Laser powder deposition weld rework for gas turbine engine non-fusion weldable nickel castings
A method of reworking or repairing a component includes removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity that results in a through hole; sealing the through hole with a backing; and at least partially filling the cavity with a multiple of layers of a multiple of laser powder deposition spots, each of the multiple of laser powder deposition spots formed of a filler alloy, a first layer of the multiple of layers includes a perimeter of the multiple of laser powder deposition spots that overlap a wall of the cavity and the backing.
1. A method of reworking a component, comprising:
removing a defect from a component manufactured of a non-fusion weldable base alloy to form a cavity that results in a through hole;
sealing the through hole with a backing; and
at least partially filling the cavity with a multiple of layers of a multiple of laser powder deposition spots, each of the multiple of laser powder deposition spots formed of a filler alloy, a first layer of the multiple of layers includes a perimeter of the multiple of laser powder deposition spots that at least partially overlap a wall of the cavity and the backing.
2. The method as recited in claim 1 , wherein the first layer of the multiple of layers forms a complete perimeter formed prior to any other layers.
3. The method as recited in claim 2 , further comprising forming a desired surface roughness on the backing.
4. The method as recited in claim 3 , wherein the desired surface roughness on the backing provides about equal laser energy absorption between the backing and the wall.
5. The method as recited in claim 3 , wherein the desired surface roughness on the backing is at least about 125 micro inches (0.003 mm).
6. The method as recited in claim 3 , wherein the backing is between about 0.010 to 0.020 inches (0.254-0.508 mm).
7. The method as recited in claim 3 , wherein the backing is between about 0.010 to 0.020 inches (0.254-0.508 mm).
8. The method as recited in claim 1 , wherein the each spot in a layer is located between two spots from a prior layer.
9. The method as recited in claim 1 , wherein the filler alloy is a fusion weldable powder material.
10. The method as recited in claim 9 , wherein the non-fusion weldable base alloy is a high gamma prime nickel based alloy.
11. A method of reworking a component, comprising:
removing a defect from a component manufactured of a non-fusion weldable base alloy to form a cavity that results in a through hole;
forming a desired surface roughness on a backing;
sealing the through hole with the backing; and
at least partially filling the cavity with a multiple of layers of a multiple of laser powder deposition spots, each of the multiple of laser powder deposition spots formed of a filler alloy.
12. The method as recited in claim 11 , further comprising completely sealing the backing along a wall of the cavity and the backing.
13. The method as recited in claim 11 , wherein a first layer of the multiple of layers includes a perimeter of the multiple of laser powder deposition spots that overlap a wall of the cavity and the backing.
14. The method as recited in claim 13 , wherein the first layer of the multiple of layers forms a complete perimeter around an interface between the backing and the wall.
15. The method as recited in claim 11 , wherein the desired surface roughness on the backing provides about equal laser energy absorption between the backing and the wall.
16. The method as recited in claim 11 , wherein the each spot in a layer is located between two spots from a prior layer.
17. The method as recited in claim 11 , wherein the desired surface roughness on the backing is at least about 125 micro inches (0.003 mm).