초록 ▼

Methods for repairing and manufacturing a gas turbine blade, and the gas turbine blade repaired and manufactured with such methods are presented with, for example, the repair method comprising providing a gas turbine blade, the blade comprising a blade tip and a blade body; removing at least one por

Methods for repairing and manufacturing a gas turbine blade, and the gas turbine blade repaired and manufactured with such methods are presented with, for example, the repair method comprising providing a gas turbine blade, the blade comprising a blade tip and a blade body; removing at least one portion of the blade tip; providing at least one freestanding tip insert; and disposing the at least one tip insert onto the gas turbine blade body such that the at least one tip insert replaces the at least one removed portion of the blade tip.

대표청구항 ▼

1. A method for repair of a gas turbine blade, comprising:providing a gas turbine blade, said blade comprising a first material and further comprising a blade tip and a blade body; removing at least one portion of said blade tip; providing at least one freestanding tip insert comprising a second mat

1. A method for repair of a gas turbine blade, comprising:providing a gas turbine blade, said blade comprising a first material and further comprising a blade tip and a blade body; removing at least one portion of said blade tip; providing at least one freestanding tip insert comprising a second material; and disposing said at least one tip insert onto said gas turbine blade body such that said at least one tip insert replaces said at least one removed portion of said blade tip; wherein said second material has at least one attribute selected from the group consisting of a. a melting temperature greater than a melting temperature of said first material by at least about 80° C.; b. a fatigue life at least about three times greater than a fatigue life of said first material; and e. a creep life at least about three times greater than that of said first material. 2. The method of claim 1, wherein said blade tip comprises at least one squealer, and said at least one portion of said blade tip comprises said at least one squealer.3. The method of claim 1, wherein disposing comprises joining said at least one tip insert to said blade by means of a process selected from the group consisting of welding, brazing, and diffusion bonding.4. The method of claim 1, wherein said at least one tip insert comprises at least one internal cooling channel.5. The method of claim 1, wherein said at least one tip insert comprises a plurality of cooling holes.6. The method of claim 1, wherein said at least one tip insert comprises a superalloy based on a metal selected from the group consisting of iron, cobalt, and nickel.7. The method of claim 6, wherein said at least one tip insert comprises a directionally solidified material.8. The method of claim 6, wherein said at least one tip insert comprises a single crystal material.9. The method of claim 1, wherein said blade comprises a first material and said at least one tip insert comprises a second material, and wherein each of a creep life, a fatigue life, and an oxidation resistance for said first material is essentially equivalent to each of a creep life, a fatigue life, and an oxidation resistance of said second material, respectively.10. The method of claim 1, wherein said second material comprises a platinum group metal modified nickel-based superalloy.11. The method of claim 10, wherein said superalloy comprises a metal selected from the group consisting of Pt, Pd, Rh, Ir, and Ru.12. The method of claim 1, wherein said second material has an oxidation resistance at least about 3 times greater than an oxidation resistance of said first material.13. The method of claim 12, wherein said second material comprises a material selected from the group consisting of Rh, Pt, Pd, and mixtures thereof.14. The method of claim 13, wherein said at least one tip insert further comprises a substrate material, and wherein said second material is disposed on said substrate material.15. The method of claim 14, wherein said second material comprises a layer with a cross-sectional thickness in the range from about 0.13 mm to about 0.64 mm.16. The method of claim 13, wherein said second material comprises Rh at a level of at least about 65 atomic percent.17. The method of claim 13, wherein said second material further comprises a metal selected from the group consisting of Ir, Ru, and mixtures thereof, at a level of up to about 5 atomic percent.18. The method of claim 13, wherein said second material further comprises Cr.19. The method of claim 18, wherein the Cr is present at a level of up to about 25 atomic percent.20. The method of claim 18, wherein said second material further comprises Al.21. The method of claim 20, wherein said directionally solidified eutectic material comprises Ni, Ta, and C.22. The method of claim 20, wherein the Al is present at a level of up to about 18 atomic percent.23. The method of claim 20, wherein said second material further comprises Ni.24. The method of claim 23, wherein the Ni is present at a level of up to about 45 atomic percent.25. The method of claim 12, wherein said second material comprises a refractory superalloy.26. The method of claim 25, wherein said refractory superalloy comprises Rh.27. The method of claim 1, wherein said second material comprises a directionally solidified eutectic material.28. The method of claim 1, wherein said second material comprises an oxide dispersion strengthened material.29. The method of claim 28, wherein said oxide dispersion strengthened material comprises Ni, Cr, and yttrium oxide.30. A gas turbine blade repaired by the method of claim 1.31. A method for repair of a gas turbine blade, comprising:providing a gas turbine blade, said blade comprising a first material and further comprising a blade tip and a blade body; removing at least one portion of said blade tip; providing at least one freestanding tip insert, said at least one tip insert comprising a second material chosen from at least one of a single crystal nickel-based superalloy, a NiTaC directionally solidified cutcctic alloy, and an oxide dispersion strengthened alloy; wherein said second material has at least one attribute selected from the group consisting of a. fatigue life at least about three times greater than a fatigue life of said first material, and b. a creep life at least about three times greater than that of said first material; and disposing said at least one tip insert onto said gas turbine blade body such that said tip insert replaces said at least one removed portion of said blade. 32. A method for repair of a gas turbine blade, comprising:providing a gas turbine blade, said blade comprising a first material and further comprising a blade tip said a blade body; removing at least one portion of said blade tip; providing at least one freestanding tip insert, said at least one tip insert comprising a second material selected from the group consisting of rhodium, platinum, palladium, and mixtures thereof, wherein said second material has a melting temperature greater than a melting temperature of said first material by at least about 80° C.; and disposing said at least one tip insert onto said gas turbine blade body such that said tip insert replaces said at least one removed portion of said blade. 33. A gas turbine blade comprising:a turbine blade body comprising a first material; and a blade tip; wherein said blade tip comprises at least one tip insert comprising a second material joined to said blade body, and wherein said second material has at least one attribute selected from the group consisting of a. a melting temperature greater than a melting temperature of said first material by at least about 80° C.; b. a fatigue life at least about times than a fatigue life of said first material; and c. a creep life at least about three times greater than that of said first material. 34. The gas turbine blade of claim 33, wherein a cross sectional thickness of said at least one tip insert is less than a wall thickness of said turbine blade body.35. The gas turbine blade of claim 33, wherein a cross sectional thickness of said at least one tip insert is at least equal to a wall thickness of said turbine blade body.36. The gas turbine blade of claim 33, wherein said at least one blade tip comprises at least one squealer.37. The gas turbine blade of claim 33, wherein said at least one tip insert is joined to said blade body by means of a process selected from the group consisting of welding, brazing, and diffusion bonding.38. The gas turbine blade of claim 33, wherein said at least one tip insert comprises at least one internal cooling channel.39. The gas turbine blade of claim 33, wherein said at least one tip insert comprises a plurality of cooling holes.40. The gas turbine blade of claim 33, wherein said at least one tip insert comprises a superalloy based on a metal selected from the group consisting of iron, cobalt, and nickel.41. The gas turbine blade of claim 40, wherein said at least one tip insert comprises a directionally solidified material.42. The gas turbine blade of claim 40, wherein said at least one tip insert comprises a single crystal material.43. The gas turbine blade of claim 33, wherein said second material comprises a platinum group metal modified nickel-based superalloy.44. The gas turbine blade of claim 43, wherein said superalloy comprises a metal selected from the group consisting of Pt, Pd, Rh, Ir, and Ru.45. The gas turbine blade of claim 33, wherein said second material has an oxidation resistance at least about three times greater than an oxidation resistance of said first material.46. The gas turbine blade of claim 45, wherein said second material comprises a refractory superalloy.47. The gas turbine blade of claim 46, wherein said refractory superalloy comprises Rh.48. The gas turbine blade of claim 33, wherein said at least one tip insert further comprises a substrate material, and wherein said second material is disposed on said substrate material.49. The method of claim 48, wherein said second material comprises a layer with a cross sectional thickness in the range from about 0.13 mm to about 0.64 mm.50. The gas turbine blade of claim 33, wherein said second material comprises Rh at a level of at least about 65 atomic percent.51. The gas turbine blade of claim 33, wherein said second material further comprises a metal selected from the group consisting of Ir, Ru, and mixtures thereof, at a level of up to about 5 atomic percent.52. The gas turbine blade of claim 33, wherein said second material further comprises Cr.53. The gas turbine blade of claim 52, wherein the Cr is present at a level of up to about 25 atomic percent.54. The gas turbine blade of claim 52, wherein said second material further comprises Al.55. The gas turbine blade of claim 54, wherein the Al is present at a level of up to about 18 atomic percent.56. The gas turbine blade of claim 54, wherein said second material further comprises Ni.57. The gas turbine blade of claim 56, wherein the Ni is present at a level of up to about 45 atomic percent.58. The gas turbine blade of claim 33, wherein said directionally solidified eutectic material comprises Ni, Ta, and C.59. The gas turbine blade of claim 33, wherein said oxide dispersion strengthened material comprises Ni, Cr, and yttrium oxide.60. A gas turbine blade comprising:a turbine blade body comprising a first material; and a blade tip; wherein said blade tip comprises at least one tip insert joined to said blade body, said at least one tip insert comprising a second material chosen from at least one of a single crystal nickel-based superalloy, a NiTaC directionally solidified eutectic alloy, and an oxide dispersion strengthened alloy, wherein said second material has at least one attribute selected from the group consisting of a. a fatigue life at least about three times greater than a fatigue life of said first material, and b. a creep life at least about three times greater than that of said first material. 61. A gas turbine blade comprising:a turbine blade body comprising a first material; and a blade tip; wherein said blade tip comprises at least one tip insert joined to said blade body, said at least one tip insert comprising a second material selected from the group consisting of rhodium, platinum, palladium, and mixtures thereof, wherein said second material has a melting temperature greater than a melting temperature of said first material by at least about 80° C.