Integrated rapid 3D mapping and laser additive repair of gas turbine engine components

Abstract

National Research Council Canada (NRC) has developed precision laser additive repair of worn gas turbine components. The repair system uses integrated 3D mapping and laser additive deposition. The integrated inspection and repair system is capable of inspecting and repairing a worn gas turbine injector less than one hour. This innovative system dramatically improves repair time and cost of high value gas turbine components. In this paper, a case study will be presented as a joint effort by NRC and UTC Aerospace Systems to evaluate the feasibility of repair of worn fuel injectors from a land based gas turbine engine. The project evaluated the use of laser cladding of cobalt alloy L-605 for repair of worn components on a Rolls Royce 501K engine. Testing results reveals that laser clad L-605 on wrought L-605 substrate demonstrates comparable or even substantially improved fatigue life as compared to the baseline wrought L-605 specimens at elevated temperature. Laser-clad L-605 also shows comparable wear resistance. The paper will demonstrate the improved repair of the fuel injectors via laser cladding repair and the metallurgical evaluation of the repair. The paper documents the improvement of the repair from several weeks and fabrication of several replacement components to a matter of only a few hours to inspect and repair using the NRC laser additive manufacturing system.National Research Council Canada (NRC) has developed precision laser additive repair of worn gas turbine components. The repair system uses integrated 3D mapping and laser additive deposition. The integrated inspection and repair system is capable of inspecting and repairing a worn gas turbine injector less than one hour. This innovative system dramatically improves repair time and cost of high value gas turbine components. In this paper, a case study will be presented as a joint effort by NRC and UTC Aerospace Systems to evaluate the feasibility of repair of worn fuel injectors from a land based gas turbine engine. The project evaluated the use of laser cladding of cobalt alloy L-605 for repair of worn components on a Rolls Royce 501K engine. Testing results reveals that laser clad L-605 on wrought L-605 substrate demonstrates comparable or even substantially improved fatigue life as compared to the baseline wrought L-605 specimens at elevated temperature. Laser-clad L-605 also shows comparable wear resi...