Method for repairing superalloy components using phase coagulation - Patents.com

Abstract

To provide a method for repairing a component made of a superalloy material.SOLUTION: A method for repairing a superalloy component (10, 10-1, 10-2, 10-3, 10-4, 10-5, 10-7, 10-8, 10-9) includes subjecting the superalloy component including a repair area (20) to a phase agglomeration cycle (130) which includes stepped heating and controlled cooling of the component. The method (100) further includes applying a weld material (25) to the repair area (20) to create a weld surface (12, 26), and covering the weld surface (12, 26) with a braze material (25). Then, the component is subjected to a brazing cycle (220) to produce a brazed component (10-3). The brazed component (10-3) is cleaned, and the cleaned component is subjected to a restorative heat treatment to restore the microcrystalline structure and mechanical properties of the component.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] TECHNICAL FIELD This disclosure relates generally to joining techniques, and specifically to methods for repairing or maintaining damaged components made from high gamma prime superalloys. [Background technology]

[0002] Some conventional turbomachines, such as gas turbine systems, are utilized to generate electrical power. Generally, a gas turbine system includes a compressor, one or more combustors, and a turbine. Air may be drawn into the compressor via its inlet, where it is compressed by passing through multiple stages of rotating blades and stationary nozzles. The compressed air is channeled to one or more combustors, where fuel is introduced and the fuel / air mixture is ignited and combusted to form combustion products that serve as the working fluid for the turbine.

[0003] The working fluid then flows through a fluid flowpath of the turbine, the flowpath being defined between a plurality of rotating blades and a plurality of stationary nozzles disposed between the rotating blades, such that each set of rotating blades and each corresponding set of stationary nozzles collectively defines a turbine stage. As the rotating blades rotate a rotor of the gas turbine system, a generator coupled to the rotor may generate electrical power. Rotation of the turbine blades also rotates compressor blades coupled to the rotor.

[0004] As combustion systems are designed to operate at increasingly higher temperatures to improve efficiency, manufacturers must select materials for turbine components capable of withstanding these high-temperature environments. High gamma prime superalloys (such as Rene 108) are often chosen for their excellent mechanical and (low) oxidation properties at the target conditions. Such superalloys can be used in blades, nozzles, and shrouds.

[0005] However, Rene 108 and other high gamma prime superalloys have poor weldability and are some of the most difficult materials to weld within the superalloy category. When high gamma prime superalloys are welded using conventional welding procedures, large cracks develop in the heat affected zone of the weld metal and base metal. Unwanted cracks along the weld line lead to poor welds.

[0006] Improved processes for welding high gamma prime superalloys (eg, in repair processes) are needed. Summary of the Invention

[0007] In one aspect of the disclosure, a method of repairing a superalloy component includes subjecting a superalloy component including a repair area to a phase coagulation cycle including staged heating and controlled cooling of the component. The method further includes applying a weld material to the repair area to create a weld surface and covering the weld surface with a braze material. The component is then subjected to a brazing cycle to produce a brazed component. The brazed component is cleaned and the cleaned component is subjected to a recuperative heat treatment to restore the microcrystalline structure and mechanical properties of the component. The superalloy component is comprised of a high gamma prime superalloy.

[0008] This specification describes, to one of ordinary skill in the art, a full and enabling disclosure of the present system and method, including the best mode of using same. This specification refers to the accompanying figures. [Brief description of the drawings]

[0009] [Figure 1] 1 is a flow chart illustrating a method of repairing a superalloy component including schematic views of the superalloy component at various process steps in accordance with the present disclosure. [Diagram 2] 1 is a flow chart illustrating a method of repairing a superalloy component including schematic views of the superalloy component at various process steps in accordance with the present disclosure. [Diagram 3]1 is a flow chart illustrating a method of repairing a superalloy component including schematic views of the superalloy component at various process steps in accordance with the present disclosure. [Figure 4] 1 is a flow chart illustrating a method of repairing a superalloy component including schematic views of the superalloy component at various process steps in accordance with the present disclosure. [Diagram 5] 1 is a graph of a phase aggregation cycle that is part of the method. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] One or more specific aspects / embodiments of the method are described below. In order to provide a concise description of these aspects / embodiments, not all features of an actual implementation are described herein. It is to be understood that in the development of such an actual implementation, such as an engineering or design project, numerous implementation-specific decisions must be made to achieve the developer's particular objectives, such as meeting mechanical, system, and business constraints, and that these constraints may vary from implementation to implementation. It is further to be understood that such a development effort may be complex and time-consuming, but is nevertheless a routine undertaking of design, fabrication, and manufacture for those of ordinary skill in the art having the benefit of this disclosure.

[0011] When introducing elements of various embodiments of the present disclosure, the articles "a," "an," and "the" are intended to mean that there are one or more of the element. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements. Any examples of operating parameters and / or environmental conditions do not exclude other parameters / conditions of the disclosed embodiments. In addition, it should be understood that references to "one embodiment," "one aspect," or "embodiments" or "aspects" of the method are not intended to be interpreted as excluding the existence of additional embodiments or aspects that also incorporate the recited features.

[0012] The present disclosure is directed to methods of repairing components made of superalloy materials, and more particularly, to components made of high gamma prime superalloys. Examples of such high gamma prime superalloys include, but are not limited to, B-1900, GTD-111, Inconel 100, Inconel 713, Inconel 792, MAR-M-246, MAR-M-509, Rene 77, Rene 125, U-500, CMSX single crystal alloy, and the superalloys shown in Table 1 below. All values ​​in Table 1 are in weight percent (wt.%). The term "Bal" represents the balance of the composition (remaining wt.%).

[0013] [Table 1]

[0014] 1-4 illustrate generally a high gamma prime superalloy component 10. The component 10 may be a turbomachine airfoil (e.g., a rotating blade or a stationary nozzle) or another part (e.g., a turbine shroud) made of a high gamma prime superalloy. The superalloy may be formed of conventionally cast (CC), directionally solidified (DS), or single crystal (SX) material.

[0015] 1, the method 100 begins at step 110 where the component 10 is received and inspected. The inspection may be performed visually or using an instrument that scans the component 10. As shown, the component 10 includes a crack or defect 15 that protrudes inwardly from the surface 12. The crack 15 may be a straight crack or may be characterized by a complex shape (e.g., branching). In some examples (not shown), the crack 15 may extend completely through the component 10.

[0016] In step 120, component 10 is machined to produce machined component 10-1. The machining step 120 prepares surface 12 for repair, for example, by smoothing cracks 15 and creating bonding surface 16.

[0017] In step 130, the machined component 10-1 is subjected to a phase coagulation cycle (shown in FIG. 5) that takes place in a temperature controlled furnace 40. The phase coagulation cycle of step 130 involves heating the machined component 10-1 to a prescribed temperature and then cooling the heated component at a slow, controlled rate (e.g., between 0.5°F per minute and about 5°F per minute). The phase coagulation cycle of step 130 causes phase coagulation of different microstructures or crystalline matrices that may be present in the machined component 10-1 to form a smooth surface that is easy to weld.

[0018] In step 140, the phase-aggregated component 10-2 is ready to receive the weld material 20. Prior to applying the weld material 20, a base layer 18 (also known as a "butter pass") can optionally be applied to the bonding surface 16. The weld material 20 may have the same superalloy composition as the phase-aggregated component 10-2, or may have a different composition that is another high-gamma prime superalloy.

[0019] The weld material 20 may be a filler material applied in layers to fill the void of the crack 15 (FIG. 1). For example, the weld material 20 may be a weld wire that is welded with a modulated pulsed laser source. The crack 15 is repeatedly welded and filled with weld filler until the crack 15 is filled to the desired amount.

[0020] Alternatively, the weld material 20 may be a coupon sized and shaped to fit the gap shape. When using coupons, the coupons may be tack welded and then welded in place.

[0021] Because high gamma prime superalloys (such as Rene 108) are prone to microcracks, the welding step 140 is preferably accomplished in an inert environment (e.g., a bath of argon gas) to prevent oxidation of the microcracks. The welded component 10-2 remains in the inert environment until the component 10-2 reaches ambient temperature.

[0022] 2, in step 150, brazing material 25 is applied over weld material 20. High temperature brazing has been successfully implemented in the gas turbine industry for the repair of critical components such as superalloy components in high load areas and rotating parts. Brazing produces joints characterized by high temperature strength, excellent creep, excellent low cycle fatigue properties, and oxidation resistance at the repaired location.

[0023] The braze material 25 may be applied onto the weld area 20 using granular braze material, paste braze material, flexible braze tape, or in some examples, a rigid braze preform. The braze material 25 may have the same or different mechanical properties as the base material (i.e., superalloy composition) of the component 10. Typically, the braze material is a nickel-based braze alloy, which may be used alone or blended with a powder of a superalloy such as those described above. The braze alloy may be mixed with a binder (e.g., 8%-12%) and then applied on top.

[0024] As shown diagrammatically, brazing material 25 is applied to surface 12 of welded component 10-2 to completely cover weld material 20, thereby creating brazed component 10-3.

[0025] In step 160, the brazed component 10-3 is subjected to a heat treatment known as a brazing cycle, which is carried out in a high vacuum furnace 40. The position of the parts in the furnace 40 depends on the orientation of the cracks, and generally the parts are positioned so that the weight forces combined with the capillary forces promote the flow of the brazing alloy in the majority of the cracks to be brazed. During the brazing cycle, the brazing material 25 flows into any gaps or voids around the weld material 20. The brazing material 25 can also flow into any microcracks that develop near the weld material 20 during the brazing cycle. The brazing cycle can be carried out in the same furnace 40 used for the phase condensation cycle, although the heating and cooling profiles are substantially different. That is, the heating during the brazing cycle is carried out at a lower temperature and for a shorter duration than the phase condensation cycle. Also, the cool-down speed is significantly reduced.

[0026] In an exemplary (and non-limiting) brazing cycle, the furnace 40 is slowly heated to a temperature range of about 200° C. to about 400° C. During this first heating stage, the binder gradually evaporates, resulting in a slight contraction of the brazing material 25. After this short dwell time to eliminate most of the binder, the temperature continues to gradually increase. After reaching a temperature high enough to completely melt the brazing alloy and homogenize the powder mixture, the temperature is reduced to an intermediate temperature between the liquidus and solidus temperatures. During a long dwell time (e.g., >3 hours) at the intermediate temperature, the liquidus front slowly migrates due to the diffusion of the melting point depressant elements into the base metal. The mechanism described is generally defined as diffusion brazing or transition liquid phase brazing (TLP brazing).

[0027] Step 170 represents an optional step of subjecting the heat treated brazed component 10-3 to a hot isostatic pressing (HIP) cycle. The HIP cycle is performed in a pressurized vessel 50 and creates a high temperature and pressure environment in the brazed component 10-3, which closes any small internal cracks in the brazed component 10-3, such as those that may have developed during the brazing cycle of step 160.

[0028] In step 180, the brazed component 10-3 (or optionally HIPed component 10-4) is subjected to a blending or recontouring step to restore the desired geometry of the component surface. Typically, the brazing composition may include binders that evaporate during the brazing cycle, so that a large amount of the brazing composition is deposited on the weld material 20 (or any subsequent cracks). A blending tool 60 is used to smooth out the excess brazing material 25 and create the blended surface 26. The blending tool 60 may be operated manually (e.g., a hand grinder) or the blending tool 60 may be part of a machining device.

[0029] Continuing with FIG. 3, in step 190, the blended component 10-5 is cleaned by immersing the blended component 10-5 in a salt bath 70. The salt bath 70 removes tenacious, thermodynamically stable oxidation and, to some extent, corrosion products from the cracks 15 and from the surface 12 of the component 10. Uncoated parts are also susceptible to severe thermo-mechanical fatigue (TMF) degradation and erosion, and therefore may require a salt bath to remove the resulting contaminant scale. The salt bath reduces the oxide surface scale thickness by 70%-90% and removes inner oxidation products from cooling holes and cavities. Contaminants (oil, grease, etc.) can also be dissolved.

[0030] Salt bath cleaning is performed in a discontinuous process where the component 10 is placed in a chemically resistant basket and immersed in a molten salt bath 70 for a predetermined period of time. The salt bath 70 for removing metal oxides may consist primarily of sodium hydroxide and different amounts of a strong oxidizing agent, such as sodium nitrate. Some catalysts may be added to the salt bath 70 to accelerate and control the oxidizing properties of the salt bath. Additional compounds may also be added to protect the base metal from undesired chemical attack.

[0031] The salt bath 70 preferably has as low a viscosity as possible during the entire exposure time of the component 10 so that the molten salt can penetrate into the cracks and internal cavities. The salt bath 70 used for metal oxide removal can operate in a temperature range of about 400° C. to about 500° C. In the case of Rene 108, the salt bath 70 is highly desirable because the cracks are deeply oxidized and the optional subsequent cleaning step 200, the so-called "fluoride ion cleaning" (FIC), alone is not sufficient to remove all the oxide.

[0032] The optional second cleaning step 200 employs dynamic subatmospheric fluoride ion cleaning (FIC), which is a highly effective process for removing deeply embedded oxides from superalloys containing significant amounts of aluminum and titanium. The cleaning effect is based on chemical reactions such as the conversion of highly thermodynamically stable metal oxides in reducible fluorides, as well as the formation of volatile metal fluorides. These reactions take place in a reactor 80 heated to a temperature range of about 900° C. to about 1200° C. at pressures of about 50 Torr to about 765 Torr.

[0033] Gases (e.g. argon (Ar), hydrogen (H2), and / or hydrogen fluoride (HF)) are injected sequentially to allow the reaction and reduction of the metal oxides. Finally, an extract of the gaseous reaction products is obtained by evacuating the system. This evacuation step is important because the described chemical reactions represent a dynamic equilibrium. That is, if the chemical reaction products (metal fluorides and water) are not continuously removed during the process cycle, the reaction will reach the product side to some extent and easily reverse. The crack must be supplied with fresh reaction gases through an intermediate evacuation step of the reactor volume.

[0034] The FIC step 200 involves a series of cleaning cycles that are tailored according to the specific alloy, the degree of damage, and the components. Excessive material erosion, especially with regard to aluminum, titanium, and yttrium depletion, as well as erosion of sensitive areas and brazed joints must be avoided, as this can lead to a reduction in the mechanical properties or oxidation resistance of the base metal.

[0035] On the other hand, the wetting behavior of the brazing alloy (used in step 210) is improved by the consumption of the cleaned surface (since elements that are easily oxidized, such as titanium, can prevent wetting). In the particular case of Rene 108, cleaning is very difficult, since the cracks may be relatively long (typically >4 mm) and / or may be strongly oxidized. The flow time of the HF gas is strongly related to the crack length, and for this reason a specific long FIC process is applied to the component 10 made of Rene 108 to be able to thoroughly clean any cracks in the salt bath cleaned component 10-6.

[0036] The effectiveness of the FIC process is evaluated by investigating characteristic metallurgical criteria, mainly the depth of material erosion and the removal of oxides from the cracks. The oxide scale must be completely removed from the crack surfaces and from accessible wide cracks. In very fine cracks where access by the process gases is difficult, localized residual oxides can be tolerated to some extent. Grain boundary carbide erosion and generally IGA can occur, which is tolerated according to thresholds defined for the specific case. The FIC process is considered one of the most reliable methods for removing oxides from cracked material, even in the presence of very fine thermomechanical fatigue cracks. For this reason, in combination with a suitable brazing process, it can also be used for the repair of highly loaded areas of components.

[0037] In step 210, the brazing process is repeated to seal any cracks 30 that may have resulted from the previous process. An additional braze layer 25 is applied over the weld area 20. The resulting component 10-7 is subjected to another brazing cycle 220 using a vacuum furnace 40. The brazing cycle 220 may be of similar duration as that described in step 160.

[0038] 4, the heat treated component 10-8 is subjected to a blending step 230. In a similar manner as described in step 180, a blending tool 60 is used to smooth the braze material 25 and create a blended surface 26. The blending tool 60 may be operated manually or its operation may be automated, for example, by operating the blending tool 60 using a robotic arm.

[0039] In step 240, non-destructive testing (NDT) is performed on the component 10-8. One suitable NDT inspection method for defect detection is fluorescent penetrant inspection (FPI), although other inspection techniques can be used. Using an inspection tool 90 (such as a camera or ultraviolet light), the inspector carefully examines all surfaces in question and evaluates any defects detected according to predefined criteria. Problem areas can be marked, so that the location of the mark can be easily identified for further analysis or repair.

[0040] If new cracks are identified during inspection step 240, the components 10-8 may be re-brazed (step 250). The brazing process includes application of braze material to the affected areas (as in step 210), heating the brazed components in a thermal cycle (as in step 220), and blending the brazed areas using a blending tool 60 (as in step 230).

[0041] A subsequent inspection step (not shown separately) may be performed to ensure that any cracks in component 10-8 are completely repaired.

[0042] Optionally, in step 260, a thermal barrier coating 32 may be applied to the surface 12 of the component 10-8 to create a coated component 10-9. The thermal barrier coating 32 may help extend the life of the component in the high temperature and harsh environment of the gas turbine.

[0043] In step 270, component 10-9 (or alternatively component 10-8) is subjected to a recovery heat treatment cycle using the previously used vacuum furnace 40. The recovery heat treatment cycle includes a heat up period (where the phase distribution is as uniform as possible) and a cool down period (where the gamma prime particles are reprecipitated).

[0044] The heat ramp occurs by heating component 10-9 in a vacuum and the temperature is raised as quickly as possible to a first predetermined temperature that is 90%-95% of the solution temperature (i.e., T5) of the superalloy. The component is maintained at the first predetermined temperature for a first defined period of time (e.g., 2 hours-3 hours, ±15 minutes). A first cool down period using an inert gas fan reduces the temperature of component 10-9 to 900°F-1200°F. The component 10-9 is cooled at a rate of at least 30°F / min.

[0045] The first cool-down period is followed by a second heating period, in which the temperature in the vacuum is raised as rapidly as possible to a second predetermined temperature that is 70%-75% of the solution temperature of the superalloy. Component 10-9 is maintained at the second predetermined temperature for a second defined period of time (e.g., 4 hours-5 hours, ±15 minutes). A second cool-down period using an inert gas fan reduces the temperature of component 10-9 to 1000°F (±100°F) at a cooling rate of at least 25°F / min. Component 10-9 may then be allowed to cool to ambient temperature at any convenient rate.

[0046] During the recovery heat treatment cycle 270, the crystallite structure of the component 10-9 is restored to a similar (but not exactly the same) state as the pretreatment of the component 10-1. Specifically, the precipitated gamma prime particles (e.g., Ni-Al or Ni-Ti) may have a different size and / or a different distribution compared to the incoming component 10-1. In a component 10-9 that has been subjected to the phase aggregation cycle 130 and the recovery heat treatment cycle 270, the concentration of gamma prime particles and carbide compounds in the bulk material of the component 10-9 may be higher than in a corresponding component that has not been subjected to these cycles 130, 270. The recovery heat treatment cycle 270 returns the mechanical properties of the component 10-9, thereby making it a useful component for use (e.g., in a gas turbine).

[0047] FIG. 5 illustrates a chart of an exemplary phase aggregation cycle as described in step 130 of flowchart 100. The chart is not necessarily to scale. Component 10 is heated at a ramp rate 310 over a first time "t1" to reach temperature T2. Component 10 is maintained at temperature T2 for a short, predetermined period of time (e.g., less than 5 minutes) until time "t2", as represented by plateau 320 of phase aggregation cycle curve 130. A second heating ramp 330 occurs between time "t2" and time "t3", during which the temperature increases from temperature T2 to temperature T4. In one embodiment, temperature T4 is greater than twice temperature T2 (e.g., about 225% of temperature T2). Temperature T4 is maintained for a relatively short, predetermined period of time (e.g., less than 1 hour) until time "t4", as represented by plateau 340 of phase aggregation cycle curve 130.

[0048] A third heating ramp 350 occurs between time "t4" and time "t5" during which the temperature is increased from temperature T4 to temperature T5. Temperature T5 is the solution temperature of the superalloy, which is about 115% of temperature T4 and about 250% to about 270% of temperature T2. Temperature T5 is maintained for a relatively long predetermined period of time (e.g., 1 to 3 hours) until time "t6", as represented by plateau 360 of phase cohesion cycle curve 130.

[0049] In one embodiment, the ramp rates used in steps 310, 330, and 350 are the same or approximately the same. Exemplary (and non-limiting) ramp rates may be on the order of about 15°F per minute to about 30°F per minute. In a particular embodiment, the ramp rate may be about 25°F per minute. Alternatively, ramp rates 310, 330, and 350 may occur at different rates.

[0050] After plateau 360, a controlled cool-down 370 begins during which the temperature moves from temperature T5 at time "t6" to temperature T3 at time "t7." This cool-down rate 370 coalesces different microstructures within component 10, which helps prepare component 10 for subsequent processing (e.g., welding and brazing).

[0051] In an exemplary embodiment, temperature T3 is about 175% of temperature T2 and 65%-70% of temperature T5, and cool-down rate 370 is about 0.5°F per minute to about 5°F per minute. Thus, the time between time "t6" and time "t7" is measured in hours (e.g., 15-30 hours). In one exemplary embodiment, cool-down rate 370 may be about 1°F per minute. In another exemplary embodiment, cool-down rate 370 may be about 3°F per minute. In some embodiments, cool-down rate 370 may be about 5°F per minute.

[0052] Optionally, component 10 may be held at temperature T3 for a short, predetermined period of time (e.g., less than 5 minutes), with the holding step not separately shown. The gas fan quench period from time "t7" to time "t8" follows curve 380. During this forced cooling period, the temperature drops from temperature T3 to temperature T1, which is less than 25% of temperature T2 and less than 10% of temperature T5. Final cooling of the component may occur at a rate defined by curve 390, thus allowing component 10 to reach ambient temperature.

[0053] As used herein throughout the specification and claims, approximation language can be applied to modify any quantitative expression that can be reasonably varied without causing a change in the basic function involved. Thus, values ​​modified by terms such as "approximately", "about" and "substantially" are not limited to the exact value specified. In at least some instances, approximation language can correspond to the precision of the instrument for measuring the value. Here, and throughout the specification and claims, range limitations can be combined and / or substituted, and such ranges are identified and include all subranges encompassed therein, unless the context and language dictate otherwise. The terms "approximately" and "about" applied to a particular value in a range can apply to both values ​​and indicate + / - 10% of the stated value, unless dependent on the precision of the instrument for measuring the value.

[0054] This specification uses examples to disclose the invention, including the best mode, and to enable any person skilled in the art to practice the invention, including making and using any device or system, and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims. [Explanation of symbols]

[0055] 10 Superalloy Components 10-1 Superalloy components 10-2 Superalloy components 10-3 Superalloy components 10-4 Superalloy components 10-5 Superalloy components 10-6 Superalloy components 10-7 Superalloy components 10-8 Superalloy components 10-9 Superalloy components 12 Welding Surface 15 Cracks / Defects 16 Adhesive surface 18 Base Layer 20 Welding materials / welding area / repair area 25 Brazing / Welding Materials 26 Blended Surface / Welded Surface 30 Crack 32 Thermal barrier coating 40 Vacuum Furnace / High Vacuum Furnace 50 Pressurized vessels 60 Blend Tool 70 Salt Bath 80 Reactor 90 Inspection Tools 100 Methods / Flowcharts 110 Steps 120 steps 130 steps / phase coagulation cycle / phase coagulation cycle curve 140 steps / welding step 150 steps 160 steps 170 steps 180 steps 190 Steps 200 steps / wash step 210 Steps 220 steps / brazing cycle 230 steps / blend step 240 steps / inspection step 250 steps 260 steps 270 steps / recovery heat treatment cycle 310 Incline speed 320 Plateau 330 Ramp Speed / Second Heat Up 340 Plateau 350 ramp speed / third heating rise 360 Plateau 370 Cooldown Speed 380 curve 390 curve T1 temperature T2 temperature T3 temperature T4 temperature T5 temperature t1 Time t2 Time t3 Time t4 Time t5 Time t6 time t7 time t8 time

Claims

1. A method (100) of repairing a superalloy component (10), the method comprising the following sequence of steps: (a) subjecting the superalloy component (10) to a phase coagulation cycle (130), the superalloy component (10) including at least one repair region (20); (b) applying a welding material (25) to the at least one repair area (20) to create a weld surface (12, 26); (c) covering said weld surfaces (12, 26) with a brazing material (25); (d) subjecting said superalloy component (10) to a brazing cycle (220) to produce a brazed component (10-3); (e) cleaning the brazed component (10-3); (f) subjecting the cleaned component (10-6) to a recovery heat treatment; Contains wherein the phase coagulation cycle (130) in step (a) comprises heating the superalloy component (10) to a first prescribed temperature (T5) using a uniform ramp rate (310) and one or more periods of holding the superalloy component (10) at a plateau (320, 340) temperature; allowing the superalloy component (10) to cool down at a prescribed cool-down rate (370) to a second prescribed temperature (T3); and performing forced cooling of the superalloy component (10) to a third prescribed temperature (T1); heating the superalloy component (10) comprises holding the superalloy component (10) at the first defined temperature (T5) for a first defined period of time; 20. The method (100) of claim 19, wherein heating the superalloy component (10) to a first defined temperature (T5) comprises heating to a first plateau (320) temperature, holding for a second defined period of time, heating to a second plateau (340) temperature that is higher than the first plateau (320) temperature, and holding for a third defined period of time that is longer than the second defined period of time and shorter than the first defined period of time, wherein the second plateau (340) temperature is 85% of the first defined temperature (T5).

2. The method (100) of claim 1, wherein the superalloy component (10) comprises a high gamma prime superalloy.

3. 3. The method (100) 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(247), or MAR M 247.

4. 2. The method of claim 1, wherein the specified cool down rate is between 0.5°F per minute (0.28°C per minute) and 5°F per minute (2.8°C per minute).

5. 2. The method (100) of claim 1, wherein the second predefined temperature (T3) is between 65% and 70% of the first predefined temperature (T5) and the third predefined temperature (T1) is less than 10% of the first predefined temperature (T5).

6. The method (100) of claim 1, wherein step (a) further comprises allowing the superalloy component (10) to cool to ambient temperature after the forced cooling.

7. 2. The method (100) of claim 1, further comprising, prior to step (a), machining the at least one repair area (20) to produce at least one surface (12, 26) to which the weld material (25) is applied.

8. 8. The method (100) of claim 7, further comprising, prior to step (b), applying a base layer (18) of welding material (25) to the at least one machined surface (12, 26).

9. The method (100) of claim 1 , wherein step (b) is performed in an inert environment.

10. The method (100) of claim 1, wherein step (b) comprises welding a coupon of material (25) to the at least one repair area (20).

11. The method (100) of any preceding claim, further comprising, after step (d), subjecting the brazed component (10-3) to a hot isostatic cycle in a vacuum furnace (40).

12. The method (100) of claim 1, further comprising, after step (d), blending the brazing region (20) to produce a smooth surface (12, 26) of the brazed component (10-3).

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