Method of repairing superalloy components using phase agglomeration

1. A method of repairing a superalloy component, the method comprising the following sequential steps:

(a) subjecting the superalloy component to a phase agglomeration cycle, the superalloy component comprising at least one repair area;

(b) applying weld material to the at least one repair area to create a weld surface;

(c) covering the weld surface with brazing material;

(d) subjecting the superalloy component to a braze cycle to produce a brazed component;

(e) cleaning the brazed component; and

(f) subjecting the cleaned component to a restorative heat treatment;

wherein step (a) includes heating the superalloy component to a first prescribed temperature, using a uniform ramp rate and one or more periods of holding the superalloy component at a plateau temperature; allowing the superalloy component to cool down at a prescribed cool-down rate to a second prescribed temperature; and performing forced cooling of the superalloy component to a third prescribed temperature;

wherein the step of heating the superalloy component comprises holding the superalloy component at the first prescribed temperature for a first prescribed period; and

wherein the step of heating the superalloy component to a first prescribed temperature comprises heating to a first plateau temperature, holding for a second prescribed period, heating to a second plateau temperature greater than the first plateau temperature, and holding for a third prescribed period longer than the second prescribed period and shorter than the first prescribed period; wherein the second plateau temperature is about 85% of the first prescribed temperature.

2. The method of claim 1 , wherein the superalloy component is comprised of a high gamma prime superalloy.

3. The method of claim 2 , wherein the high gamma prime superalloy comprises at least one of: B-1900, GTD-111, Inconel 100, Inconel 713, Inconel 738, Inconel 792, Inconel 939, MAR-M-246, MAR-M-509, Rene 77, Rene 108, Rene 125, U-500, CM 247, or Mar M 247.

4. The method of claim 1 , wherein the prescribed cool-down rate is between about 0.5° F. per minute and about 5° F. per minute.

5. The method of claim 1 , wherein the second prescribed temperature is between 65% and 70% of the first prescribed temperature; and wherein the third prescribed temperature is less than 10% of the first prescribed temperature.

6. The method of claim 1 , wherein step (a) further includes, after the forced cooling step, allowing the superalloy component to cool to ambient temperature.

7. The method of claim 1 , further comprising, prior to step (a), machining the at least one repair area to produce at least one surface on which the weld material is applied.

8. The method of claim 7 , further comprising, prior to step (b), applying a base layer of weld material to the at least one surface that has been machined.

9. The method of claim 1 , wherein step (b) occurs in an inert environment.

10. The method of claim 1 , wherein step (b) comprises welding a coupon of material into the at least one repair area.

11. The method of claim 1 , further comprising, after step (d), subjecting the brazed component to a hot isostatic pressure cycle in a vacuum furnace.

12. The method of claim 1 , further comprising, after step (d), blending the brazed areas to produce a smooth surface of the brazed component.

13. The method of claim 1 , wherein step (e) further comprises immersing the brazed component in a salt bath.

14. The method of claim 13 , wherein step (e) further comprises cleaning the brazed component with a fluoride ion cleaning process after immersing the brazed component in a salt bath.

15. The method of claim 1 , further comprising, after step (e), applying additional brazing material to the weld material and to any visible cracks; subjecting the brazed component with the additional brazing material to the braze cycle; and blending the brazed areas.

16. The method of claim 1 , further comprising, prior to step (f), performing a non-destructive inspection of the brazed component.

17. The method of claim 1 , further comprising, prior to step (f), applying a thermal barrier coating to the surface of the brazed component.