Refurbished Turbine Vanes and Method of Refurbishment Thereof

In the accompanying drawings:

FIG. 1 is an elevational view of the convex side of a vane of the type refurbished by the process of the invention.

FIG. 2 is an elevational view of the concave side of the vane.

FIG. 3 is a cross section through the vane, taken on the line 3--3 of FIG. 1.

FIG. 4 is a section taken on the line 4--4 of FIG. 2.

FIG. 5 is a fragmentary cross section showing a portion (designated by the lines X--X) of FIG. 3 greatly enlarged.

FIG. 6 is an elevational view of the convex side of a worn vane. This view is similar to the showing of FIG. 1 but illustrates certain steps in the processing of the component.

FIG. 7 is an elevational view of the concave side of the vane of FIG. 6, showing other steps and welded beadments as incorporated on the vane prior to the plasma spraying, and

FIG. 8 is a cross section through the vane, taken on the line 8--8 of FIG. 6.

Considering first FIGS. 1-4, the finished or refurbished vane 10 designated therein is seen to comprise convex and concave airfoil portions 12, 14 joined at a broad leading edge 16 and also at a narrow trailing edge 18. The vane 10 is hollow, having an airfoil-shaped inner space 20 between the airfoil portions. Adjacent the trailing edge 18, the vane 10 has cooling passages 22 which communicate with the interior space 20. Such passages are clearly seen particularly in FIG. 2.

The vane 10 of FIGS. 1-4 has been refurbished according to the process of the invention, and in FIGS. 3 and 4 the cross sectional areas 24 designate overlay metal which has been added to the vane surfaces by a plasma spray process and thereafter refinished to conform to the original contours as specified for new vanes. The overlay metal of the areas 24 can be applied to build up a thickness of as much as 30 to 40 thousandths of an inch, and can be feathered as shown, as the overlay approaches the trailing edge 18 of the vane.

I have found that vanes which have their surfaces built-up by a plasma spray procedure according to the process of the invention meet rigid requirements for reuse, and are capable of an extended useful operative life.

The application of the overlay metal is such that the resultant alloy closely conforms to the alloy of the base metal of which the vane was originally cast. This is accomplished by the use of additional silica in the metal powder used in the plasma spraying. I have found that by the addition of 10% of silica to the powdered alloy, the burn-off of silica during the plasma spraying is such that the resultant alloy of the overlay can be made essentially the same as the alloy of the base metal. The base metal alloy of vanes refurbished by the invention can be that known commercially as Haynes Alloy No. 25, or No. 31, having a composition given by the table below.

Part by weight:

1. Carbon-- 0.09

2. Silicon-- 0.22

3. Manganese-- 1.55

4. Phosphorus-- 0.018

5. Sulfur-- 0.007

6. Chromium-- 20.32

7. Nickel-- 10.56

8. Tungsten-- 14.30

9. Iron-- 2.25

10. Cobalt-- 50.685

The above alloy is used in various welding procedures on the vanes as described below, being supplied in the form of welding rod or wire known commercially as type L-605.

For the plasma spraying of the overlay metal, the Haynes alloy as above constituted is used in the form of a metal powder to which there is added 10% of silica. During the plasma spraying, the heat of the process burns off essentially the 10% additional silica whereby there remains the original alloy having a composition as set forth by the above table.

I have found that the bond between the base metal 12, 14 and overlay 24 in consequence is especially strong and durable, and not likely to fail during use of the vane.

The process of refurbishing vanes, starting with used, worn components is essentially as follows:

Referring to FIG. 6, a vane to be refurbished according to the invention is cut to provide a pair of slits 26 adjacent the end flanges 28, said slits being made from the trailing edge 18 substantially parallel with the end flanges and for a distance roughly as shown in the figure. The slits 26 relieve stresses caused by any unequal heating of the vane during the processing. After formation of the slits 26, a welded bead 30 can be applied to the trailing edge, in cases where the chordal distance (from the leading edge) has become shortened by wear. Also, welded repairs indicated as short beads 32 are made to the leading and trailing edges to fuse over any hairline cracks. A pair of beads 34, 36 (formed by welding worn areas of the convex and concave surfaces respectively) reinforce the blade airfoil structure, such beads extending in spaced relation to the trailing edge 18 and substantially coextensive therewith.

Also, as seen in FIG. 7, the air cooling passages 22 of the vane are welded closed by beads 40. Finally, the slots 26 are welded closed by beads 42. Thereafter, following any surface processing that is employed, the airfoil surfaces are plasma sprayed to deposit a layer of alloy metal 24 indicated by the broken outline in FIG. 8. The layer 24 which is the built-up surfacing done by plasma spraying, can be as thick as from 30 to 40 thousandths of an inch, tapering to feathered edges as the trailing edge 18 of the vane is approached. Prior to the plasma spraying build-up, a surface processing of the vanes is carried out, in the form of a sand blast, or shot peen.

The showings of FIGS. 6-8 illustrate steps in the preparation of a worn vane, prior to building up the surfaces by spraying of the molten metal in a plasma.

A complete procedure involving the process of the invention is as follows:

1. The used vanes are stripped of dirt, oil, etc, by placing them in a hydrochloric acid bath for 3 to 4 hours at a temperature of 180.degree. F.

2. Thereafter, the vanes are rinsed in clear water and then vacuum annealed for two hours at a temperature of 2,175.degree..

3. The annealed vanes are then visually inspected.

4. After passing visual inspection they are Zyglo inspected by means of a fluorescent penetrant.

5. The vanes are then slotted approximately one inch deep, starting at the trailing edges, the slots being located about one quarter inch from the ends.

6. The air cooling holes are welded closed.

7. All cracks on the airfoil leading edge and trailing edge are welded.

8. If the trailing edges of the vanes are worn thin, they are built-up by welding, preferably using a Tungsten Inert Gas process, with Haynes No. 25 welding rod.

9. Convex and concave surfaces of the vane body adjacent but spaced from the trailing edge and coextensive therewith are reinforced by being built-up, involving placement of welding beads thereon, preferably using a Tungsten Inert Gas process. The beads can be as high as from 30 to 40 thousandths of an inch.

10. The slots that were made adjacent the two ends of the airfoil surfaces are welded closed and the surface conditioned by roughening and cleaning with a sand blasting or shot peening operation.

11. The worn airfoil surfaces are then plasma sprayed with metal alloy powder having added silica, to a thickness of from 30 to 40 thousandths at the leading edge, and tapering to feathered edges as the trailing airfoil edges are approached. Where the vanes have been originally cast with an alloy such as Haynes No. 25 Alloy (the composition of which is given above) the powdered metal used in the plasma spraying is also of the same alloy composition and additionally has added silica, preferably in the amount of 10% additional.

12. The blades after being thus built-up, are sintered in a vacuum or hydrogen furnace (5 microns) at 2,200.degree. F. for one hour, and then furnace cooled.

13. The built-up airfoil surfaces are now recut by an abrading process, such as one using an abrasive belt, to produce the original surface measurements. The refinishing is preferably accomplished by an automatic machine employing an endless abrasive belt as described and claimed in the copending application of Ralph T. DeMusis identified above.

14. The blades are then inspected by a Zyglo process.

15. The air cooling holes are recut by a laser beam, as per original specifications.

16. The blades are then hand polished as may be required.

17. Finally the blades are inspected for accuracy of dimension.

The process of the invention as set forth above, and the resultant refurbished vane product have been successfully carried out and have passed rigid tests, where the vane metal has been that known commercially as Haynes No. 25 Alloy, whose composition is given in the table herein.

FIG. 5 pictures a photomicrograph of a section through a refurbished vane, taken at the location generally designated in FIG. 3 between the broken lines X--X. The designation of FIG. 5 represents an enlargement or magnification approximately of 100 times. The section of overcast metal 24, having been etched, reveals a dense grain structure which is joined to the roughened surface of the vane airfoil portion 14 at an interface 46. Such roughened surface is the result of sand blasting or ball-peening the vane in preparation for the plasma spray overcast. The vane airfoil portion 14 is shown conventionally by the usual cross-hatching lines. The use of cross-hatching in the overlay 24 is considered not desirable since the cross-section surface has been etched to reveal grain structure and grain lines are of more importance. It will be seen that the grain structure of the overlay 24 is characterized by a desirable uniformity, as the section is transversed from the outer surface to the interface 46. The uniformity and the density of the plasma spray coating is important in providing for uniform wear or attrition when the vane is in use, with an absence of porous or soft spots which could break down quickly.

Turbine vanes refurbished in accordance with my invention as explained above were tested as to the bond strength of the plasma sprayed overlay or recast material on the airfoil surfaces. It was found that the plasma spray deposit is uniform and of high density. Also, the bond between the overlay material and the base metal was excellent, with no evidence of separation at any points around the periphery of the airfoil. A spectro-chemical analysis of the overlay material revealed a cobalt based alloy of the Haynes Alloy No. 25 type. Moreover, the overlay material was capable of being successfully coated with oxidation and sulfidation-resistent alloys. The strength of the overlay to base metal bond was equivalent or superior to conventional plasma spray tube deposits.

The cost represented by the refurbishment process, while significant, constitutes a small fractional value of the initial cost of producing turbine vanes of this type. The resultant refurbished product meets the essential high quality standards set for new turbine vanes, and accordingly the present invention constitutes a distinct advance and improvement in the art.

Variations and modifications are possible without departing from the spirit of the invention.