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Gas Turbine Repair Technology A metallurgical evaluation of such a NozzaloyTM repair (Figure 4) demonstrates its ability to form a sound bond and contamination-free inter- face. NozzaloyTM extends repair intervals by in- hibiting crack initiation by a factor greater than four when compared to those filler metal alloys more commonly used in the industry. NozzaloyTM not only shows the highest resis- tance to crack initiation, but the crack propaga- tion rate is also as low as the base metal. (See Figure 5 and Figure 6.) minor and major repairs on hot gas path sur- faces. A key attribute of ADH is that it causes no parts distortion during application and high- temperature processing. This technique was originally developed by GE’s Aircraft Engine group for vane (nozzle) repair. GE Power Systems’ Inspection and Repair Services (I&RS) has modified the process for use with heavy- duty industrial gas turbine alloys. ADH lends itself to nozzle surface erosion restoration, craze crack repair and replacement of trailing edge metal loss. Typical erosion dam- age of a nozzle sidewall that is readily repaired with ADH is shown in Figure 7. Figure 7. Nozzle requiring ADH repair The ADH process uses a mixture of superalloy powders and an organic binder tailored to meet the part’s specific design requirements. The mixture of ADH materials is designed to melt, solidify and diffuse when placed through a con- trolled thermal cycle in a vacuum furnace. ADH components produce a liquid which iso- thermally resolidifies, thus avoiding undesirable eutectic phases. With further thermal treat- ment, ADH repairs closely approach the com- position, microstructure and properties of the parent metal. (See Figure 8.) The ADH alloy system selected for nozzle re- pairs is compatible with previous repair weld- ments and is readily weldable. (See Figure 4.) Key mechanical test data acquired for comparison 350 300 250 200 LENGTH PROPAGATION FACTORS 150 100 50 CRACK INITIATION & GROWTH CURVES CRACK 0 0 50 100 150 200 250 300 350 400 450 500 NUM BER OF CYCLES Figure 5. NozzaloyTM crack initiation L - 605 (WELDMENT) NO Z Z A L O Y FSX - 414 BASE MA TERIA L NUMBER OF CYCLES TOCRACK INITIATION 350 300 250 200 150 100 50 0 20 L - 605 (WELDMENT) NOZZALOY MATERIAL FSX - 414 BASE MATERIAL THERMAL FATIGUE CHARACTERISTICS Figure 6. NozzaloyTM thermal fatigue characteristics 300 310 Activated Diffusion Healing: Distortion- Free Nozzle Restoration Activated Diffusion Healing (ADH) is a unique repair method used in nozzle restoration. The process deposits a metallurgically sound propri- etary alloy combination to a nozzle substrate for GE Power Systems ■ GER-3957B ■ (04/01) 5PDF Image | Gas Turbine Repair Technology GE
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