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Gas Turbine Repair Technology Figure 27. Robotic application of TBC on MS7001E transition piece Figure 28. Robotic application of TBC on MS6001B combustion liner Figure 29. Photomicrograph of Class B TBC that of GE’s gas turbine manufacturing opera- tion (GE Gas Turbine, LLC), which applies TBC to new OEM components. This standardization allows the use of the same qualified programs throughout the service center network, ensur- ing quality product every time. The significance in using OEM generated programs is that all hardware must be restored to OEM di-mensions or else the robotic arm would crash into the out- of-tolerance component. It also minimizes the global inventory of spare parts needed for the thermal spray equipment. TBCs are divided into classes depending on the bond coat and top coat thickness. Class B TBCs (0.014"/0.3556 mm to +/-0.004"/0.1016 mm top coat) are the standard for pre-DLN series combustion liners. (See Figure 29.) Class C coat- ings (0.020"/0.508 mm to +/- 0.002"/0.0508 mm top coat) significantly improve the cooling ef- fect on selected DLN liners. Transition pieces may receive either coating (Class B or Class C). However, the differences between robotically-applied and manually-ap- plied coatings are more pronounced on these components. The nature of the hot gas im- pingement on the transition piece wall cause greater thermal distortion than what typically occurs in combustion liners (e.g. axial flow). Thickness uniformity is critical to transition piece coatings reaching their expected life. If thickness variations occur during manual spray applications, then chances are high that the coating will spall during thermal cycling. This is shown in Figure 30 and Figure 31 by two transi- tion pieces run in a rainbow test. Figure 30 dis- plays a transition piece with robotically-applied coating. The TBC coating is still intact after 8,000 hours. Figure 31 illustrates a transition piece from the same unit, with a manually- applied coating. This transition piece has spalled coat-ing under the hanger bracket. TBCs on nozzles have been proven to extend the life of nozzle segments, and are also offered as a repair or upgrade modification to stage 1 nozzles. Figure 32 shows TBC applied to nozzle GE Power Systems ■ GER-3957B ■ (04/01) 17PDF Image | Gas Turbine Repair Technology GE
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