High entropy alloy repair of nickel and cobalt superalloys
A method for repairing damage at a damage site on the surface of a nickel- or cobalt-based alloy. The method includes: machining at the damage site; and applying a high entropy alloy (HEA) repair material to the damage site via high velocity oxy-fuel (HVOF) spray, high velocity air-fuel (HVAF) spray, or cold spray.
1 . A method for repairing damage at a damage site on the surface of a nickel- or cobalt-based alloy component, the method comprising:
machining at the damage site; and
applying a high entropy alloy (HEA) repair material to the damage site via high velocity oxy-fuel (HVOF) spray, high velocity air-fuel (HVAF) spray, or cold spray,
wherein the repair material comprises in atomic percent:
16.0 to 25.0 Fe;
16.0 to 25.0 Co;
16.0 to 25.0 Cr;
16.0 to 25.0 Mn; and
16.0 to 25.0 Ni.
2 . The method of claim 1 wherein:
the applying is via HVOF.
3 . The method of claim 1 wherein:
the surface is full annulus or a sector of an annulus; and
the applying is only to a partial circumferential extent of said full annulus or sector.
4 . The method of claim 1 wherein:
the surface is an inner diameter surface.
5 . The method of claim 1 wherein:
the surface is an axial end surface of a groove.
6 . The method of claim 1 wherein:
the surface is an axial end surface of a radial tab.
7 . The method of claim 1 wherein:
the surface is an inner diameter surface of a mounting pin socket.
8 . The method of claim 1 wherein the repair material comprises in atomic percent:
no more than 1.0 other individually and 5.0 other total.
9 . The method of claim 8 wherein:
the repair material is applied to a thickness of at least 0.50 millimeter;
a powder feed rate of the HVOF spray is 40 g/min. to 50 g/min.; and
a rate of oxygen is 100% to 250% a rate of fuel in the HVOF spray, measured in LPM.
10 . The method of claim 1 wherein:
the repair material is applied to a thickness of at least 0.50 millimeter.
11 . The method of claim 10 wherein the repair material comprises by atomic percent:
no more than 1.0 other individually and 5.0 other total.
12 . The method of claim 1 wherein one or more of:
the repair material is applied to a thickness of at least 0.50 millimeter;
a powder feed rate of the HVOF spray is 40 g/min. to 50 g/min.; and
a rate of oxygen is 100% to 250% a rate of fuel in the HVOF spray, measured in LPM.
13 . The method of claim 1 further comprising:
surface finishing to remove excess repair material;
disengaging the surface of the component from a second component prior to the machining; and
after the applying, reengaging the surface of the component to the second component or to a replacement second component, wherein the reengaging or engaging is without any further thermal sprayed coating atop the repair material.
14 . The method of claim 1 wherein the component is a first component of a gas turbine engine, the gas turbine engine comprising:
one or more compressor sections;
a combustor;
one or more turbine sections; and
a gaspath passing through the one or more compressor sections, the combustor section, and the one or more turbine sections,
wherein:
the first component is sealed to a second component by a seal;
the first component has a substrate;
the substrate has a recess to which the repair material is applied; and
a contact area between the seal and the first component includes the repair material and an adjacent surface of the substrate.
15 . The method of claim 14 wherein:
the contact area is at least 355° and 1° to 5° of that is with the repair material.
16 . The method of claim 14 wherein:
the repair material has a thickness of 0.30 mm to 2.0 mm.
17 . The method of claim 14 wherein the repair material comprises in atomic percent:
no more than 1.0 other individually and 5.0 other total.
18 . The method of claim 17 wherein:
the repair material has a thickness of 0.30 mm to 2.0 mm.
19 . The method of claim 14 wherein:
the second component has a radially outwardly open groove axially capturing the seal and the first component encircles the seal; or
the first component has a radially outwardly open groove axially capturing the seal and the second component encircles the seal.
20 . The method of claim 14 wherein:
the first component comprises a counterface of the seal; and
the seal is selected from the group consisting of piston seal rings, brush seals, and finger seals.
21 . The method of claim 1 wherein the component has:
a contact surface for contacting another component; and
the machining forms:
a recess at the contact surface to which the repair material is applied.
22 . The method of claim 21 wherein at least one of:
the component is in a gas turbine engine comprising: one or more compressor sections; a combustor; one or more turbine sections; and a gaspath passing through the one or more compressor sections, the combustor section, and the one or more turbine sections;
the another component is a seal or a locating pin; and
the contact area between the component and the another component includes the HEA-repair material and an adjacent surface of a substrate of the first component.