Coating processes – Restoring or repairing – Metal article
Reexamination Certificate
2006-08-22
2006-08-22
Meeks, Timothy (Department: 1762)
Coating processes
Restoring or repairing
Metal article
C427S009000, C427S402000, C427S405000
Reexamination Certificate
active
07094444
ABSTRACT:
According to an embodiment of the invention, a method for repairing a coated high pressure turbine blade, which has been exposed to engine operation, to restore coated airfoil contour dimensions of the blade, and improve upon the prior bond coat is disclosed. The method comprises providing an engine run high pressure turbine blade including a base metal substrate made of a nickel-based alloy and having thereon a thermal barrier coating system. The thermal barrier coating system comprises a diffusion bond coat on the base metal substrate and a top ceramic thermal barrier coating comprising a yttria stabilized zirconia material. The top ceramic thermal barrier coating has a nominal thickness t. The method further comprises removing the thermal barrier coating system, wherein a portion of the base metal substrate also is removed, and determining the thickness of the base metal substrate removed. The portion of the base metal substrate removed has a thickness, Δt. The method also comprises applying a β phase NiAl overlay coating to the substrate, and determining the difference in thickness, Δx, between the β phase NiAl overlay coating and the previously removed bond coat. The method further comprises reapplying the top ceramic thermal barrier coating to a nominal thickness of t+Δt−Δx, wherein Δt compensates for the portion of removed base metal substrate. Advantageously, the coated airfoil contour dimensions of the high pressure turbine blade are restored to about the coated dimensions preceding the engine run.
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Darolia Ramgopal
Lee Ching-Pang
Rigney Joseph D.
General Electric Company
Harrington & Smith ,LLP
Meeks Timothy
Turocy David
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