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Gas Turbine Repair Technology Reduction of Hot Zones (RED) as predicted by Design Engineering modeling with the applica- tion of Advanced Thermal Barrier Coatings. Figure 13. Automated weld repair system during the welding process. The welding system generates heat into the part, the welding torch and the fixture which must be dissipated while in operation. A water chiller is part of this sys- tem to perform the function of cooling the components. The process selected for welding the filler ma- terial to the bucket is the plasma arc welding process. A key to the process is the stable low currents which enables accurate weld place- ment and welding on thin knife edge surfaces. Key to the success of this welding process is the distance that the welding torch maintains from the weldment. An arc length controller utilizes the arc voltage and sensing devices to adaptive- ly adjust the torch height and maintain a con- stant arc length for successful welding results. (See Figure 14.) Post-weld heat treatment, Hot Isostatic Press (HIP), finish machining and grinding are easily accomplished while returning the bucket to its repair part dimensional requirements. The ele- vated temperature WRAPTM welding is also used for the restoration of rubbed tips and angel wing sealing surfaces. Additionally, the elevated temperature WRAPTM process is used to generate cutter teeth on the integral labyrinth seal surface of shrouded buckets. This uprate is offered on new and serv- iced parts. The use of honeycomb material in stage two and three shrouds requires that the stage two and three buckets have “cutter teeth” on the bucket tip seals. Their purpose is to allow the buckets to cleanly cut into the honeycomb material when the rotor moves axially relative to the shrouds. Restoration of integral shroud “Z” interlocks is accomplished via the fusion application of wear- resistant hard surfacing materials. In the case of GTD-111, the elevated temperature WRAPTM process is again employed. For “Z” interlocks originally employing plasma-sprayed chrome carbide, this original material can be reapplied or, at the customer’s option, upgraded to fu- sion-applied hard surfacing. Bucket cooling effectiveness is a critical part of ensuring bucket life and integrity. Higher fired machines employ conduction and convection cooling as well as film cooling techniques to en- sure that bucket temperatures do not exceed Figure 14. Close-up plasma torch GE Power Systems ■ GER-3957B ■ (04/01) 9 Figure 15. TBC effect on airfoil bulk metal surface temperaturesPDF Image | Gas Turbine Repair Technology GE
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