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High strength, ductile braze repairs for stationary gas turbine components—Part I / Warren Miglietti in Transactions of the ASME . Journal of engineering for gas turbines and power, Vol. 132 N° 8 (Août 2010) 

Public ISBD [article]  in Transactions of the ASME . Journal of engineering for gas turbines and power > Vol. 132 N° 8 (Août 2010) . - 12 p. Titre : High strength, ductile braze repairs for stationary gas turbine components—Part I Type de document : texte imprimé Auteurs : Warren Miglietti, Auteur ; Madeleine Du Toit, Auteur Année de publication : 2011 Article en page(s) : 12 p. Note générale : Génie Mécanique Langues : Anglais (eng) Mots-clés : Aerospace  components  Aerospace  engines  Brazing  Cracks  Ductility  Filler  metals  Fracture  Gas  turbines  Hardness  Hardness  testing  Maintenance  engineering  Scanning  electron  microscopy  Tensile  testing Index. décimale : 620.1 Essais des matériaux. Défauts des matériaux. Protection des matériaux Résumé : Both aviation and land based turbine components such as vanes/nozzles, combustion chambers, liners, and transition pieces often degrade and crack in service. Rather than replacing with new components, innovative repairs can help reduce overhaul and maintenance costs. These components are cast from either Co-based solid solution superalloys such as FSX-414 or Ni-based gamma prime precipitation strengthened superalloys such as IN738. The nominal compositions of FSX-414 and IN738 are Co–29.5Cr–10.5Ni–7W–2Fe [max]–0.25C–0.012B and Ni–0.001B–0.17C–8.5Co–16Cr–1.7Mo–3.4Al–2.6W–1.7Ta–2Nb–3.4Ti–0.1Zr, respectively. Diffusion brazing has been used for over 4 decades to repair cracks and degradation on these types of components. Typically, braze materials utilized for component repairs are Ni- and Co-based braze fillers containing B and/or Si as melting point depressants. Especially when repairing wide cracks typically found on industrial gas turbine components, these melting point depressants can form brittle intermetallic boride and silicide phases that affect mechanical properties such as low cycle and thermal fatigue. The objective of this work is to investigate and evaluate the use of hypereutectic Ni–Cr–Hf and Ni–Cr–Zr braze filler metals, where the melting point depressant is no longer B, but Hf and/or Zr. Typically, with joint gaps or crack widths less than 0.15 mm, the braze filler metal alone can be utilized. For cracks greater than 0.15 mm, a superalloy powder is mixed with the braze filler metal to enable wide cracks to be successfully brazed repaired. As a means of qualifying the diffusion braze repair, both metallurgical and mechanical property evaluations were carried out. The metallurgical evaluation consisted of optical and scanning electron microscopies, and microprobe analysis. The diffusion brazed area consisted of a fine-grained equiaxed structure with carbide phases, gamma (gamma) dendrites, flower shaped/rosette gamma-gamma prime (gamma-gamma[prime]) eutectic phases, and Ni7Hf2, Ni5HF, or Ni5Zr intermetallic phases dispersed both intergranularly and intragranularly. Hardness tests showed that the Ni–Hf and Ni–Zr intermetallic phase only has a hardness range of 250–400 HV, whereas, the typical Cr-boride phases have hardness ranges from 800 HV to 1000 HV. Therefore the hardness values of the Ni–Hf and Ni–Zr intermetallic phases are 2.5–3.2 times softer than the Cr-boride intermetallic phases. As a result the low cycle fatigue (LCF) properties of the wide gap Ni–Cr–Hf and Ni–Cr–Zr brazed joints are superior to those of the Ni–Cr–B braze filler metals. The mechanical property evaluations were tensile tests at both room temperature and elevated temperature, stress rupture test from 760°C to 1093°C, and finally LCF tests, the latter being one of the most important and severe tests to conduct since the cracks being repaired are thermal fatigue driven. At the optimum braze thermal cycle, the mechanical test results achieved were a minimum of 80% and sometimes equivalent to that of the base metal properties. DEWEY : 620.1 ISSN : 0742-4795 En ligne : http://scitation.aip.org/getabs/servlet/GetabsServlet?prog=normal&id=JETPEZ00013 [...] [article] High strength, ductile braze repairs for stationary gas turbine components—Part I [texte imprimé] / Warren Miglietti, Auteur ; Madeleine Du Toit, Auteur . - 2011 . - 12 p. Génie Mécanique Langues : Anglais (eng) in Transactions of the ASME . Journal of engineering for gas turbines and power > Vol. 132 N° 8 (Août 2010) . - 12 p. Mots-clés : Aerospace  components  Aerospace  engines  Brazing  Cracks  Ductility  Filler  metals  Fracture  Gas  turbines  Hardness  Hardness  testing  Maintenance  engineering  Scanning  electron  microscopy  Tensile  testing Index. décimale : 620.1 Essais des matériaux. Défauts des matériaux. Protection des matériaux Résumé : Both aviation and land based turbine components such as vanes/nozzles, combustion chambers, liners, and transition pieces often degrade and crack in service. Rather than replacing with new components, innovative repairs can help reduce overhaul and maintenance costs. These components are cast from either Co-based solid solution superalloys such as FSX-414 or Ni-based gamma prime precipitation strengthened superalloys such as IN738. The nominal compositions of FSX-414 and IN738 are Co–29.5Cr–10.5Ni–7W–2Fe [max]–0.25C–0.012B and Ni–0.001B–0.17C–8.5Co–16Cr–1.7Mo–3.4Al–2.6W–1.7Ta–2Nb–3.4Ti–0.1Zr, respectively. Diffusion brazing has been used for over 4 decades to repair cracks and degradation on these types of components. Typically, braze materials utilized for component repairs are Ni- and Co-based braze fillers containing B and/or Si as melting point depressants. Especially when repairing wide cracks typically found on industrial gas turbine components, these melting point depressants can form brittle intermetallic boride and silicide phases that affect mechanical properties such as low cycle and thermal fatigue. The objective of this work is to investigate and evaluate the use of hypereutectic Ni–Cr–Hf and Ni–Cr–Zr braze filler metals, where the melting point depressant is no longer B, but Hf and/or Zr. Typically, with joint gaps or crack widths less than 0.15 mm, the braze filler metal alone can be utilized. For cracks greater than 0.15 mm, a superalloy powder is mixed with the braze filler metal to enable wide cracks to be successfully brazed repaired. As a means of qualifying the diffusion braze repair, both metallurgical and mechanical property evaluations were carried out. The metallurgical evaluation consisted of optical and scanning electron microscopies, and microprobe analysis. The diffusion brazed area consisted of a fine-grained equiaxed structure with carbide phases, gamma (gamma) dendrites, flower shaped/rosette gamma-gamma prime (gamma-gamma[prime]) eutectic phases, and Ni7Hf2, Ni5HF, or Ni5Zr intermetallic phases dispersed both intergranularly and intragranularly. Hardness tests showed that the Ni–Hf and Ni–Zr intermetallic phase only has a hardness range of 250–400 HV, whereas, the typical Cr-boride phases have hardness ranges from 800 HV to 1000 HV. Therefore the hardness values of the Ni–Hf and Ni–Zr intermetallic phases are 2.5–3.2 times softer than the Cr-boride intermetallic phases. As a result the low cycle fatigue (LCF) properties of the wide gap Ni–Cr–Hf and Ni–Cr–Zr brazed joints are superior to those of the Ni–Cr–B braze filler metals. The mechanical property evaluations were tensile tests at both room temperature and elevated temperature, stress rupture test from 760°C to 1093°C, and finally LCF tests, the latter being one of the most important and severe tests to conduct since the cracks being repaired are thermal fatigue driven. At the optimum braze thermal cycle, the mechanical test results achieved were a minimum of 80% and sometimes equivalent to that of the base metal properties. DEWEY : 620.1 ISSN : 0742-4795 En ligne : http://scitation.aip.org/getabs/servlet/GetabsServlet?prog=normal&id=JETPEZ00013 [...]

High strength, ductile braze repairs for stationary gas turbine components—Part II / Warren Miglietti in Transactions of the ASME . Journal of engineering for gas turbines and power, Vol. 132 N° 8 (Août 2010) 

Public ISBD [article]  in Transactions of the ASME . Journal of engineering for gas turbines and power > Vol. 132 N° 8 (Août 2010) . - 10 p. Titre : High strength, ductile braze repairs for stationary gas turbine components—Part II Type de document : texte imprimé Auteurs : Warren Miglietti, Auteur ; Madeleine Du Toit, Auteur Année de publication : 2011 Article en page(s) : 10 p. Note générale : Génie Mécanique Langues : Anglais (eng) Mots-clés : Brazing  Gas  turbines  Scanning  electron  microscopy  Superalloys Index. décimale : 620.1 Essais des matériaux. Défauts des matériaux. Protection des matériaux Résumé : Both aviation and land based turbine components such as vanes/nozzles, combustion chambers, liners, and transition pieces often degrade and crack in service. Rather than replacing with new components, innovative repairs can help reduce overhaul and maintenance costs. These components are cast from either Co-based solid solution superalloys such as FSX-414, or Ni-based gamma prime precipitation strengthened superalloys such as IN738. The nominal compositions of FSX-414 and IN738 are Co–29.5Cr–10.5Ni–7W–2Fe (max)–0.25C–0.012B and Ni–0.001B–0.17C–8.5Co–16Cr–1.7Mo–3.4Al–2.6W–1.7Ta–2Nb–3.4Ti–0.1Zr, respectively. Diffusion brazing has been used for over 4 decades to repair cracks and degradation on these types of components. Typically, braze materials utilized for component repairs are Ni and Co-based braze fillers containing B and/or Si as melting point depressants. Especially when repairing wide cracks typically found on industrial gas turbine components, these melting point depressants can form brittle intermetallic boride and silicide phases that effect mechanical properties such as low cycle and thermal fatigue. The objective of this work is to investigate and evaluate the use of hypereutectic Ni–Cr–Hf and Ni–Cr–Zr braze filler metals, where the melting point depressant is no longer B, but Hf and/or Zr. Typically, with joint gaps or crack widths less than 0.15 mm, the braze filler metal alone can be utilized. For cracks greater than 0.15 mm, a superalloy powder is mixed with the braze filler metal to enable wide cracks to be successfully braze repaired. As a means of qualifying the diffusion braze repair, both metallurgical and mechanical property evaluations were carried out. The metallurgical evaluation consisted of optical and scanning electron microscopy, and microprobe analysis. The diffusion brazed area consisted of a fine-grained equiaxed structure, with carbide phases, gamma (gamma) dendrites, flower shaped/rosette gamma-gamma[prime] (gamma-gamma prime) eutectic phases and Ni7Hf2, Ni5HF, or Ni5Zr intermetallic phases dispersed both intergranularly and intragranularly. Hardness tests showed that the Ni–Hf and Ni–Zr intermetallic phase only has a hardness range of 250–400 Hv; whereas, the typical Cr-boride phases have hardness ranges from 800 Hv to 1000 Hv. Therefore, the hardness values of the Ni–Hf and Ni–Zr intermetallic phases are 2.5–3.2 times softer than the Cr-boride intermetallic phases. As a result, the low cycle fatigue (LCF) properties of the wide gap Ni–Cr–Hf and Ni–Cr–Zr brazed joints are superior to those of the Ni–Cr–B braze filler metals. The mechanical property evaluations were tensile tests at both room temperature and elevated temperature, stress rupture tests from 760°C to 1093°C and finally LCF, the latter being one of the most important and severe tests to conduct, since the cracks being repaired are thermal fatigue driven. At the optimum braze thermal cycle, the mechanical test results achieved were a minimum of 80% and sometimes equivalent to that of the base metals properties. DEWEY : 620.1 ISSN : 0742-4795 En ligne : http://scitation.aip.org/getabs/servlet/GetabsServlet?prog=normal&id=JETPEZ00013 [...] [article] High strength, ductile braze repairs for stationary gas turbine components—Part II [texte imprimé] / Warren Miglietti, Auteur ; Madeleine Du Toit, Auteur . - 2011 . - 10 p. Génie Mécanique Langues : Anglais (eng) in Transactions of the ASME . Journal of engineering for gas turbines and power > Vol. 132 N° 8 (Août 2010) . - 10 p. Mots-clés : Brazing  Gas  turbines  Scanning  electron  microscopy  Superalloys Index. décimale : 620.1 Essais des matériaux. Défauts des matériaux. Protection des matériaux Résumé : Both aviation and land based turbine components such as vanes/nozzles, combustion chambers, liners, and transition pieces often degrade and crack in service. Rather than replacing with new components, innovative repairs can help reduce overhaul and maintenance costs. These components are cast from either Co-based solid solution superalloys such as FSX-414, or Ni-based gamma prime precipitation strengthened superalloys such as IN738. The nominal compositions of FSX-414 and IN738 are Co–29.5Cr–10.5Ni–7W–2Fe (max)–0.25C–0.012B and Ni–0.001B–0.17C–8.5Co–16Cr–1.7Mo–3.4Al–2.6W–1.7Ta–2Nb–3.4Ti–0.1Zr, respectively. Diffusion brazing has been used for over 4 decades to repair cracks and degradation on these types of components. Typically, braze materials utilized for component repairs are Ni and Co-based braze fillers containing B and/or Si as melting point depressants. Especially when repairing wide cracks typically found on industrial gas turbine components, these melting point depressants can form brittle intermetallic boride and silicide phases that effect mechanical properties such as low cycle and thermal fatigue. The objective of this work is to investigate and evaluate the use of hypereutectic Ni–Cr–Hf and Ni–Cr–Zr braze filler metals, where the melting point depressant is no longer B, but Hf and/or Zr. Typically, with joint gaps or crack widths less than 0.15 mm, the braze filler metal alone can be utilized. For cracks greater than 0.15 mm, a superalloy powder is mixed with the braze filler metal to enable wide cracks to be successfully braze repaired. As a means of qualifying the diffusion braze repair, both metallurgical and mechanical property evaluations were carried out. The metallurgical evaluation consisted of optical and scanning electron microscopy, and microprobe analysis. The diffusion brazed area consisted of a fine-grained equiaxed structure, with carbide phases, gamma (gamma) dendrites, flower shaped/rosette gamma-gamma[prime] (gamma-gamma prime) eutectic phases and Ni7Hf2, Ni5HF, or Ni5Zr intermetallic phases dispersed both intergranularly and intragranularly. Hardness tests showed that the Ni–Hf and Ni–Zr intermetallic phase only has a hardness range of 250–400 Hv; whereas, the typical Cr-boride phases have hardness ranges from 800 Hv to 1000 Hv. Therefore, the hardness values of the Ni–Hf and Ni–Zr intermetallic phases are 2.5–3.2 times softer than the Cr-boride intermetallic phases. As a result, the low cycle fatigue (LCF) properties of the wide gap Ni–Cr–Hf and Ni–Cr–Zr brazed joints are superior to those of the Ni–Cr–B braze filler metals. The mechanical property evaluations were tensile tests at both room temperature and elevated temperature, stress rupture tests from 760°C to 1093°C and finally LCF, the latter being one of the most important and severe tests to conduct, since the cracks being repaired are thermal fatigue driven. At the optimum braze thermal cycle, the mechanical test results achieved were a minimum of 80% and sometimes equivalent to that of the base metals properties. DEWEY : 620.1 ISSN : 0742-4795 En ligne : http://scitation.aip.org/getabs/servlet/GetabsServlet?prog=normal&id=JETPEZ00013 [...]

Wide gap braze repair of gas turbine blades and vanes / Huang, Xiao in Transactions of the ASME . Journal of engineering for gas turbines and power, Vol. 134 N° 1 (Janvier 2012) 

Public ISBD [article]  in Transactions of the ASME . Journal of engineering for gas turbines and power > Vol. 134 N° 1 (Janvier 2012) . - 17 p. Titre : Wide gap braze repair of gas turbine blades and vanes : a review Type de document : texte imprimé Auteurs : Huang, Xiao, Auteur ; Warren Miglietti, Auteur Année de publication : 2012 Article en page(s) : 17 p. Note générale : Génie mécanique Langues : Anglais (eng) Mots-clés : Aerospace  components  Blades  Gas  turbines Index. décimale : 620.1 Essais des matériaux. Défauts des matériaux. Protection des matériaux Résumé : Gas turbine blades and vanes in modern gas turbines are subjected to an extremely hostile environment. As such, sophisticated airfoil designs and advanced materials have been developed to meet stringent demands and at the same time, ensure increased performance. Despite the evolution of long-life airfoils, damage still occurs during service thus limiting the useful life of these components. Effective repair of after-service components provides life-cycle cost reduction of engines, and as well, contributes to the preservation of rare elements heavily used in modern superalloys. Among these methods developed in the last four decades for the refurbishment and joining of superalloy components, wide gap brazing (WGB) technology has been increasingly used in the field owing to its ability to repair difficult to weld alloys, to build up substantially damaged areas in one operation, and to provide unlimited compositional choices to enhance the properties of the repaired region. In this paper, the historical development of wide gap repair technology currently used in industry is reviewed. The microstructures and mechanical properties of different WGB joints are compared and discussed. Subsequently, different WGB processes employed at major OEMs are summarized. To conclude this review, future developments in WGB repair of newer generations of superalloys are explored. DEWEY : 620.1 ISSN : 0742-4795 En ligne : http://asmedl.org/getabs/servlet/GetabsServlet?prog=normal&id=JETPEZ000134000001 [...] [article] Wide gap braze repair of gas turbine blades and vanes : a review [texte imprimé] / Huang, Xiao, Auteur ; Warren Miglietti, Auteur . - 2012 . - 17 p. Génie mécanique Langues : Anglais (eng) in Transactions of the ASME . Journal of engineering for gas turbines and power > Vol. 134 N° 1 (Janvier 2012) . - 17 p. Mots-clés : Aerospace  components  Blades  Gas  turbines Index. décimale : 620.1 Essais des matériaux. Défauts des matériaux. Protection des matériaux Résumé : Gas turbine blades and vanes in modern gas turbines are subjected to an extremely hostile environment. As such, sophisticated airfoil designs and advanced materials have been developed to meet stringent demands and at the same time, ensure increased performance. Despite the evolution of long-life airfoils, damage still occurs during service thus limiting the useful life of these components. Effective repair of after-service components provides life-cycle cost reduction of engines, and as well, contributes to the preservation of rare elements heavily used in modern superalloys. Among these methods developed in the last four decades for the refurbishment and joining of superalloy components, wide gap brazing (WGB) technology has been increasingly used in the field owing to its ability to repair difficult to weld alloys, to build up substantially damaged areas in one operation, and to provide unlimited compositional choices to enhance the properties of the repaired region. In this paper, the historical development of wide gap repair technology currently used in industry is reviewed. The microstructures and mechanical properties of different WGB joints are compared and discussed. Subsequently, different WGB processes employed at major OEMs are summarized. To conclude this review, future developments in WGB repair of newer generations of superalloys are explored. DEWEY : 620.1 ISSN : 0742-4795 En ligne : http://asmedl.org/getabs/servlet/GetabsServlet?prog=normal&id=JETPEZ000134000001 [...]