Liburdi Group of Companies

Transcription

1 Liburdi Group of Companies Liburdi Engineering Ltd Liburdi Turbine Services Inc Liburdi Automation Inc Liburdi Dimetrics Corp Dundas, Ontario Charlotte, North Carolina St Petersburg, Russia

2 New Applications New Technologies F Class Component Repairs Blades of advanced casting technologies Directionally Solidified DS and Single Crystal Alloys, High Strength alloys challenges for conventional welding Need for TBC coatings for airfoils Complex cooling systems, thin airfoil walls Internal coatings stage 1 and stage 2 Aero Engine repair technologies applied to Industrial F Class The Enabling Technologies

3 Higher Strength Alloys Directionally Solidified, Single Crystal Metal Temperature Capability, o C IN- 100 Polycrystal Columnar crystal Single crystal DS 200Hf B190 0 MM247 Rhenium bearing alloys PWA 1480 DS Increases in Maximum Metal Temperatures for Blade Alloys

4 Liburdi Experience Aero and F Industrial Blades F Class derived from Aero Blade Internal cooling circuit design, alloy selection, coatings Advanced technologies applied from GE, Rolls-Royce aero experience CF6 Aero Blade -- 7FA Blade Cooling F404 Aero 7241(FA)

5 Aero and F Industrial Blades FEA Modelling Capability

6 Advanced Repair Technologies Turbine Blades and Buckets New Challenges New Repair Technologies Required Require effective internal stripping process Special (automated) Laser and MicroPlasma welding of blade tips Rejuvenation applied to restore microstructure LPM Powder metallurgy applied to repair un-weldable alloys

7 Aero and F Industrial Blades Blade Tip Oxidation Restoration Severe high Temp oxidation damage / metal loss at the tip Similar to aero aero-derivative experience F7FA Stage 1 Bucket Aero Blade F404 LM1600

8 Aero and F Industrial Blades Welding DS Alloys Weld restoration of tips Weld metal with superior oxidation resistance vs the original casting material Overlay coating and diffusion LSR TM coating to protect substrate. Frame 7FA, Frame 6FA Stage 1 Buckets

9 Aero and F Industrial Blades Welding Single Crystal Alloys Single Crystal Alloy PWA1483 Tip Repair to restore original dimension and performance Tip Upgrade - welding with specialized weld alloy for oxidation resistance High strength airfoil casting, high strength weld metal Automated Plasma Arc or Laser welding required

10 High Strength Power Metallurgy Process for Single Crystal Alloys Radial tip cracks in Single Crystal alloy repaired with LPM Powder Metallurgy, after welding to restore tip height

11 Aero and F Industrial Blades Advanced Coating Systems External airfoil surfaces NiCoCrAlY Overlay with over-aluminize or MCrAlY bond coat with DVC or EB-PVD TBC. Recoating internal airfoil surfaces diffusion aluminide (silicon modified). Internal Aluminide Coating MCrAlY+Al Coating 10µm DVC TBC Coating EB-PVD TBC Coating

12 Aero and F Industrial Blades Rejuvenation of Alloy Properties Full Solution Heat Treatments Rejuvenation Heat Treatments HIP and Vacuum Furnace Restore alloy microstructure. Restore original material properties. Requires removal of internal coatings. Full Solution Heat treatments developed for Equiaxed and DS alloys GTD111, GTD111DS, MM247, MM247DS, Rene80, Rene80DS IN738, U500. Single Crystal alloy full solution rejuvenation in development Service run GTD111DS aged microstructure Rejuvenated GTD111DS restored microstructure

13 Aero and F Industrial Vanes - Challenges Cobalt and Nickel alloys Internal impingement cooling, extensive film cooling, EDM, laser drilled cooling holes ( 600 holes in one cast segment) MCrAlY and TBC coating on first row and second row Coating consumption and spalling Lean and shingling Bowing, burning and corrosion TMF cracking

14 High Strength Repair of Nozzles Multi-Airfoil nozzle segments are prone to Thermal Mechanical Fatigue stresses and cracks Conventional welding repairs are limited in strength tend to crack again after repair

15 High Strength Repair of Nozzles Heavy crack damage removed by grinding and ready to begin repair Main structural cracks, branching cracks, depleted material adjacent to cracks all removed. extensive material removal

16 High Strength Repair of Nozzles Enabling Technology Powder Metallurgy Select filler materials for matching strength Select filler materials for higher strength Advantages over welding Non fusion process eliminates HAZ cracking Distortion free heat treatments High strength

17 High Strength Repair of Nozzles 48,000 hours during advanced repair Areas with large cracks repaired with high-strength LPM material Even thinned airfoils can be restored with sheets of LPM material 92,000 hours second repair Areas with repaired cracks show less re-cracking, sometimes none LPM material can be re-repaired

18 High Strength Repair of Nozzles 24,000 hours after LPM Powder Metallurgy repair no cracks in repaired areas LPM repair alloy higher strength Nickel superalloy compared to original Cobalt casting

19 High Strength Repair of Nozzles Re-construction Trailing Edge Thickness restoration with LPM layer applied to both sides to re-establish throat dimension and original trailing edge wall dimensions Thin TE Before repair TE After re-construction

20 LPM TM Powder Metallurgy Enabling Technology for Repair and New Part Mfgr High Strength, Distortion Free Process Used extensively for Repair of Nozzles/Vanes GE Frame 3,5,6,7,9 W251,W501, V84 Used by OEMs for Manufacture of F Class blades New Part Manufacture HPT Blade Tip Closures LPT Blade Shroud Z-Notch Hard Face Abrasive (engineered) HPT Tip