atmosphere. Upon cooling of the weld pool, the weld pool solidifies to form a weld between the first component and the second component.

摘要翻译： 使用气体钨弧焊工艺施加焊缝的方法。 填料元件提供给焊接位置。 填充元件包括在形成焊缝期间使用的第一材料和能够在熔化时产生炉渣的第二材料。 焊接电弧提供热量，其熔化第一和第二部件的部分以及靠近焊接位置的填充元件以形成焊接池。 第二种材料熔化并形成熔渣，其流到熔池的外表面并且屏蔽焊接池暴露于大气中的反应性元件。 在熔池冷却时，熔池凝固以在第一部件和第二部件之间形成焊缝。

公开(公告)号：US08132710B2

公开(公告)日：2012-03-13

申请号：US12194900

申请日：2008-08-20

申请人： Gerald J. Bruck ,  Douglas A. Arrell

发明人： Gerald J. Bruck ,  Douglas A. Arrell

IPC分类号： B23K1/018

CPC分类号： B23K1/018 ,  B23K1/008 ,  Y10T29/49822 ,  Y10T428/12986

摘要： An assembly (10) that can be both joined and parted by temperature processing. A parting member (20) captured between two members of the assembly exhibits a state change as a function of temperature such that the two members can be joined with a meltable joining material (18) at a joining temperature, operated at an operating temperature lower than the joining temperature, and then separated at a parting temperature higher or lower than the operating and joining temperatures as a result of a parting force caused by the state change of the parting member. In one embodiment, the parting member has a coefficient of thermal expansion higher than a coefficient of thermal expansion of the assembly members such that differential thermal expansion causes the parting member to expand across the interface (16) between the members to generate the parting force.

摘要翻译： 可以通过温度处理连接和分配的组件（10）。 捕获在组件的两个构件之间的分离构件（20）表现出作为温度的函数的状态变化，使得两个构件可以在接合温度下与可熔融接合材料（18）接合，操作温度低于 接合温度，然后在由于分离构件的状态变化引起的分离力的结果，高于或低于操作和接合温度的分离温度下分离。 在一个实施例中，分离构件的热膨胀系数高于组装构件的热膨胀系数，使得差分热膨胀导致分离构件在构件之间的界面（16）上膨胀以产生分离力。

公开(公告)号：US20110266330A1

公开(公告)日：2011-11-03

申请号：US12771329

申请日：2010-04-30

申请人： Gerald J. Bruck ,  Michael Ott ,  David W. Hunt ,  Petya M. Georgieva

发明人： Gerald J. Bruck ,  Michael Ott ,  David W. Hunt ,  Petya M. Georgieva

IPC分类号： B23K20/12

CPC分类号： B23K20/128

摘要： A friction stir welding method including: feeding a filler material through a first passage in a friction stir weld tool and into a substrate during friction stir welding of the substrate; and rotating the filler material with respect to the substrate while feeding the filler material. In this method, heat generated by rotational frictional contact of the filler material contributes to plasticization of the filler material.

摘要翻译： 一种摩擦搅拌焊接方法，包括：在所述基板的摩擦搅拌焊接期间，通过摩擦搅拌焊接工具中的第一通道供给填料，并进入基板; 并且在填充填料的同时相对于基底旋转填料。 在该方法中，通过填充材料的旋转摩擦接触产生的热量有助于填充材料的增塑。

公开(公告)号：US20100044417A1

公开(公告)日：2010-02-25

申请号：US12194900

申请日：2008-08-20

申请人： Gerald J. Bruck ,  Douglas A. Arrell

发明人： Gerald J. Bruck ,  Douglas A. Arrell

IPC分类号： B23K1/018

CPC分类号： B23K1/018 ,  B23K1/008 ,  Y10T29/49822 ,  Y10T428/12986

摘要： An assembly (10) that can be both joined and parted by temperature processing. A parting member (20) captured between two members of the assembly exhibits a state change as a function of temperature such that the two members can be joined with a meltable joining material (18) at a joining temperature, operated at an operating temperature lower than the joining temperature, and then separated at a parting temperature higher or lower than the operating and joining temperatures as a result of a parting force caused by the state change of the parting member. In one embodiment, the parting member has a coefficient of thermal expansion higher than a coefficient of thermal expansion of the assembly members such that differential thermal expansion causes the parting member to expand across the interface (16) between the members to generate the parting force.

摘要翻译： 可以通过温度处理连接和分配的组件（10）。 捕获在组件的两个构件之间的分离构件（20）表现出作为温度的函数的状态变化，使得两个构件可以在接合温度下与可熔融接合材料（18）接合，操作温度低于 接合温度，然后在由于分离构件的状态变化引起的分离力的结果，高于或低于操作和接合温度的分离温度下分离。 在一个实施例中，分离构件的热膨胀系数高于组装构件的热膨胀系数，使得差分热膨胀导致分离构件在构件之间的界面（16）上膨胀以产生分离力。