Abstract: Methods are provided for forming a coating system on a gas turbine component. In one embodiment, and by way of example only, the method includes cold spraying a material onto the component surface to form an overlay coating, the material comprising MCrAlY, wherein M comprises a constituent selected from the group consisting of Ni, Co, or Fe, or combinations of Ni, Co, and Fe. Then, the overlay coating is heat treated. The overlay coating is then shot peened and vibro polished. A thermal barrier coating is then applied onto the overlay coating to form the coating system via air plasma spaying or electron beam physical vapor deposition technique.

Abstract: There is provided a method for depositing a modified MCrAlY coating on a surface of a gas turbine engine component. The method includes cold gas dynamic spraying techniques to provide a metallurgical bond between a substrate, such as a superalloy substrate, and the modified MCrAlY composition. The method further includes post deposition heat treatments including hot isostatic pressing. The modified MCrAlY composition includes one or more elements of Pt, Hf, Si, Zr, Ta, Re, Ru, Nb, B, and C, which improves the corrosion and environmental resistance of the coated component.

Abstract: There is provided a method for depositing a modified MCrAlY coating on a surface of a gas turbine engine component. The method includes cold gas dynamic spraying techniques to provide a metallurgical bond between a substrate, such as a superalloy substrate, and the modified MCrAlY composition. The method further includes post deposition heat treatments including hot isostatic pressing.

Abstract: There is provided a method for depositing a modified MCrAlY coating on a turbine blade tip. The method utilizes laser deposition techniques to provide a metallurgical bond between a turbine blade substrate, such as a superalloy substrate, and the modified MCrAlY composition. Further the modified MCrAlY coating has sufficient thickness such that a post-welding grinding operation to size the turbine blade to a desired dimension will not remove the modified MCrAlY coating entirely. The modified MCrAlY coating thus remains on the finished turbine blade tip after grinding.

Abstract: There is provided a method for depositing a modified MCrAlY coating on a turbine blade tip. The method utilizes laser deposition techniques to provide a metallurgical bond between a turbine blade substrate, such as a superalloy substrate, and the modified MCrAlY composition. Further the modified MCrAlY coating has sufficient thickness such that a post-welding grinding operation to size the turbine blade to a desired dimension will not remove the modified MCrAlY coating entirely. The modified MCrAlY coating thus remains on the finished turbine blade tip after grinding.

Abstract: Methods for repair of single crystal superalloys by laser welding and products thereof have been disclosed. The laser welding process may be hand held or automated. Laser types include: CO2, Nd:YAG, diode and fiber lasers. Parameters for operating the laser process are disclosed. Filler materials, which may be either wire or powder superalloys are used to weld at least one portion of a single crystal superalloy substrate.

Abstract: The present invention provides a low-melt nickel-based alloy powder applied in an activated diffusion brazing repair on gas turbine components. In one embodiment, and by way of example only, the low-melt alloy powder comprises between about 6.7% and about 9.2% by weight Cr, between about 9.7% and about 10.3% by weight Co, between about 3.7% and about 4.7% by weight W, between about 3.3% and about 6.3% by weight Ta, between about 3.6% and about 5.2% by weight Al, between about 1.3% and about 4.0% by weight Hf, between about 0.02% and about 0.06% by weight C, between about 1.0% and about 3.2% by weight B, and Ni. Optionally, the low-melt alloy powder may include between about 1.4% and about 3.2% by weight Re.

Abstract: A method for repairing an eroded surface of a gas turbine compressor component includes depositing an amorphous alloy onto the eroded surface, melting the amorphous alloy with a laser beam on the eroded surface, and re-solidifying the amorphous alloy to form a welded deposit. The weld is then machined to restore the component to its original dimensions.

Abstract: Methods are provided for repairing a worn surface of a steel die-cast die. The method includes heating an amorphous material to a predetermined temperature with a laser beam and allowing the melted amorphous material to solidify to thereby form an amorphous layer over the worn surface. These processes are useful for eliminating or minimizing cracking and/or part distortion and minimize heat-affected zone during welding. In addition, the formation of an amorphous layer over the worn surface allows the repaired die-cast die to better withstand typical operating environments than previous repair materials. These methods combine low heat input welding with amorphous alloys to effectively repair die-cast dies.

Abstract: A nickel-based superalloy includes, in terms of weight, about 0.06% to about 0.10% carbon, about 6.0% to about 6.4% aluminum, about 5.8% to about 6.3% tantalum, about 6.5% to about 7.0% chromium, about 8.8% to about 9.3% cobalt, about 0.6% to about 1.0% molybdenum, about 2.4% to about 2.8% rhenium, about 4.8% to about 5.3% tungsten, about 0.3% to about 0.80% hafnium, about 0.01% to about 0.03% zirconium, about 0.10% to about 0.18% silicon, and nickel. A method for repairing a surface of a turbine component includes the step of applying the nickel-based superalloy to a damaged area of the component surface. Post-deposition processes are also performed as necessary.

Abstract: In a method for coating a surface of a turbine component with an environment-resistant aluminide, a coating is formed by cold gas-dynamic spraying a powder material on the turbine component surface, the powder material comprising aluminum, platinum, and at least one additional metal selected from the group consisting of nickel, chromium, hafnium, silicon, yttrium, rhenium, zirconium, cobalt, and tantalum. After forming the coating, at least one thermal diffusion treatment is performed on the turbine component to metallurgically homogenize the coating and thereby form an aluminide coating that includes by weight about 12 to about 30% aluminum, up to about 50% platinum, about 2 to about 25% chromium, about 1 to about 5% hafnium, about 1 to about 5% silicon, about 0.1 to about 1% yttrium, and about 1 to about 3% Zr, and nickel.

Abstract: A nickel-based superalloy includes, in terms of weight, in terms of weight, about 0.08% to about 0.12% carbon, about 6.0% to about 6.4% aluminum, about 5.8% to about 6.3% tantalum, about 6.5% to about 7.0% chromium, about 9.3% to about 9.8% cobalt, about 1.3% to about 1.7% molybdenum, about 2.4% to about 2.8% rhenium, about 3.8% to about 4.3% tungsten, about 0.9% to about 1.3% hafnium, about 0.01% to about 0.03% zirconium, up to about 0.10% silicon, and nickel. A method for repairing a surface of a turbine component includes the step of applying the nickel-based superalloy to a damaged area of the component surface, and post-deposition processes.

Abstract: A method for coating a surface of a turbine component with an environment-resistant and wear-resistant material includes the step of cold gas-dynamic spraying a powder material on the turbine component surface, the powder material comprising a mixture of MCrAlY powder and an abrasive powder such as cubic boron nitride, diamond, carbides, and oxides, with M being selected from Ni, Co and mixtures thereof. The method can further include the step of heat treating the turbine component after the cold gas-dynamic spraying. Thus, the present invention can be employed to greatly improve the performance and the durability of HPT components, and dramatically prolong their service life.

Abstract: A method for repairing a titanium alloy surface of a turbine component includes the step of cold gas-dynamic spraying a powder material comprising at least one titanium alloy directly on the titanium alloy surface. The method may further include the steps of hot isostatic pressing the cold gas-dynamic sprayed turbine component, and performing a separate heat treating step after the hot isostatic pressing. Thus, the cold gas-dynamic spray process and post-spray processing can be employed to effectively repair degraded areas on compressor turbine components.

Abstract: A method is provided for repairing degraded and/or eroded areas on gas turbine blades and vanes. The method is directed to turbine blades and vanes made of advanced superalloy materials with high elevated-temperature properties. The method uses multiple laser beams to perform steps of preheating the repair area, welding the repair area, and post-welding heating of the repaired area. The method uses an array of two or more lasers to perform the steps of heating, welding, and post-weld heat treatment in nearly simultaneous operation thereby dramatically reducing or eliminating the hot cracking associated with other welding methods used with superalloy materials. The method is further directed to cladding or material buildup of degraded turbine blades where the weld material is the same as the matrix or better superalloy materials.

Abstract: A new method for increasing the durability of a turbine engine is provided. The method utilizes a cold gas-dynamic spray technique to apply wear resistant materials to turbine blades. These wear resistant materials improve the durability of the turbine blades, and thus can improve the overall durability, reliability and performance of the turbine engine themselves. In the cold gas-dynamic spray process particles at a temperature below their fusing temperature are accelerated and directed to a target surface on the turbine blade. When the particles strike the target surface, the kinetic energy of the particles is converted into deformation of the particle, causing the particle to form a strong bond with the target surface. Post-spray processing is then performed to consolidate the coating materials and restore material properties in the turbine blade. Thus, the cold gas-dynamic spray process can apply a coating of wear resistant materials to the turbine blades.

Abstract: A method is provided for repairing degraded and/or eroded areas on gas turbine blades and vanes. The method is directed to turbine blades and vanes made of advanced superalloy materials with high elevated-temperature properties. The method uses multiple laser beams to perform steps of preheating the repair area, welding the repair area, and post-welding heating of the repaired area. The method uses an array of two or more lasers to perform the steps of heating, welding, and post-weld heat treatment in nearly simultaneous operation thereby dramatically reducing or eliminating the hot cracking associated with other welding methods used with superalloy materials. The method is further directed to cladding or material buildup of degraded turbine blades where the weld material is the same as the matrix or better superalloy materials.

Abstract: A method of repairing high-strength superalloy turbine blades and joining superalloy components is provided. A damaged region of the turbine blade is welded without preheating it. The welded turbine blade is then subjected to a hot isostatic pressing process. The method results in a repaired turbine blade that has a desirable microstructure and robust mechanical properties.

Abstract: A new method for repairing turbine engine components is provided. The method utilizes a cold gas-dynamic spray technique to repair degradation on turbine blades, vanes and other components. In the cold gas-dynamic spray process particles at a temperature below their fusing temperature are accelerated and directed to a target surface on the turbine blade. When the particles strike the target surface, the kinetic energy of the particles is converted into plastic deformation of the particle, causing the particle to form a strong bond with the target surface. Post-spray processing is then performed to consolidate and homogenize the applied materials and restore integrity to the material properties in the repaired turbine component. Thus, the cold gas-dynamic spray process and post-spray processing can be employed to effectively repair degraded areas on gas turbine components.

Abstract: Methods for repair of single crystal superalloys by laser welding and products thereof have been disclosed. The laser welding process may be hand held or automated. Laser types include: CO2, Nd:YAG, diode and fiber lasers. Parameters for operating the laser process are disclosed. Filler materials, which may be either wire or powder superalloys are used to weld at least one portion of a single crystal superalloy substrate.