Material deposition method for repairing aeronautical components

1 . A method for repairing an aeronautical component comprising a nickel-based alloy, the method comprising the following steps:

a) performing surface preparation on a damaged portion of the component; and

b) depositing a plurality of layers on the damaged portion of the component by cold spraying a powdered material by a non-oxidizing carrier gas,

wherein

the powdered material which is deposited is the same alloy as the nickel-based alloy comprised in the component to be repaired,

deposition is performed with pressure conditions between 40 and 80 bar and temperature conditions between 85° and 1100° C. of the carrier gas, and

step b) comprises:

depositing an anchoring layer of the plurality of layers with first pressure and temperature conditions of the carrier gas; and

depositing at least one growth layer of the plurality of layers on the anchoring layer with second pressure and temperature conditions of the carrier gas,

wherein the first pressure and temperature conditions are different from the second pressure and temperature conditions, and

wherein the second pressure and temperature conditions are 65-75 bar and 1000-1100° C.

2 . The method according to claim 1 , further comprising depositing a plurality of growth layers.

3 . The method according to claim 2 , wherein depositing the plurality of growth layers comprises depositing at least four growth layers.

4 . The method according to claim 1 , wherein step a) comprises machining and/or cleaning the surface of the damaged portion of the component and/or providing roughness to said surface.

5 . The method according to claim 4 , wherein the roughness is provided by abrasion.

6 . The method according to claim 1 , further comprising applying a protective surface layer for protection against corrosion, wear, and/or impact on at least the damaged portion of the component after step b).

7 . The method according to claim 6 , wherein the application of the protective surface layer comprises coating at least the damaged portion of the component with aluminum.

8 . The method according to claim 6 , further comprising performing a heat treatment on the damaged portion of the component in temperature conditions between 800 and 1340° C. after the application of the protective surface layer.

9 . The method according to claim 1 , further comprising performing a heat treatment on the damaged portion of the component in temperature conditions between 800 and 1340° C. after step b).

10 . The method according to claim 1 , further comprising performing non-destructive tests on the damaged portion of the component to check a condition thereof.

11 . The method according to claim 1 , wherein in step b) deposition is performed at a distance of 15-40 mm from the surface of the damaged portion of the component.

12 . The method according to claim 11 , wherein in step b) deposition is performed at a distance of 25 mm from the surface of the damaged portion of the component.

13 . The method according to claim 1 , wherein the powdered material has a particle size comprised between 10 and 75 μm.

14 . The method according to claim 1 , wherein in step b) the first pressure and temperature conditions are 40-70 bar and 1000-1100° C.

15 . The method according to claim 1 , wherein the nickel-based alloy is one of the following: MAR-M247, CM247LC, or CMSX-4,

wherein MARM-247 comprises the following elements expressed as % by weight: 0.13-0.17% carbon, 8-8.80% chromium, 9-11% cobalt, 0.5-0.8% molybdenum, 9.75-10.25% tungsten, 2.8-3.1% tantalum, 5.35-5.65% aluminum, 0.9-1.2% titanium, 0.01-0.02% boron, 0.03-0.06% zirconium, and 1.4-1.6% hafnium,

wherein CM247LC comprises the following elements expressed as % by weight: 0.07-0.08% carbon, 8-8.5% chromium, 9.0-9.4% cobalt, 0.4-0.6% molybdenum, 9.3-10% tungsten, 3.1-3.3% tantalum, 5.4-5.7% aluminum, 0.6-0.9% titanium, 0.010-0.018% boron, 0.006-0.015% zirconium, and 1.3-1.6% hafnium, and

wherein CMSX-4 comprises the following elements expressed as % by weight: 6.0-6.6% chromium, 9.0-10% cobalt, 0.5-0.7% molybdenum, 6.0-6.6% tungsten, 6.3-7.0% tantalum, 5.40-5.75% aluminum, 0.9-1.1% titanium, 0.07-0.12% hafnium, and 2.8-3.1% rhenium.

16 . The method according to claim 1 , wherein the nickel-based alloy further comprises one or more of the following elements: tungsten, cobalt, chromium, aluminum, molybdenum, tantalum, titanium, hafnium, carbon, boron, and zirconium.

17 . The method according to claim 1 , wherein the nickel-based alloy comprises up to 0.2% carbon, 5-14% chromium, 5-15% cobalt, up to 4% molybdenum, up to 12% tungsten, up to 12% tantalum, up to 1% vanadium, up to 1% niobium, 3-6% aluminum, up to 5% titanium, up to 2% hafnium, up to 0.02% boron, up to 0.06% zirconium, and up to 3.1% rhenium.

18 . The method according to claim 1 , wherein the first pressure and temperature conditions are 45-70 bar and 850-1100° C.