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: 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 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: The present invention provides an apparatus for repairing turbine blades of a gas turbine engine by a laser welding operation. The method uses a miniaturized laser and related apparatus. The miniaturized laser is fed through a borescope access hole to a desired location such as a high pressure turbine blade. The laser is then powered and manipulated so as to perform the desired welding operation. Filler material may also be provided in situ to accomplish the welding procedure. The method realizes a significant cost savings to the vehicle operator in that repairs can be accomplished without the need to remove the engine or disassemble the engine.

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: 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: A hand-held laser welding wand includes internal flow passages through which filler media, gas, and coolant may flow. The wand is dimensioned to be grasped with a single hand, thus filler media of various types and forms, gas, and coolant may be supplied to the hand-held laser welding wand via external systems and delivery devices without substantially impairing operation of the wand.

Abstract: A hand-held laser welding wand includes one or more filler media delivery flow passages. The wand is dimensioned to be grasped with a single hand, thus filler media of various types and forms may be supplied to the weld area on a workpiece using various types of delivery systems and methods, including fully automated, semi-automated, or manually. The filler media may be delivered via the filler media delivery passages or separate from the passages.

Abstract: A 3-D adaptive laser powder fusion welding system provides for both modeling/gauging of a workpiece as well as repair, restoration, and/or manufacture thereof. By providing a work platform and apparatus support system, five degrees of control in the form of two linear axes and three rotational axes are provided. The sixth linear axis is controlled via the displacement of a laser powder fusion (LPF) welding head and a laser rangefinding head. The laser rangefinding head system enables the workpiece W to be modeled electronically or otherwise. Additionally, the rangefinding system enables a model part to serve as a template from which repairs or construction are affected. The LPF welding head then affects any repairs or manufacture that are needed on the workpiece W. The LPF welding head is powered by filler material. The entire system is generally controlled by computer which enable the operator to be separated from a generally hot and hostile welding environment.