Methods for forming or repairing parts with overhanging sections and related turbine parts

Abstract

A method for forming or repairing a part having an overhanging section. The method may include removing a portion and adding a section to the part. The section includes the overhanging section. Adding includes sequentially layering at least one or more material layers onto the part, the at least one or more material layers approximating the dimensions of the section including the overhanging section. Sequential layering may be performed in various ways, such as laser welding, and may produce various layers within the overhanging section. The method may include machining at least one or more material layers to form the section including the overhanging section.

Description

Technical Field

[0001] This disclosure relates generally to the manufacture and repair of parts, and more specifically to methods for forming or repairing turbine parts (such as turbine blades) having overhanging sections. Background Technology

[0002] Industrial parts may include portions that overhang other sections of the part. These overhanging sections may need to be added during manufacturing or repaired after a period of use. An illustrative application includes the expanded tips of turbine blades, such as those available from General Electric Co., Schenectady, New York. The expanded tips of the turbine blades include airfoils having pressure and suction sides joined along their leading and trailing edges. The expanded tips are attached to the radially outer end of the airfoil and may extend circumferentially beyond the pressure and / or suction sides of the airfoil, i.e., using the turbine's axis as a reference. Conventional unexpanded turbine blades require, for example, two-dimensional stacking of material in the vertical or radial directions using casting or additive manufacturing. To manufacture the expanded tips of turbine blades, material is added in both the circumferential and radial directions. Repairing the expanded tips of turbine blades is currently not possible, therefore they are replaced. Similar situations coexist with other turbine hot gas path components and other industrial parts with overhanging sections. Summary of the Invention

[0003] One aspect of this disclosure provides a turbine component comprising: a body having a first side, a second side, and a longitudinal axis; and an overhanging section extending overhangingly from at least one of the first side and the second side of the body, wherein at least a portion of the overhanging section comprises a plurality of material layers, wherein each material layer extends at an acute angle relative to the longitudinal axis of the body.

[0004] Another aspect of this disclosure relates to a method comprising: adding a segment to a part, the segment including an overhanging segment, the addition comprising sequentially layering a plurality of material layers on a surface of the part, the plurality of material layers approximating the dimensions of the segment including the overhanging segment; and machining the plurality of material layers to form the segment including the overhanging segment.

[0005] One aspect of this disclosure relates to a method of forming an overhanging section on a part, the method comprising: forming a surface on the part at an angle neither perpendicular to nor parallel to a target external flat surface of the overhanging section; sequentially layering a plurality of material layers on the part, the plurality of material layers approximating the dimensions of the overhanging section; and machining the plurality of material layers to form the overhanging section and the target external flat surface, the target external flat surface being at an angle relative to the plurality of material layers.

[0006] One aspect of this disclosure provides a turbine component comprising: a body having a first side, a second side, and a longitudinal axis; and an overhanging section extending overhangingly from at least one of the first side and the second side of the body, wherein at least a portion of the overhanging section comprises a plurality of material layers, wherein each material layer extends at a perpendicular angle relative to the longitudinal axis of the body.

[0007] Another aspect of this disclosure includes a turbine component comprising: a body having a first side and a second side; and an overhanging section extending overhangingly from at least one of the first side and the second side of the body, wherein at least a portion of the overhanging section comprises a first plurality of material layers extending in a first direction and a second plurality of material layers extending in a second direction, the second direction being non-coplanar with respect to the first plurality of material layers.

[0008] One aspect of this disclosure relates to a method comprising: adding a segment to a part, the segment including an overhanging segment, the addition comprising: sequentially layering a first plurality of material layers extending in a first direction onto the part; and sequentially layering a second plurality of material layers extending in a second direction other than the first direction onto the part; the second plurality of material layers intersecting with the first plurality of material layers, wherein the first plurality of material layers and the second plurality of material layers together approximate the dimensions of the segment including the overhanging segment and are non-coplanar relative to each other; and machining the first plurality of material layers and the second plurality of material layers to form the segment including the overhanging segment.

[0009] The exemplary aspects of this disclosure are designed to address the problems described herein and / or other problems not discussed herein. Attached Figure Description

[0010] These and other features of the present disclosure will be more readily understood from the following detailed description of various aspects of the present disclosure in conjunction with the accompanying drawings depicting various embodiments thereof, wherein:

[0011] Figure 1 This is a schematic diagram of an exemplary industrial application in the form of a gas turbine according to an embodiment of the present disclosure, the gas turbine including turbine components having overhanging sections such as expanded top guides.

[0012] Figure 2 yes Figure 1 A cross-sectional view of the compressor section of the gas turbine;

[0013] Figure 3 yes Figure 1 A cross-sectional view of the turbine section of a gas turbine;

[0014] Figure 4 It is a perspective view of an exemplary turbine component in the form of a turbine rotor blade, which has an expanded tip guide.

[0015] Figure 5 A cross-sectional view of an exemplary overhang section in the form of an expanded top rail is shown, which includes the portion to be removed and the line to be removed.

[0016] Figure 6 It shows the removal Figure 5 The part is a cross-sectional view of the component after the surface is generated, and the new overhanging section will be built on this surface;

[0017] Figure 7 A cross-sectional view showing multiple material layers sequentially layered on the surface of a part is shown;

[0018] Figure 8 An enlarged cross-sectional view of multiple material layers is shown, each layer consisting of a series of solder beads;

[0019] Figure 9 A schematic plan view of a series of solder beads in two material layers extending in different directions is shown;

[0020] Figure 10 Machining is shown Figure 7 The parts are used to form a cross-sectional view of the new overhang section;

[0021] Figure 11 A cross-sectional view of an overhanging section in the form of an expanded top rail is shown, which includes the portion to be removed and the line to be removed.

[0022] Figure 12 It shows the removal Figure 11 The part is rotated and the surface is generated by creating a cross-sectional view of the part, on which the new overhanging section will be constructed;

[0023] Figure 13A This illustrates the sequential layering of multiple material layers in a substantially horizontal position. Figure 12 A cross-sectional view of the surface of the part;

[0024] Figure 13B It shows the relationship with Figure 13A Cross-sectional view of multiple material layers sequentially layered on a surface at different rotation angles;

[0025] Figure 14 Machining is shown Figures 13A to 13B The parts are used to form a cross-sectional view of the new overhang section;

[0026] Figure 15This illustrates the sequential layering of a first plurality of material layers in a first direction. Figure 6 A cross-sectional view of the first surface of the part;

[0027] Figure 16 It shows the removal Figure 6 The part and optionally the two surfaces after which a cross-sectional view of the part is generated, and the new overhanging section will be built on these two surfaces;

[0028] Figure 17 A cross-sectional view of the part is shown after the part has been rotated and the first multiple material layers have been layered.

[0029] Figure 18A A cross-sectional view is shown showing a second plurality of material layers sequentially layered on a second surface of a part in a second direction;

[0030] Figure 18B A cross-sectional view is shown showing a second plurality of material layers sequentially layered on a second surface of a part in a second direction;

[0031] Figure 18C The diagram shows a cross-sectional view of a part after the first and second material layers have been sequentially layered onto the part between rotations.

[0032] Figure 18D A cross-sectional view is shown showing multiple layers of material sequentially layered on a part at a non-perpendicular angle;

[0033] Figure 18E A cross-sectional view is shown showing multiple layers of material sequentially layered on a part at a non-perpendicular angle;

[0034] Figure 19 A cross-sectional view is shown of a stepped extension formed by sequentially layering a plurality of material layers on a first surface of a part in a first direction.

[0035] Figure 20 The following is shown after the part was rotated. Figure 19 A sectional view of the part;

[0036] Figure 21 This illustrates the sequential layering of a second plurality of material layers in a second direction. Figure 20 A cross-sectional view on the second surface of the part;

[0037] Figure 22 Machining is shown Figure 21 The parts are used to form a cross-sectional view of the new overhang section;

[0038] Figure 23A cross-sectional view of a pair of overhanging sections in the form of double-expanded top rails is shown in an exemplary part, the double-expanded top rails including the portion to be removed and the intended removal line;

[0039] Figure 24 A cross-sectional view of an exemplary overhanging section in the form of inwardly extending, double-expanding top guide rails is shown; and

[0040] Figure 25 A cross-sectional view of an exemplary overhanging section in the form of an expanded top guide rail is shown, having a portion to be removed and the part rotated at a predetermined angle to form an inclined build surface; and

[0041] Figure 26 A cross-sectional view is shown showing multiple layers of material sequentially layered on an inclined surface of a part.

[0042] It should be noted that the accompanying drawings of this disclosure are not necessarily drawn to scale. The drawings are intended to depict only typical aspects of this disclosure and should therefore not be considered as limiting the scope of this disclosure. In the drawings, similar numbers denote similar elements between figures. Detailed Implementation

[0043] Various aspects and advantages of this application are set forth in the following description, or may be apparent from the description, or may be learned by practice of this disclosure. Reference will now be made in detail to embodiments of this disclosure, one or more examples of which are illustrated in the accompanying drawings. Numerical designations are used to refer to features in the drawings in the detailed description. It should be understood that each example is provided in a manner that interprets this disclosure, and not as a limitation thereof. Indeed, it will be apparent to those skilled in the art that modifications and variations may be made to this disclosure without departing from the scope or spirit of this disclosure. For example, a feature shown or described as part of one embodiment may be used in another embodiment to produce yet another embodiment. This disclosure is intended to cover such modifications and variations that fall within the scope of the appended claims and their equivalents. Certain terms have been chosen to describe this disclosure and its constituent subsystems and parts. To the extent possible, these terms have been chosen based on general terminology in the technical field. Nevertheless, it should be understood that such terms may often have different interpretations. For example, something that may be referred to herein as a single component may elsewhere be referred to as consisting of multiple components, or something that may be referred to herein as comprising multiple components may elsewhere be referred to as a single component. Therefore, in understanding the scope of this disclosure, attention should be paid not only to the specific terminology used, but also to the appended description and context, and to the structure, construction, function, and / or use of the referenced and described components, including the way the terminology is associated with the several drawings, and the precise use of the terminology in the appended claims. Furthermore, although the examples below are presented as illustrative applications relating to turbine blades in compressors or turbines of gas turbine systems, the technology of this application is also (without limitation) applicable to other classes of turbines, and a wide range of other industrial parts, as will be understood by those skilled in the art.

[0044] Given the substance of how a gas turbine operates, certain terms prove particularly useful in describing certain aspects of its function and advantageous in describing the disclosed methods. As will be understood, these terms can be used both to describe a gas turbine or one of its subsystems (e.g., a compressor, burner, or turbine) and to describe or claim protection for components or sub-components used therein. In the latter case, the terms should be understood to describe those components that will be properly installed and operated within the gas turbine engine or main subsystem. Unless otherwise specifically stated, these terms and their definitions are as follows.

[0045] The terms “forward” and “rearward” refer to directions relative to the orientation of the gas turbine, and more specifically, to the relative positioning of the compressor section and turbine section of the engine. Thus, as used herein, the term “forward” refers to the compressor end, and “rearward” refers to the turbine end. It should be understood that each of these terms can be used to indicate a direction of movement or relative position along the central axis of the engine. As mentioned above, these terms can be used to describe the properties of a gas turbine or a major subsystem thereof, as well as the components or sub-components located therein. Thus, for example, when a component such as a turbine blade is described or claimed to have a “forward face,” it can be understood to refer to a face facing the forward direction as defined by the orientation of the gas turbine (i.e., the compressor is specified towards the front end and the turbine towards the rear end). Consider a similar turbine-like major subsystem as another example (and assume a typical gas turbine arrangement, such as…). Figure 1 (As shown in one arrangement), the forward and backward directions can be defined relative to the front end and rear end of the turbine, where the working fluid enters the turbine at the front end and exits the turbine at the rear end.

[0046] The terms “downstream” and “upstream” are used herein to indicate a position within a specified duct or flow path relative to the direction (hereinafter “flow direction”) of the flow moving through that duct or flow path. Thus, “downstream” refers to the direction in which fluid flows through a specified duct, while “upstream” refers to the opposite direction. These terms should be interpreted as referring to the flow direction through the duct under given normal or intended operation. Given the construction of a gas turbine, particularly the arrangement of the compressor and turbine sections around a common shaft or rotor, and the cylindrical construction common to many burner types, terms describing position relative to the axis are used regularly herein. In this regard, it should be understood that the term “radial” refers to movement or position perpendicular to the axis. Relatedly, it may be necessary to describe the relative distance from the central axis. In this case, for example, if the first component is closer to the central axis than the second component, the first component will be described as “radially inward” or “inner” of the second component. On the other hand, if the first component is further away from the central axis, the first component will be described as “radially outward” or “outer” of the second component. As used herein, the term “axial” refers to movement or position parallel to an axis, while the term “circumferential” refers to movement or position about an axis. Unless otherwise stated or clearly indicated by the context, these terms should be interpreted in relation to the central axis of the compressor section and / or turbine section of the gas turbine (as defined by the rotor extending through each), even if these terms describe or claim protection for the properties of non-integral components such as rotor or stator blades operating therein.

[0047] Unless otherwise specified, the term "turbine blade" or "blade" refers to the rotating blade of a compressor or turbine, and therefore may include both compressor rotor blades and turbine rotor blades, and may also refer to the stationary blade of a compressor or turbine, and therefore may include both compressor stator blades and turbine stator blades. The term "blade" can be used to generally refer to any type of blade. Therefore, unless otherwise specified, the term "turbine blade" or "blade" includes all types of turbine engine blades, including compressor rotor blades, compressor stator blades, turbine rotor blades, turbine stator blades, etc.

[0048] In addition, several descriptive terms may be used regularly in this document, as described below. The terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of a single component.

[0049] As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that, when used in the specification, the terms “comprising” and / or “including” specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. “Optional” or “optionally” means that the event or condition subsequently described may or may not occur, or that the component or element subsequently described may or may not be present, and the description includes instances where the event occurs or the component is present and instances where the event does not occur or the component is not present.

[0050] When an element or layer is referred to as “on another element or layer,” “attached to another element or layer,” “connected to another element or layer,” or “linked to another element or layer,” it may be directly on, attached to, connected to, or linked to another element or layer, or an intervening element or layer may be present. In contrast, when an element is referred to as “directly on another element or layer,” “directly attached to another element or layer,” “directly connected to another element or layer,” or “directly linked to another element or layer,” an intervening element or layer may not be present. Other terms used to describe the relationship between elements should be interpreted in a similar manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0051] With reference to the background art, please now refer to the accompanying drawings for details. Figures 1 to 3An exemplary gas turbine is shown that can be used therein, or a turbine component thereof, according to this disclosure. Figure 1 This is a schematic diagram of a gas turbine 10. Generally speaking, a gas turbine operates by extracting energy from a pressurized stream of hot gas, which is generated by the combustion of fuel in a compressed air feed stream. For example... Figure 1 As shown, the gas turbine 10 can be configured to have an axial-flow compressor 12 mechanically connected to a downstream turbine section or turbine 14 via a common shaft or rotor, and a combustor 16 positioned between the compressor 12 and the turbine 14. Figure 1 As shown, the gas turbine 10 can be formed around a common central axis 18.

[0052] Figure 2 It shows that it can be used Figure 1 A view of an exemplary multi-stage axial compressor 12 in a gas turbine 10. As shown, the compressor 12 may have multiple stages, each stage including a row of compressor rotor blades 20 and a row of compressor stator blades 22. Thus, the first stage may include a row of compressor rotor blades 20 rotating about a central axis, followed by a row of compressor stator blades 22 that remain stationary during operation. Figure 3 It shows that it can be used Figure 1 A partial view of an exemplary turbine section or turbine 14 in a gas turbine 10. Turbine 14 may also include multiple stages. Three exemplary stages are shown, but more or fewer stages may be present. Each stage may include multiple turbine nozzles or stator blades 24 that remain stationary during operation, followed by multiple turbine buckets or rotor blades 26 that rotate about a shaft during operation. The turbine stator blades 24 are generally circumferentially spaced from each other and fixed to an outer housing about an axis of rotation. The turbine rotor blades 26 may be mounted on a turbine impeller or disc (not shown) to rotate about a central axis. It should be understood that the turbine stator blades 24 and turbine rotor blades 26 are located in a hot gas path or working fluid flow path through turbine 14. The direction of flow of combustion gas or working fluid within the working fluid flow path is indicated by arrows.

[0053] In one example of the operation of the gas turbine 10, the compressor rotor blades 20 rotate within an axial compressor 12 to compress the airflow. In the combustor 16, energy is released when the compressed air is mixed with fuel and ignited. The resulting flow of hot gas or working fluid from the combustor 16 is then directed through the turbine rotor blades 26, causing the turbine rotor blades 26 to rotate about a shaft. In this way, the energy of the working fluid flow is converted into the mechanical energy of the rotating blades, and, given the connection between the rotor blades and the shaft, into the mechanical energy of the rotating shaft. The mechanical energy of the shaft can then be used to drive the rotation of the compressor rotor blades 20, enabling the necessary supply of compressed air and / or, for example, generating electricity through a generator.

[0054] For background art purposes, Figure 4 A perspective view of an exemplary part 28 having an overhanging section 30 is provided. For descriptive purposes, part 28 is shown as an expanded tip turbine blade 25, and more specifically as a turbine rotor blade 26. It should be noted that, in addition to the turbine blade 25 as described herein, the teachings of this disclosure are also applicable to any part 28 having an overhanging section 30, such as any other hot gas path (HGP) part of the gas turbine 10. The teachings of this disclosure are also applicable to other industrial parts having overhanging sections.

[0055] Turbine blade 25 may include a root 31 configured for attachment to a turntable. The root 31 may include, for example, a dovetail 32 configured to fit into a corresponding dovetail slot in the periphery of the turntable. The root 31 may further include a shank 34 extending between the dovetail 32 and a platform 36. As shown, the platform 36 typically forms the junction between the root 31 and the airfoil 40, wherein the airfoil is the active component of the turbine rotor blade 26 that intercepts the working fluid flow through the turbine 14 and causes the desired rotation. The platform 36 may define an inner end of the airfoil 40. The platform 36 may also define a section extending through the inner boundary of the working fluid flow path of the turbine 14.

[0056] The airfoil 40 of a turbine blade typically includes a concave pressure surface 42 and circumferentially or laterally opposed convex suction surfaces 44. The pressure surface 42 and suction surface 44 may extend between opposing leading edges 46 and trailing edges 48, respectively, and axially in the radial direction between an inner end and an outer tip, the inner end being defined at a junction with a platform 36, and the outer tip including an expanded tip guide. The airfoil 40 may include a curved or wavy shape designed to promote desired aerodynamic performance.

[0057] As used herein, turbine blades 25 and their components can be described according to the orientation characteristics of turbine 14. It should be understood that, in this context, it is assumed that turbine blades 25 are properly mounted within turbine 14. Such orientation characteristics may include relative to the central axis 18 of turbine 14 (…). Figure 1 The radial, axial, and circumferential directions are defined. The forward and rearward directions are defined relative to the front and rear ends of the turbine 14, where the working fluid enters the turbine 14 from the combustor 16 and exits the turbine 14 from the rear ends. The rotational direction is defined relative to the turbine blades 25 around the central axis 18 of the turbine 14 during operation. Figure 1 The expected rotation direction is used to define it.

[0058] As described above, this disclosure provides a method for forming or repairing a part 28 having, for example, an overhanging segment 30 at the extended tip of a turbine blade 25. For repair purposes, the method may include removing a portion and adding a segment to the part. For the purpose of initially forming part 28, the method may add a segment to a portion of an already formed part 28. In any case, the added or formed segment includes the overhanging segment. Addition includes sequentially layering one or more layers of material onto the part. When completed, the multiple layers of material approximate the size of the segment including the overhanging segment. Sequential layering may include, for example, laser welding, cold metal transfer (CMT), tungsten inert gas (TIG) welding, laser sintering, direct metal laser melting (DMLM), net-forming methods, near-net-shape methods, etc., and may be performed in various ways to produce various layers within the segment. The method and the resulting part may be formed by a net-forming method that minimizes or eliminates post-build treatments or finishing. The method may include machining at least one or more layers of material to form the segment including the overhanging segment.

[0059] Figure 5 An enlarged cross-sectional view of a used part 28 according to an embodiment of the present disclosure is shown, the used part having a body 60 having a first side 62 and an opposing second side 64. The body 60 may also have a longitudinal axis 75. The longitudinal axis may be any reference axis of the body 60, for example, passing through its length. With regard to the airfoil 40, when the airfoil is positioned on the gas turbine 10 ( Figure 1 In this case, the longitudinal axis can be a radial axis. The overhanging section 30 extends overhangingly from, for example, a first side 62 of the body 60. The overhanging section 30 does not contain vertical structural supports in a portion thereof. In one embodiment, the overhanging section 30 is opposite to a opposing member 66 on a second side 64 of the body 60 and has a greater mass than the opposing member 66. In the example shown, part 28 includes a turbine blade 25 comprising an expanded top guide 70 that overhangs on the first side 62 above, for example, the suction surface 44 of the blade. Therefore, the expanded top guide 70 is the overhanging section 30 of part 28. Figure 4 Example of a gas turbine 10. The body 60 includes an airfoil 40, and an expanded tip guide 70 is opposed to a counter member 66, which extends from one end of the airfoil 40 in the form of a radially extending tip guide 134. The expanded tip guide 70 is positioned relative to the axis 18 of the gas turbine 10. Figure 1 Extending circumferentially. In other embodiments, the overhanging section 30 may be opposite another overhanging section (e.g., an extended top guide 70) that may have or may not have a different mass and extends around the periphery of the airfoil 40—see, for example Figure 23 and Figure 24 .

[0060] The damaged overhang may include the overhanging extended top guide 70, i.e., the overhanging extended top guide without structural support. Part 72 may include any structure that is to be removed, and may include parts that are not damaged or parts that have various types of damage, such as, but not limited to, worn surfaces, cracks, openings, roughness, etc. In this case, such as Figure 6 As shown, portion 72 can be removed from part 28 to create surface 74 on the part (e.g., on turbine blade 25). Portion 72 may also be defined by surface / line 74a, wherein the removed portion is deeper and extends into a non-expanding section of the suction surface 44. Portion 72 can be removed using any technique now known or developed hereafter, including but not limited to: electrical discharge machining (EDM), mechanical cutting / grinding, laser cutting, etc. Figure 6 As shown, while some remnants of the expanded top guide 70 may or may not be retained, portion 72 is removed to form surface 74, on which the removed segment can be reformed. Surface 74 may be flat, curved, or have a three-dimensional shape or contour. Also as... Figure 6 As shown, in one embodiment, the angle of surface 74 can be substantially horizontal, i.e., with the body in a vertical position—the longitudinal axis 75 is vertical. As will be described herein, surface 74 can also be formed at a non-horizontal angle, and the part can be rotated as needed to allow the formation of new layers. In one non-limiting example, at most half of the expanded top guide 70 is removed, for example, based on the removal of at most half of portion 72. In another non-limiting example, more than half of the expanded top guide 70 is removed, for example, based on the removal of more than half of portion 72.

[0061] Embodiments of this disclosure may also include the initial fabrication of the expanded top guide 70. In this case, as... Figure 6 As shown, the starting structure can be manufactured using any suitable techniques for the materials and structures being constructed. Non-limiting examples may include casting and additive manufacturing. In any case, surface 74 is generated, on which the overhanging section will be constructed.

[0062] Figure 7A cross-sectional view is shown showing the addition of segment 76 to part 28, where segment 76 includes a new overhanging segment 78. The addition involves sequentially layering multiple material layers 82 onto part 28, specifically onto surface 74. When completed, the multiple material layers 82 collectively approximate the size of the segment including the new overhanging segment 78. That is, the added segment approximates the size of the new overhanging segment 78 or the portion 72 that is to be replaced. As used herein, “approximate size” generally indicates that the new overhanging segment 78 can be formed by removing material using machining, with little or no additional material addition. The addition of material layers 82 can be provided in a variety of ways. For example, material layers 82 can be formed using laser welding, laser cladding, cold metal transfer (CMT), tungsten inert gas (TIG) welding, additive manufacturing, metal sintering, direct metal laser melting (DMLM), etc. In this case, as Figure 8 As shown in the enlarged cross-sectional view of the material layer 82, the sequential layering of multiple material layers 80 on part 28 includes forming a series of solder beads 84 to form each layer 82. Any number of solder beads 84 can be used to form a single layer. Layers can be formed using any mode of welding, for example, starting from the center or periphery and forming them with continuous spiral solder beads, or forming individual linear solder beads side by side extending from one side of surface 74 to the other, or combinations thereof. During the sequential layering, surface 74 may be positioned in a substantially horizontal position (e.g., no more than + / - 3° to the horizontal plane) to facilitate uniform layering of the material, and then part 72 can be replaced by sequentially layering at least one or more material layers 80 82 on surface 74.

[0063] exist Figure 7 In this design, only a single or plurality of 80 material layers 82 are used. Here, the second ends 90 of the plurality of material layers 82 are stepped to approximate the size of the overhanging section (to be formed). In one example, the first ends 86 of the single or plurality of 80 material layers 82 are shown as being substantially aligned with the surface 88 of the part 28, and the second ends 90 of the single material layer 82 are stepped to approximate the size of the overhanging section (to be formed). Here, the second ends 90 extend gradually over a larger area above the suction surface 44 of the turbine blade 25 in an overhanging manner, moving upwards as shown. Here, each layer 82 may have its first ends 86 aligned radially or vertically. It should be noted that the first ends 86 of the single or plurality of material layers 82 may not be precisely aligned as shown and may have uneven edges relative to the surface 88 of the part 28. These uneven edges may subsequently be machined to align with the surface 88 of the part 28.

[0064] Figure 9A schematic plan view of the solder beads 84 of layer 82 is shown. As shown, the solder beads 84 of different layers 82A may be angled relative to the solder beads 84 of other layers 82B. For example, a series of solder beads 84 for at least one first material layer 82A of a plurality of 80 material layers 82 may be formed at a non-parallel angle with a series of solder beads 84 for at least one second material layer 82B of the same plurality of 80 layers. Any angle can be used to facilitate the formation of new segment 76. Figure 10 The strength of the solder ball. In addition to the orientation of the solder ball, the local temperature of the structure can be controlled to prevent thermal cracking during sequential delamination. For example, the user can jump from one place to another on the build surface 74 to allow cooling in one area while working in another, and ensure that new solder balls are applied to locations that have already cooled before the application of new solder balls.

[0065] Figure 10 Part 28 is shown after machining multiple layers 80 of material 82 to form a new segment 76 including a new overhanging segment 78. In this process, part 72 is replaced ( Figure 5 In the case of ), the cantilever section 78 can be matched with part 72 ( Figure 5 The shape and size of the new overhanging section. Alternatively, the new overhanging section may have different shapes and sizes to provide improved performance and / or lifespan. Machining may include any method of material removal that allows for surface blending, resulting in the desired shape and size of the new section 76. Non-limiting and non-comprehensive examples of machining may include milling, grinding, cutting, polishing, etc. As noted, the body 60 may include the airfoil 40 of the turbine blade 25. In this case, the overhanging section 78 includes an extended tip guide 70 extending from one of the first side 62 (shown) and the second side 64 of the airfoil 40. Figure 10 In the turbine blade 25, there is an extended top guide 70 extending from the airfoil 40, wherein the radially facing outer surface 138 of the overhang section 78 is parallel to the turbine axis 18.

[0066] exist Figure 7 In this process, surface 74 is formed to be parallel to the radially facing outer surface 92 of the new segment 76, for example, possibly relative to the gas turbine 10. Figure 1 ) axis 18 ( Figure 1Parallel extension. In other words, surface 74 extends perpendicular to the longitudinal axis 75 of the part, or, in the case of a turbine blade, perpendicular to the radial axis 75 of the body 60 of the airfoil 40. Therefore, part 28 includes at least a portion of an overhanging section 78 comprising a plurality of material layers 82, wherein each material layer 82 extends at a perpendicular angle to the longitudinal axis 75 of the body 60. A portion of the overhanging section 78 may include at most half, or more than half, of the overhanging section 78 extending from the bottom surface 136 to the radially facing outer surface of the overhanging section 78 (when the blade is mounted). In alternative embodiments, such as... Figure 25 As shown, part 28 can be rotated such that surface 74 is tilted relative to the horizontal plane. For example, the rotation angle θ1 can be from about 15° to about 60°, such that the longitudinal axis 75 of part 28 is rotated by an angle θ1 relative to the vertical position. Figure 26 A cross-sectional view is shown showing the addition of a new segment 76 to part 28, wherein the new segment 76 includes a new overhanging segment 78. The addition involves sequentially layering multiple 80-degree inclined material layers 82 onto part 28, specifically onto the inclined surface 74. When completed, the multiple 80-degree material layers 82 collectively approximate the dimensions of the new segment 76 including the overhanging segment 78, which has a larger dimension than would be used in other parts. Figure 7 The horizontal surface shown allows for a larger overhang angle. That is, the added segment 76 approximates the desired addition of a new overhang segment 78 or the replacement of a damaged segment 72. Figure 5 The dimensions of the part can be adjusted, or, if necessary, have a larger overhang angle. For example, the overhang angle θ2 can be approximately 50° to approximately 65°, or approximately 55° to approximately 60°. The overhang angle θ2 is measured between the longitudinal axis 75 of the part and the line intersecting the bottom corner (or edge) of the overhang material layer 82, such as... Figure 26 As shown in the diagram, the tilted construction reduces the perceived overhang of each layer, making it possible to successfully achieve a greater amount of overhang.

[0067] like Figure 11 As shown, in an alternative embodiment, the portion 72 from which part 28 is removed may include a surface 94 that is not perpendicular to the longitudinal axis 75 of the body 60, i.e., the radial axis 75 of the body 60 of the airfoil 40. Instead, surface 94 may form an acute angle δ with respect to the longitudinal axis 75 of the body 60 (i.e., the radial axis 75 of the airfoil 40). For clarity, the acute angle is between 0° and 90°. Surface 94 may also be relative to the axis 18 of the gas turbine 10 (in... Figure 11 (Added with a dashed line) forming an acute angle α. Additionally, surface 94 will be at an angle that is neither perpendicular to nor parallel to the outer flat surface 96 of the new radially facing overhanging section 78 of the final product (i.e., the newly expanded top guide). Figure 14 ).

[0068] like Figure 13A As shown, surface 94 can be rotated so that it is substantially horizontal (+ / -3°) before multiple layers 80 of material 82 are sequentially layered upon it. Alternatively, as Figure 13B As shown, part 28 can be rotated to position surface 94 at an angle β other than horizontal and vertical positions before the plurality of material layers 82 are sequentially layered. After a certain number of material layers 82 are sequentially layered, part 28 can optionally be rotated to... Figure 13B The position. Angle β can be any angle that allows multiple material layers 82 to be in a desired stepped manner (i.e., not substantially horizontal as defined herein). For example, angle β can cause the end 98 of layer 82 to be stepped outward in a manner that allows the end to be later machined to align with surface 88, and cause the end 100 of layer 82 to be stepped outward in a manner that forms a new overhanging section 78 of part 28. Angle β can allow the overhanging section 78 to be formed in such a range that if surface 94 is horizontal, the overhanging section cannot be formed. For example, the outward length L2 of the new overhanging section 78 ( Figure 14 It can be greater than the initial outward length L1 of the original overhang section 30. Figure 11 Alternatively, the angle ε2 of the new overhanging section 78 relative to the radial axis 75 of the main body 60 can be greater than the initial angle ε1 of the original overhanging section 30 relative to the radial axis 75 of the main body 60. Figure 11 Angle β can be any angle that allows for sequential layering but does not allow the formation of undesirable layers, such as those in the form of dripping, collapsing, or breaking.

[0069] Figures 13A to 13B It is also shown that multiple layers 80 82 are sequentially layered on surface 94. In this case, each end 98, 100 of layer 82 can be stepped. That is, as... Figures 13A to 13B As shown, the sequential layering of a plurality of 80 material layers 82 may include first ends 98 of the plurality of material layers formed in a stepped manner from a first side of surface 94, and second ends 100 of the plurality of 80 material layers 82 formed in a stepped manner from a second side of surface 94. One of the first and second ends (100 as shown) approximates the dimensions of a segment 76 including an overhanging section 78, as described herein. Ends 98 may be stepped to align with surface 88 of part 28 upon completion, and as noted, ends 100 may be stepped to form new overhanging sections 78 of part 28, such as tip rails for new expansions of turbine blades 25. Here, as... Figure 14 As shown by the dashed line, after machining, layer 82 in the new overhanging section 78 of the finished product is relative to the gas turbine 10. Figure 1The axis 18 (shown schematically in dashed lines) extends at an acute angle α relative to the outer surface 96 of the target. Figure 14 The target surface 96 extends at an acute angle α and at an acute angle δ relative to the longitudinal axis 75 of the body 60 or part 28 (i.e., the radial axis 75 of the airfoil 40). Additionally, when completed, the target outer surface 96 forms an angle α with respect to the plurality of material layers 82 and the surfaces 94 on which the layers are constructed. It should be understood that although the target surface 96 is shown as flat, it may not be a flat surface. For example, surface 96 may be curved or have a three-dimensional profile.

[0070] Figure 14 This illustrates machining multiple layers 82 of material 80 to form an overhang section 78 and a flat outer surface 138 of the target. The outer (planar) surface 96 of the target is at an angle α relative to the multiple layers 82 of material 80. Figure 14 As shown, turbine component 28 includes a body 60 having a first side 62, a second side 64 opposite to the first side 62, and a longitudinal axis 75. Overhanging sections 76 extend overhangingly from at least one of the first side 62 (shown) and the second side 64 of the body 60. Figure 23 The overhanging sections extending from both sides are shown. (As shown) Figure 14 As shown, at least a portion of the overhang section 78 includes a plurality of material layers 82, each material layer 82 extending at an acute angle δ relative to the longitudinal axis 75 of the body 60. In one embodiment, a radially extending top guide 134 may extend from the airfoil 40 (from the other side of the body 60), and when in the operating position, the radially facing outer surface 138 of the overhang section 78 may be parallel to the turbine axis 18.

[0071] refer to Figures 15 to 22 In another embodiment of this disclosure, more than one or more material layers 82 may be used to form a new segment 76 including a new overhanging segment 78. Here, segment 76 may be added to part 28 including overhanging segment 78 by sequentially layering more than one or more material layers. The method may include sequentially layering a first plurality of material layers extending in a first direction onto the part, and sequentially layering a second plurality of material layers extending in a second direction different from the first direction onto the part, for example, the two plurality of layers are constructed on a vertical surface formed on the part. The second plurality of material layers typically intersect with the first plurality of material layers, i.e., to form a new segment 76. The different layers in each plurality of layers may be varied in material; for example, the material layers may alternate materials within a given plurality of layers. Alternatively or additionally, the material within each plurality of layers may be the same, but two plurality of layers may use different materials. The same or different materials as the body 60 may be used in one or two plurality of material layers 82.

[0072] like Figure 6 and Figure 15 As shown, if applied to a used part, any portion 72 of part 28 can be removed, thereby creating surface 74. Additionally, new segments 76 can be formed from the initially formed part, such as... Figure 6 As shown in one implementation, as Figure 15 As shown, adding segment 76 to part 28, which includes overhanging segment 78, may include sequentially layering a first plurality of 110 material layers 82 extending in a first direction, which is generally horizontal, for example, as shown, but may deviate from the horizontal plane at an angle. In this example, a portion 112 of the expanded top guide 70 may be consumed. Figure 6 The first plurality of 110 layers 82 are sequentially and horizontally formed on part 28 in a manner that allows for their arrangement. Alternatively, such as Figure 16 As shown, prior to the first sequential layering, any desired material, such as the expanded top guide 70, can be removed. Figure 6 A portion 112 (shown in dashed lines) of part 28 is removed to form another surface 114. That is, another portion 112 of part 28 is removed to create another surface 114. In this case, after any necessary rotation, layers 82 can be sequentially and horizontally formed on surface 114 on part 28, i.e., without consuming any additional material. In this arrangement, the sequential layering of the first plurality of material layers 82 110 is located on surface 114 and forms an extension 116 of surface 114. The ends 118 of layers 82 are ideally aligned with surface 74 during formation, but if they are misaligned, they can be machined to align with surface 74. Figure 15 In this process, the sequential layering of the first plurality of 110 material layers 82 creates an extension 116 of surface 74. As will be described herein, alternative embodiments may form an extension with stepped ends—see, for example… Figure 18C and Figure 19 .

[0073] Figure 17 The diagram shows rotating part 28 such that surface 74 is at different angles, for example, substantially horizontal, and Figure 18A The diagram shows a second plurality of 120 material layers 82 extending in a second, different direction (e.g., perpendicular to the first plurality of 110 material layers 82) sequentially layered on part 28. In this embodiment, as indicated, the sequential layering of the first plurality of 110 material layers 82 creates an extension 116 on surface 74, and as... Figure 18A As shown, the second plurality of 120 material layers 82 are sequentially layered on the first surface 74 and the extension 116 of the first surface 74. The second plurality of 120 material layers 82 intersect with the first plurality of 110 material layers 82, that is, they are usually assembled together and fit together or substantially fit together.

[0074] Figures 18A to 18EVarious embodiments are shown that result in the first plurality of 110 material layers 82 and the second plurality of 120 material layers 82 jointly approximating the dimensions of the new segment 76 including the new overhanging segment 78 and not being coplanar with respect to each other. As will be described, the second plurality of 120 material layers 82 may extend in various non-coplanar directions (i.e., not in the same plane) relative to the first direction of the first plurality of 110 material layers 82. Figure 17 and Figure 18A An embodiment is shown in which the final horizontal second plurality of 120 material layers 82 extend above the vertical first plurality of 110 material layers 82, i.e., where the angle γ between surfaces 74, 114 is substantially perpendicular (90°+ / -2°). Figure 18B An alternative embodiment is shown in which the plurality of 110, 120 material layers are reversed in position. That is, a second plurality of 120 material layers 82 are first formed on surface 74, and then an extension 116 is provided. Then, part 28 is rotated to have surface 114, and the extension 116 can be used to form on this surface, and a first plurality of 110 material layers 82 are formed. The first plurality of 110 material layers 182 are end-up, thereby extending the adjacent ends of the second plurality of 120 material layers 82 forming the extension 116.

[0075] Figure 18C Another alternative embodiment of the part is shown after repeated sequential layering of each plurality of material layers. In other words, all material layers 82, fewer than the first plurality of 110 material layers 82 and the second plurality of 120 material layers 82, are formed on the part between rotations of the part. Here, a certain number of layers (e.g., 1 to 4 layers) fewer than all the first plurality of 110 material layers 82 and the second plurality of 120 material layers 82 are constructed on one surface 74, 114, and then the part is rotated, and another number of layers (e.g., 1 to 4 layers) fewer than all the other plurality of 110, 120 material layers 82 are constructed on the opposing surfaces 74, 114. This method produces a stepped or substantially stepped match of groups of layers 82 within each plurality of material layers 110, 120. This process can help reduce thermal stress and solve other mechanical problems.

[0076] Figures 18D to 18E Other alternative embodiments of a part in which surfaces 74 and 114 are formed in a non-coplanar direction and have a non-perpendicular angle (90°) γ are shown. Here, the positioning of surface 74 or 114 during the layering of the respective plurality of 110, 120 material layers 82 can be located at any position necessary to ensure the desired bonding of the layers and to accommodate hardware welding constraints. Figure 18D Surfaces 74 and 114 are shown at an obtuse angle γ (90° < γ < 180°), and Figure 18E Surfaces 74 and 114 are shown at an angle γ greater than 180°.

[0077] Figures 19 to 21 It shows something that is essentially similar to that relative to Figures 15 to 18E The described alternative embodiments, in addition to the sequential layering of the first plurality of 110 material layers 82 and the second plurality of 120 material layers 82 each producing stepped ends that typically intersect each other, are further described. Figure 15 and Figure 16 Similarly, the first sequential layering can consume part 112 of the part, or another surface 114 can be created by removing part 112 of the part and completing the layering on that surface. In any case, prior to layering, for the application of the used part, any part 72 of part 28 can be removed to create surfaces 74, 114.

[0078] Figure 19 The diagram shows a first plurality of material layers 82 110 layered in sequence to create a stepped extension 122 of surface 114. Figure 20 It shows any necessary rotation of the parts, and Figure 21 This illustrates the sequential layering of a second plurality of 120 material layers 82 on surface 74 and the stepped extension 122 of surface 74. Figure 20 More specifically, a second plurality of material layers 82 are sequentially layered on surface 74 such that their material layers 82 substantially mate with the stepped extensions 122 of surface 74 formed by the first plurality of material layers 82, thereby creating an interlocking engagement. Here, as Figure 21 As shown, the two or more 110, 120 material layers 82 may have mating stepped ends, or substantially mating stepped ends, with some gaps 83 possibly present at certain locations between the two material layers. That is, the ends of the first or more 110 material layers 82 meet the ends of the second or more 120 material layers 82 in a stepped manner, with some gaps 83 possibly present. Although surfaces 74, 114 are... Figures 19 to 22 The two are shown as perpendicular to each other, but relative to each other. Figures 18A to 18E Any angle γ described can be used with stepped layers.

[0079] Figure 22 Part 28 is shown after machining multiple layers 82 of material 110, 120 to form a segment 76 including a new overhanging segment 78. This process can follow any of the described processes involving sequentially layering more than one or more material layers. The machining process can be as described relative to... Figure 10 As described. Although machining is shown as according to Figure 21 The implementation plan will be carried out, but it will be recognized that... Figures 18A to 18E The implementation plan performs similar machining.

[0080] Figure 22A turbine component 28 including a body 60 is shown, the body having a first side 62 and a second side 64. An overhanging section 78 extends overhangingly from at least one of the first side 62 and the second side 64 (shown) of the body 60. At least a portion of the overhanging section 78 includes a first plurality of 110 material layers 82 extending in a first direction, and a second plurality of 110 material layers 82 extending in a second direction, the second direction being non-coplanar with respect to the first direction of the first plurality of 110 material layers 82 (see angle γ) — see Figures 18A to 18E .

[0081] Figure 23 An enlarged cross-sectional view of a part 28 having a body 60 according to another embodiment of the present disclosure is shown, the body having a first side 62 and an opposing second side 64. Here, overhanging sections 30, 230 extend overhangingly from the first side 62 and the second side 64 of the body 60, respectively. Neither of the overhanging sections 30, 230 contains a vertical structural support in a portion thereof. In this embodiment, the overhanging sections 30, 230 may have the same mass and extend to the same extent, or one or the other overhanging section may have a greater mass and extend to different extents. In the example shown, part 28 includes a turbine blade 25 including extended tip rails 70, 270 overhanging, for example, the suction surface 44 and pressure surface 42 of the blade. However, it should be noted that the extended tip rails 70 may extend around the entire periphery of the tip of the airfoil 40. Thus, the extended tip rails 70 are examples of the overhanging sections 30, 230 of part 28. The main body 60 includes an airfoil 40 and an expanded tip rail 70. The expanded tip rail 70 is positioned relative to the axis 18 of the gas turbine 10. Figure 1 It extends circumferentially. Although Figures 5 to 22 The process for repairing the expansion of the top guide 70 on one side of the airfoil 40 is shown, but it will be readily recognized that the teachings of this disclosure can be repeated many times and, where necessary, have many building surfaces 74, 94, 114, 116. Any number of sections 72 (damaged overhang sections) can be repaired or added.

[0082] Figure 24 An enlarged cross-sectional view of a part 28 having a body 60 according to another embodiment of the present disclosure is shown, the body having a first side 62 and an opposing second side 64. Figures 5 to 23 In the middle, the cantilever sections 30 and 230 extend outward relative to the main body 60 of the airfoil 40. Figure 24In this embodiment, cantilever sections 330 and 430 extend inwardly from the first side 62 and the second side 64 of the main body 60, respectively, in a cantilevered manner. Neither of the cantilever sections 330 nor 430 contains a vertical structural support in a portion thereof. In this embodiment, the cantilever sections 330 and 430 may have the same mass and extend inward by the same extent, or one or the other section may have a greater mass and extend to different extents. Although not shown, it will be appreciated that one of the inwardly extending cantilever sections 330 and 430 may be replaced by a radially extending top guide 134, such as... Figure 5 As shown in the diagram. Overhanging sections 330 and 430 may be modified or added according to any embodiment of the embodiments described herein. It should be understood that the overhanging sections may extend over the pressure surface 42, the suction surface 44, and the bottom surface 136, or all of these surfaces / faces, or combinations thereof.

[0083] Part 28 may comprise a metal. In one embodiment, part 28 is made of a metal, such as a metal or metal alloy, such as a superalloy having a columnar grain structure (e.g., a directionally solidified (DS) blade). In one embodiment, part 28 may be made of a first metal, which may comprise a pure metal or an alloy. As used herein, “superalloy” refers to an alloy that has many superior physical properties compared to conventional alloys, such as, but not limited to, high mechanical strength, high resistance to thermal creep deformation, such as Rene N5, Rene N500, Rene 108, CM247, Haynes alloys, chromium-nickel-iron alloys, MP98T, TMS alloys, and CMSX single-crystal alloys. In one embodiment, superalloys that may be particularly advantageous according to the teachings of the present invention are superalloys with high γ' (γ') values. “γ'” (γ') is the dominant strengthening phase in nickel-based alloys. Exemplary high γ' superalloys include, but are not limited to, Rene 108, N4, N5, N500, GTD 444, MarM 247, and IN 738. The new segment 76 and the plurality of 80, 110, 120 material layers 82 may include a first metal to form a turbine blade 25 having all the same material. In an alternative embodiment, segment 76 may include a second metal different from the first metal. In one embodiment, all layers 82 of a particular plurality of 80, 110, 120 layers 82 may be of the same material, but of a different material compared to the remainder of part 28. That is, part 28 includes the first metal, and the plurality of 80, 110, 120 material layers 82 include a second metal different from the first metal. Thus, the new segment 76 may be of a homogeneous material. Alternatively, the different layers 82 of the plurality of 80, 110, 120 material layers 82 may be different, resulting in different materials in the new segment 76. That is, the plurality of 80, 110, 120 material layers 82 may include at least one first material layer and at least one second material layer, the at least one first material layer including the first metal, and the at least one second material layer including a second metal different from the first metal. For example, the material layer 82 of a new segment 76 near, for example, surface 74 or surface 114 may match the material of part 28, and layers farther from surface 74 or surface 94 may be of a different material, for example, harder to withstand more wear. Alternatively, different materials may be present in the various layers. That is, at least one of the plurality of material layers 82, 80, 110, 120, may include at least one first material layer and at least one second material layer, the at least one first material layer comprising a first metal, and the at least one second material layer comprising a second metal different from the first metal. Figure 10 , Figure 14 and Figure 22 The material layers are shown in dashed lines.

[0084] refer to Figure 4 , Figure 10 , Figure 14 and Figure 22 The embodiments of this disclosure also include those for gas turbine 10 ( Figure 1 Turbine component 130. Turbine component 130 may include turbine blades 25, such as... Figure 4 and Figure 5 As shown, the turbine blade includes a body 60 in the form of an airfoil 40, the body having a first side 62 in the form of a suction surface 44 and a second side 64 in the form of a pressure surface 42. The turbine component 130, in the form of a turbine blade 25, may also include a root 31. Figure 4 ).like Figure 10 , Figure 14 and Figure 22 As shown, turbine component 130 may also include a new overhanging section 78 in the form of an expanded top guide 132, which extends in an overhanging manner from at least one of a first side 62 and a second side 64 of the body 60, i.e., from at least one of the pressure surface 42 and the suction surface 44 (the latter shown) of the airfoil 40. Figure 14 As shown, a cantilever section 78 in the form of a newly expanded top guide 132 may oppose a corresponding member 66 on a second side 64 of the body 60 in the form of a radially extending top guide 134. The cantilever section 78 and the corresponding member 66 extend from the bottom surface 136 of the body (e.g., the outer radial surface of the airfoil 40). The cantilever section 78 may have a greater mass than the corresponding member 66. Figure 23 As shown, overhanging sections 30, 230, in the form of newly expanded top guide rails 232, can be formed on the main body 60. It should be emphasized that... Figure 23 Each overhanging section 30, 230 may take the form of any of the embodiments described herein. For example... Figure 24 As shown, overhanging sections 330 and 430, in the form of newly extending inwardly expanding top guides, may also be formed on the body 60. In any case, the overhanging sections extend from the bottom surface 136 (i.e., the outer radial surface of the airfoil 40). Overhanging sections 30, 230, 330, and 430 may have the same or different masses and may extend to the same or different ranges. In any case, overhanging sections 30, 230, 330, and 430 are positioned relative to the turbine axis 18 (… Figure 1 It extends circumferentially. It should also be noted that the overhanging sections 30, 230, 330, and 430 may take the form of a single, integral overhanging section extending around the entire periphery of the airfoil 40.

[0085] As described herein, the overhanging sections 30, 230, 330, 430, in the form of an expanded top guide 132, include at least one or more material layers 82. In one embodiment, the multiple layers 82 are positioned in at most half of the overhanging section extending from the bottom surface 136 to the radially facing outer surface 201, i.e., at most half based on the removal of portion 72. Figure 14 As shown, in one embodiment, each material layer 82 may extend at an acute angle δ relative to the radial axis 75 of the body 60, and at an acute angle α relative to the radially facing outer surface 138 of the overhang section 30 (i.e., the radially facing outer surface of the expanded top guide 132). In this arrangement, in the turbine's operating position, the surfaces 94 of the plurality of material layers 82 on which the newly expanded top guide 132 is formed may also be relative to the axis 18 of the gas turbine 10 having turbine blades 26 (…). Figure 1 The radial axis 75 of the body 60 extends at an acute angle α. In another embodiment, such as Figure 22 As shown, the expanded top guide 132 may include a first plurality of 110 material layers 82 extending in a first direction and a second plurality of 120 material layers 82 extending in a second direction, the second direction being non-coplanar (not 180°) with the first direction of the first plurality of 110 material layers 82. The two plurality of layers may be adjacent to each other. Figures 18A to 18B ), with matching stepped ends ( Figure 22 ), or has a generally matching stepped end ( Figure 21 There may be some gaps 83 at certain locations between these two or more layers. In one embodiment, one of the two or more 120 material layers 82 may be substantially parallel to the gas turbine 10. Figure 1 ) axis 18 ( Figure 1 (Perpendicular to the radial axis 75), wherein the turbine component 130 is in an operating position within the turbine. Furthermore, another material layer of the plurality of 110 material layers 82 may extend in a non-coplanar direction relative to the plurality of 120 material layers 82. For example... Figures 18A to 18C As shown, non-coplanar directions can be substantially perpendicular, i.e., 90°+ / -2°. Figures 18D to 18E Other non-coplanar directions that are not substantially perpendicular (i.e., not 90°+ / -2°) are shown.

[0086] The body 60, in the form of an airfoil 40, may include a first metal, and at least one of the plurality of material layers 82 may include a second metal different from the first metal. In other embodiments, the plurality of material layers 82 80, 110, 120 may include at least one first material layer and at least one second material layer, the at least one first material layer including the first metal, and the at least one second material layer including a second metal different from the first metal. That is, different materials may be used within the given plurality of material layers. For example, the layer 82 of the new segment 76 near surface 74 may match the material of part 28, and the layer away from surface 74 may be a different material, for example, harder to withstand more wear.

[0087] like Figure 8 As shown, each material layer 82 may include a series of solder beads 84. Figure 9 As shown, a series of solder beads 84 for at least one first material layer 82A of a plurality of material layers may be at a non-parallel angle to a series of solder beads 84 for at least one second material layer 82B of a plurality of material layers.

[0088] Embodiments of this disclosure provide several methods for generating material layers for material addition and / or repair of overhanging sections of expanded tip rails, such as those on turbine rotor blades. The expanded tip rails can be machined to have desired dimensions, shapes, etc., after operation to maintain engine performance.

[0089] The foregoing figures illustrate some associated processes according to several embodiments of the present disclosure. In this respect, each figure represents a process associated with an embodiment of the described method. It should also be noted that in some alternative embodiments, the actions mentioned in the figures may not occur in the order shown in the figures, or, for example, may actually be performed substantially simultaneously or in reverse order, depending on the actions involved. Moreover, those skilled in the art will recognize that additional processes may be added to describe the process.

[0090] As used throughout the specification and claims, approximate language can be used to modify any quantitative expression that allows for variation without causing a change in its underlying function. Therefore, values ​​modified by one or more terms (such as “about,” “approximately,” and “substantially”) are not limited to specified exact values. In at least some cases, approximate language may correspond to the precision of the instrument used to measure the value. Range limitations may be combined and / or interchanged herein and throughout the specification and claims; unless otherwise indicated by context or language, these ranges are identified and include all subranges included therein. The term “about” applied to a specific value within a range applies to both endpoints and may indicate + / - 10% of the value unless otherwise dependent on the precision of the instrument measuring that value.

[0091] All means or steps plus functional elements in the following claims are intended to include any structure, material, action, and equivalent for performing a function in conjunction with other claimed elements of a particular claim. This disclosure has been described for purposes of illustration and description, but it is not intended to be exhaustive or to limit the disclosure to the forms disclosed. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of this disclosure. Embodiments have been selected and described to best explain the principles and practical application of this disclosure and to enable others skilled in the art to understand various embodiments of this disclosure with various modifications suitable for the intended particular use.

Claims

1. A turbine component (28), the turbine component comprising: The main body (60) has a first side (62), a second side (64) and a longitudinal axis (75); and A cantilever section (78) extends cantileveredly from at least one of the first side (62) and the second side (64) of the main body (60), such that the cantilever section (78) does not contain structural supports in a portion thereof. At least a portion of the overhanging section (78) comprises multiple material layers (80). Each material layer (82) extends at an acute angle δ relative to the longitudinal axis (75) of the body (60) and contains no structural support in a portion thereof.

2. The turbine component according to claim 1, wherein the body (60) comprises a first metal and the plurality of material layers (80) comprise a second metal different from the first metal.

3. The turbine component according to claim 1 or 2, wherein the plurality of material layers (80) comprises at least one first material layer (82) and at least one second material layer (82), the at least one first material layer comprising a first metal, and the at least one second material layer comprising a second metal different from the first metal.

4. The turbine component according to claim 1, 2 or 3, wherein each of the plurality of material layers (80) comprises a series of weld beads (84).

5. The turbine component according to claim 4, wherein the series of weld beads (84) for at least one first material layer (82) of the plurality of material layers (80) are at a non-parallel angle to the series of weld beads (84) for at least one second material layer (82) of the plurality of material layers (80).

6. The turbine component according to claim 1, wherein the overhanging section (78) extends from the bottom surface (136) of the body (60), wherein the plurality of material layers (80) are positioned in at most half of the overhanging section (78) extending from the bottom surface (136) to the outer surface (138) of the overhanging section (78).

7. The turbine component according to claim 1, wherein the body (60) includes an airfoil (40) of a turbine blade (25), and wherein the overhang section (78) includes an expanded top guide (70) extending from at least one of the first side (62) and the second side (64) of the airfoil (40) relative to the radial axis (75) of the airfoil (40).

8. The turbine component according to claim 7, further comprising a radially extending top guide (134) extending from the airfoil (40), wherein the radially facing outer surface (138) of the overhanging section (78) is parallel to the axis (18) of the turbine.

9. A gas turbine (10) comprising a turbine component (28) according to claim 1.

10. A method for repairing a part (28), the method comprising: Remove a portion (72) of the part (28) to form a surface (94) of the part (28) at an acute angle δ to the longitudinal axis (75) of the body (60) of the part (28). Add a section to the part (28), the section including the overhang section (78), the addition including: Rotate the part (28), and Multiple material layers (80) are sequentially layered on the surface (94) of the part (28), the multiple material layers (80) approximating the dimensions of the section including the overhanging section (78). Each of the plurality of material layers (80) (82) forms an acute angle δ with the longitudinal axis (75) of the body (60) of the part (28), and each material layer (82) gradually extends over a greater extent relative to the previous material layer (82); and The plurality of material layers (80) are machined to form the section including the overhanging section (78).

11. The method of claim 10, wherein rotating the part (28) comprises positioning the surface (94) substantially horizontal prior to the sequential layering of the plurality of material layers (80) on the surface (94).

12. The method of claim 10, wherein rotating the part (28) comprises positioning the surface (94) at an angle other than horizontal and vertical prior to the sequential layering of the plurality of material layers (80) on the surface (94).

13. The method according to claim 11 or 12, wherein the sequential layering of the plurality of material layers (80) comprises forming a first end (98) of the plurality of material layers (80) in a stepped manner from a first side of the surface (94) and forming a second end (100) of the plurality of material layers (80) in a stepped manner from a second side of the surface (94), one of the first end (98) and the second end (100) approximating the size of the segment including the overhanging segment (78).

14. The method of claim 10, wherein the part (28) comprises a first metal, and the plurality of material layers (80) comprises a second metal different from the first metal.

15. The method according to claim 10 or 14, wherein the plurality of material layers (80) comprises at least one first material layer (82) and at least one second material layer (82), the at least one first material layer comprising a first metal, and the at least one second material layer comprising a second metal different from the first metal.

16. The method according to claim 10, 14 or 15, wherein the sequential layering of the plurality of material layers (80) on the part (28) comprises forming a series of solder beads (84) to form each material layer (82).

17. The method of claim 16, wherein the series of solder beads (84) for at least one first material layer (82) of the plurality of material layers (80) are at a non-parallel angle to the series of solder beads (84) for at least one second material layer (82) of the plurality of material layers (80).

18. The method of claim 10, wherein one of the first end (98) and the second end (100) of the plurality of material layers (80) is stepped to approximate the size of the overhanging section (78).

19. The method of claim 10, wherein the part (28) comprises a turbine blade (25) of a turbine (10), and the portion (72) comprises an overhanging, extended top end (70) without structural support.

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