Solutions Flash Laser cladding repairs for aerospace and industrial gas turbine applications - Oerlikon
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Solutions Flash Laser cladding repairs for aerospace and industrial gas turbine applications SF-0026.0 – January 2020 SF-0026.0 – Laser Cladding Repairs for Aero and IGT Applications © 2020 Oerlikon Metco 1
Today’s situation
Older repair technologies are constantly being challenged by
new processes that offer benefits in performance, efficiency Deposit Thickness (µm)
and cost. Repairs to gas turbine components require -10 -1 -0.1 0 0.1 1 10 102 103 104 105
1200
cost-effective processes, quick turn-around times and robust
results. Laser cladding is a welding technology that is often 1000
used to replace GTAW (Gas Tungsten Arc Welding). Laser
Substrate Temperature °C
cladding offers these benefits over older, conventional weld- 800 GTAW
ing methods: PTA
LC
n Very low heat input and low distortion, which is es- 600
sential for parts with tight tolerances where substrate dis- Thermal
tortion is problematic Plasma Spray
400
Nitriding
n Large number of materials available to match sub- PVD
PA-CVD
strate performance in gas turbine applications, including 200 Cold Spray
wear and corrosion
n Molecular bonding resulting in better adhesion that 0
out-performs mechanically bonded processes
n Chemistry and hardness are retained without need Laser Cladding Area of Performance
for additional coatings
n Rapid cooling rate ensuring faster part throughput While the laser cladding process results in momentary substrate tem-
peratures similar to that of conventional welding and PTA, the heat input
n Lower stresses on substrates due to lower heat to the substrate is far lower with a substantially smaller heat affected
input zone, thereby reducing or eliminating substrate distortion and dilution.
n Environmentally-friendly as parts that were consid-
ered “scrap” can now be repaired for a fraction of the
cost of a new part.
The Oerlikon Metco solution
Oerlikon Metco, the leading supplier of Laser Cladding solu-
tions for IGT and Aero component repair applications, has
developed a portfolio of laser cladding materials. Oerlikon
Metco’s materials have been designed such that the laser
deposits are optimized for the many varied repairs on gas
turbine components.
Moreover, Oerlikon Metco can provide a complete solution
package, that either includes the materials and the spray
system, or services to clad customer-supplied parts. In addi-
tion, we have expert material technologists to consult on
specific requirements.
With more than 25 years of laser cladding experience for tur-
bine engines, Oerlikon Metco has the experience and com-
petence to provide repairs that our customers can have
complete confidence in the solutions we provide.
Oerlikon Metco’s laser cladding materials — like this gas atomized nickel–based
superalloy — are designed and manufactured to produce deposits with excellent
properties for laser cladding applications.
SF-0026.0 – Laser Cladding Repairs for Aero and IGT Applications
© 2020 Oerlikon Metco 2
Solution description and validation
1. The laser cladding process
n The laser beam is defocused on the workpiece
with a selected spot size
n Metal powder as the filler material is transferred
with an inert carrier gas into the melt pool
n The laser bean and the powder nozzle are
moved over the workpiece surface producing
single tracks, layers and build ups
Laser Beam Focal Point
Shielding Gas
Powder Feedstock
Overlay Deposit
Melt Pool
Base Material
2. Comparison of laser cladding to competing processes
Improvement Using
Overlay Process
Laser Cladding
PTA Welding Reduced heat input
Powder and Wire Lower dilution
GMAW / GTAW Reduced heat input
Solid and Cored Wire Lower dilution
Laser Cladding
Thermal Spray Lower porosity
Metallurgical bonding
Combustion / HVOF / EAW Higher deposit efficiency
Thermal Spray Reduced heat input
Spray and Fuse
Lower porosity Improved Process vs.
Higher deposit efficiency
GMAW / GTAW
HVOF: High Velocity Oxygen Fuel Spray; EAW: Electric Arc Wire Spray; GMAW: Gas Metal Arc Welding (MIG); GTAW: Gas Tungsten Arc Welding (TIG)
SF-0026.0 – Laser Cladding Repairs for Aero and IGT Applications
© 2020 Oerlikon Metco 3
3. Laser cladding applications
3.1 Blade tips with encapsulated CBN
Blades that run against ceramic abradable materials used in
the hot section of the engine for clearance control are gener-
ally tipped. The tipping materials consists of a matrix materi-
als that is matched to the composition of the blade and a
cutting material, such as Cubic Boron Nitride (CBN). The
CBN not only provides a cutting medium in the case of incur-
sion into the ceramic abradable, but it is also lubricious. Side View (blade face)
These properties protect the blace from damage.
The use of laser cladding to apply the blade tipping material
is more efficient and ensures a homogeneous distribution of
the CBN within the matrix.
Blade Tip
CBN encapsulated in metallic matrix
Bottom View (blade tip)
3.2 Turbine blade tip dimensional restoration
Using a contour scan to bring a blade back to dimensional
specifications via a laser cladding weld repair.
Left: Blade tip being repaired using laser cladding. Right: Structurally sound laser cladding weld build up of 8 mm)
SF-0026.0 – Laser Cladding Repairs for Aero and IGT Applications
© 2020 Oerlikon Metco 4
3.3 Seal rings 3.6 Multi-layer build up
Seal rings manufactured using laser cladding (also referred to Multiple layers of laser cladding can be used to repair com-
as Direct Metal Deposition or DMD) can have a large cost ponents where thicker deposits are needed. Hence, laser
savings compared to profile rolling and butt welding. cladding is an excellent choice to restore heavily damaged ar
areas on many types of components.
Strategies to repair substantial features of seal rings are also
performed, thereby salvaging components that would have
once been scrap. Areas repaired using laser cladding include
sealing faces, knife edges and snap diameters.
3.7 Feature additions
For some applications, laser cladding has proven to be a
cost-effective and technologically flexible process to add
structural features to a component. For example, laser clad-
ding has been used to create a grid pattern on turbine hot
section seal segments that helps to anchor and enhance
thermal barrier coatings.
Laser cladding restoration using MetcoClad 625 on the snap diameters of an
2. Laser clad MCrAlY 4. Thermal barrier
Inconel 625 aerospace gas turbine ring (prior to final machining).
used to apply the top coat applied
3D diamond grid using atmospheric
pattern plasma spray
3.4 Knife edges
Thin-walled areas, such as knife edge seals can be suc-
cess-fully restored thanks to the low heat input that results in
a minimal heat affected zone and the low dilution offered by
the laser cladding process. The near-net shape of the build-
up minimizes the finishing effort, saving time and cost for
post-deposition processing.
3.5 Thin walls
Thin-walled areas are effectively restored using laser cladding,
without part distortion and have a minimal heat-affected zone.
1. Seal segment base 3. MCrAlY bond coat
structure made by applied using HVOF
additive manufacturing spray to ensure
(Oerlikon AM) coating bonds to the
substrate
SF-0026.0 – Laser Cladding Repairs for Aero and IGT Applications
© 2020 Oerlikon Metco 5
3.8 Examples of aero and IGT applications for laser cladding repairs
Component Areas Repaired by Laser Cladding Substrate
Stator housing Ribs 410 SS
Bearing housing Seats Ti-6Al-4V
Compressor shafts Bearings
Guide vanes
Blades APU - 1st and 2nd stage turbine blades Multiple compositions of
Crack repairs - single crystal turbine blades forged and single crystal
Turbine “Z” notch - GE 90-115B 6th stage blades
Blade tipping
FOD (Foreign Object Damage) repairs
Combustion liners
Blisks Ti17, Ti-6Al-4V, Ti-6246
Compressor labyrinth Knife edges IN718
seal
Hot section seal Grid addition for thermal barrier MCrAlY
segments enhancement
Forged parts Dimensional correction on parts made Multiple material
smaller than specification requirements compositions
Cockpit window Ti-6Al-4V
frames
Wing box Ti-6Al-4V
Fasteners Ti-6Al-4V
Landing gear Ti-10V-2Fe-3Al Even complex blisks can be repaired
components with laser cladding
Track beams Ti-10V-2Fe-3Al
Exhaust and tail cones Ti-6Al-2Sn-4Zr-2Mo
Ducts Ti-15V-3Cr-3Sn-3Al
4. Laser cladding materials manufacturers our laser cladding materials in house using
Oerlikon Metco offers a range of materials designed for laser state of the art facilities and quality control. Our most popular
cladding applications. Oerlikon Metco engineers and laser cladding materials are listed in the table below.
4.1 Superalloys, steels and carbide materials
Product Name Material Type Application
Metco 1700A Hastelloy C276 Sour gas and halide corrosion resistance
Metco 1625B, Metco 1625F Inconel 625 Corrosion at extreme conditions, dimensional restoration
Metco 1220A, Metco 1220B Stellite 6 Resist siezing, galling, abrasion, adhesion and erosion; resistant to
thermal oxidation and oxidizing acids
Metco 1221A Stellite 21 Cavitation and galling resistance with superior corrosion resistance;
deposits nearly 100% dense
Metco 1223A Ultimet Wear and corrosion resistance; excellent work-hardening properties
MetcoClad 718 Inconel 718 Elevated corrosion and high strength at high temperatures,
dimensional restoration
MetcoClad 316L 316L Stainless Steel Corrosion, creep and rupture stress resistance
MetcoClad 52052 Spherical tungsten carbide and High hardness for high wear and erosion resistance
self-fluxing NiCr matrix
Metco 50075A Spherical tungsten carbide Hard face constituent for blending in customer’s matrix material, high
hardness for wear and slurry erosion
SF-0026.0 – Laser Cladding Repairs for Aero and IGT Applications
© 2020 Oerlikon Metco 6
Left: MetcoClad 50075A is a specialized spherical fused tungsten carbide that produces deposits with excellent properties for laser cladding and PTA.
Right: Metco 1221A is a high-temperature material that can be used for repair of gas turbine compressor blades that is similar to Stellite 21.
4.2 Laser clad superalloys deposit examples
Metco 1220B (composition similar to Stellite 6) Metco 1700A (composition similar to Hastelloy C276)
Characteristics Characteristics
Hardness 48 to 51 HRC Hardness 27 to 72 HRC
Abrasion resistance 65 to 75 mm3 vol. loss (ASTM G65-B) Abrasion resistance 85 to 90 mm3 vol. loss (ASTM G65-B)
Layer deposition Multiple layers are possible Layer deposition Multiple layers are possible
Cracking Crack-free deposition achievable Cracking Crack-free deposition achievable
Service features n Low frictional coefficient Service features n Highly versatile corrosion resistance
n Good combined resistance to abrasion n Excellent resistance to stress corrosion
and impact cracking
n Excellent cavitation and erosion protection n Excellent resistance to acids
n High corrosion and oxidation resistance n Strong resistance to salts
n Temperature up to 800 °C (1470 °F) n Good resistance to sulfide-induced stress
cracking
n Outstanding resistance to crevice and pit-
ting corrosion
SF-0026.0 – Laser Cladding Repairs for Aero and IGT Applications
© 2020 Oerlikon Metco 7
4.2 Titanium materials an angular/blocky particle morphology. The atomization pro-
Titanium is widely used in aerospace for its high strength-to- cesses, being somewhat more expensive, produces pow-
weight ratio, low density and corrosion resistance. A very ders with a spherical morphology.
thin, stable titanium oxide passive surface layer naturally
forms on all titanium material giving titanium its strong corro- The choice of powder manufacturing process has a distinct
sion resistance. However this very strong affinity for oxygen effect on the end result and can be critical to application suc-
combined with the powder particles’ high surface area to cess. Traditional titanium laser cladding processes have pre-
volume ratio makes titanium powder difficult and relatively viously used atomized titanium powders and systems en-
expensive to manufacture. closed inside a vacuum chamber to prevent excessive
oxidation of the titanium weld pool. Recent developments in
The two main processes for titanium powder manufacture laser cladding technology have demonstrated successful ti-
are the hydride-dehydride (HDH) process and the atomiza- tanium laser cladding using a duel-gas shield approach thus
tion process, which is the less expensive route that produces eliminating the need for a vacuum chamber. [1,2]
Left: Titanium manufactured using the HDH process characterized by a blocky/angular morphology. Right: Titanium manufactured using the atomization process
characterized by a spherical morphology.
4.2.1 Oerlikon Metco’s titanium portfolio for laser cladding
Oerlikon Metco currently offers both angular and spherical
CP Ti and Ti-6Al-4V powders for laser cladding applications.
Our standard products are shown in tables below, however
custom particle sizes are available upon request.
Product Name Chemistry Grade Particle Size (µm) Morphology
Metco 4012A Grade 1
CP Ti
Metco 4013A Grade 2 Blocky
-106 +45
Metco 4030C Grade 5 (HDH process)
Ti 6Al 4V
Metco 4032A Grade 23
Metco 4023B Grade 1
CP Ti
Metco 4024B Grade 2 Spherical
-106 +45
Metco 4031A Grade 5 (atomization process)
Ti 6Al 4V
Metco 4033A Grade 23
SF-0026.0 – Laser Cladding Repairs for Aero and IGT Applications
© 2020 Oerlikon Metco 8
4.2.2 Titanium deposit examples (current powder portfolio)
Oerlikon Metco working in collaboration with the ETH Zürich
have successfully applied angular and spherical commercial-
ly pure (CP) titanium and Ti-6Al-4V alloy powder in atmo-
sphere (no vacuum chamber) as shown in the following
images.
Single layer of a titanium clad deposit using HDH titanium powder without vacu-
um chamber. [1]
Four layers of titanium clad deposits without vacuum chamber. [2] Left: Deposit formed from HDH titanium powder. Right: Deposit formed from atomized titanium
powder.
4.2.3 New titanium powder materials
Oerlikon Metco growing portfolio of titanium powders is de- Samples of these angular titanium alloy powders can be re-
signed to meet the needs of the market. Currently, we are quested from your Oerlikon Metco Account Representative in
developing additional titanium alloy powders manufactured a standard particle size distribution of -106 +45 µm and de-
using the more cost-effective HDH process. When released signed to meet standard wrought chemistry specifications.
to the market, these products will be available in high vol- Most of these alloy powders have already been successfully
umes and competitively priced. tested using laser cladding without any vacuum chamber.
Coming Soon In Development
Ti 10V 2Fe 3Al (Ti 10 2 3) Ti 6Al 2Sn 4Zr 2Mo (Ti 6 2 4 2)
Ti 15Mo 3Nb 3Al (Ti 21S) Ti 15V 3Cr 3Sn 3Al (Ti 15 3 3 3)
Ti 3Al 8V 6Cr 4Mo 4Zr (Ti Beta C) Ti 5Al 2Sn 4Mo 2Zr 4Cr (Ti 17)
Four layers of a titanium clad deposit using angular/blocky Ti 15V 3C 3Sn 3Al
powder without vacuum chamber. [1]
SF-0026.0 – Laser Cladding Repairs for Aero and IGT Applications
© 2020 Oerlikon Metco 9
5. Laser cladding offerings
5.1 Materials and application equipment
As the worldwide leader in surface solution technologies,
Oerlikon Metco offers customers flexibility for their coating
implementation. Oerlikon Metco can provide the laser clad-
ding materials, or a complete coating facility solution that
consists of the laser cladding materials and state-of-the-art,
efficient, laser clad systems that are custom-designed for the
components to be coated. We can also provide technology
transfer that includes training and support for optimal and
consistent processing results.
5.2 Laser cladding from Metco Coating Services
However, not all customers desire such a solution. We there-
fore offer expert laser cladding application services through
our network of worldwide service centers. These service Make or buy: It’s your decision. User our expert laser cladding services or pur-
centers are well-respected for their attention to detail and chase tailored laser cladding materiasl and equipment technology.
quality of production.
We use the most modern techniques and processes at our
laser cladding facility to restore aerospace and IGT compo-
nents, including:
n In-house laboratories for repair investigation and
metallography
n Expert knowledge in materials combinations and process
control
n CAD-enabled processing
n Temperature control support
n Active cooling support
n Extensive experience in aerospace and IGT requirements,
including advanced substrate compositions and difficult
material combinations
n Highly experienced team for the entire process from initial
consultation through processing, quality control and CAD-enabled processing is just one of the ways we ensure reliable and and re-
post-service support producible deposition results with out laser cladding services
Production
Translation
Process
Strategy n Online application
n Translation into and laser cladding
Design
n Offline process machine-readable production of
simulation and program actual parts
n Offline
n 3D-design programming of optimization
component coating strategy
n 3D-design tools
Metco Coating Services process solution chain
SF-0026.0 – Laser Cladding Repairs for Aero and IGT Applications
© 2020 Oerlikon Metco 10One of Oerlikon Metco’s in-house laser cladding systems.. Laser cladding repair of a gas turbine compressor blade.
Customer Benefits
Excellent Value n Forged parts that were manufactured less than net size
n Our MetcoClad™ portfolio of powder materials are de- or shape can be dimensionally corrected using laser clad-
signed to the meet the exacting requirements needed for ding, saving cost and reducing scrap
laser cladding applications n Solutions available for customers who wish to apply coat-
n Our customers benefit from our worldwide support, from ings in-house or coating service solutions for customers
pre-sale consultation through on-going post-sale support who prefer to out-source
services n Our laser cladding services use advanced processing
techniques, in-house quality laboratories
Experience
n Oerlikon Metco has over 25 years experience with laser Effective
cladding and a highly experienced team n Laser cladding is a well-established process for the repair
n Oerlikon Metco has been a trusted supplier of materials and dimensional restoration of gas turbine components,
for demanding industries that include aerospace and allowing components that would have been scrapped to
power generation for more than 85 years be put back into service
n Our laser cladding services are active in several industries n Laser cladding is increasingly use as a low temperature
including gas turbine component repair process to apply functional deposits on advanced sub-
n Our complete portfolio of laser cladding powders ensures strates used in today’s gas turbines
the right material choice, whether for dimensional resto- n Displaces traditional high heat welding process with mini-
ration, wear resistance and/or corrosion resistance mal or no substrate deformation
n We continually expand our portfolio of laser cladding ma- n Wide choice of materials allows reproducible deposits to
terials to meet the expectations of our customers meet specific operating requirements, and can even im-
n Our laser cladding systems build on our long history of prove on the original component surface functionality
customization and integration, tailored to customer needs. n Oerlikon Metco’s state-of-the-art materials technology
and manufacturing capabilities allow us to develop new
Efficient laser cladding materials for specific applications
n Laser cladding is an excellent process for repair and di-
mensional restoration of components, saving costs and
valuable resources
SF-0026.0 – Laser Cladding Repairs for Aero and IGT Applications
© 2020 Oerlikon Metco 11References
1. “A Review of Laser Cladding/Direct Metal Deposition Op-
tions for Different Titanium Alloy Powders”, Colin Mc-
Cracken et. al., Oerlikon Metco, June 2018, San Antonio,
TX, POWDERMET2018.
2. “Reduction of the Oxygen Uptake in Laser Cladding Tita-
nium Alloys by a Duel Gas Strategy”, Jona Engal et. al.,
ETH Zürich, September 2019, Salt Lake City, UT,
PMTi2019.
The following brands are registered trademarks of their respective owners:
Hastelloy and Ultimet: Haynes International Incorporated
Inconel: Huntington Alloys Corporation
Stellite: Kennametal Incorporated
Metco and MetcoClad: Oerlikon Group:
Information is subject to change without prior notice.
SF-0026.0 – Laser Cladding Repairs for Aero and IGT Applications www.oerlikon.com/metco
© 2020 Oerlikon Metco info.metco@oerlikon.com
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