Braze-Sealed AM Superalloy Components for Heat-Treatment Cracks
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Solution Overview
Problem
Additively manufactured parts, particularly those used in turbines, are prone to cracking during thermal treatment due to complex shapes, which affects mechanical integrity and flow dynamics, leading to potential scrap and increased costs.
Innovation Solution
Applying a braze material to expected crack locations on additively manufactured components made from metallic powders, such as nickel-based superalloys, during the thermal treatment process to fill cracks that form, using techniques like direct metal laser melting and vacuum brazing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing is used to create complex geometries, then manufacturing capability and design flexibility are improved, but cracking during thermal treatment occurs reducing reliability
Solution Approach 1:
The patent applies braze material to expected crack locations on the additively manufactured component before thermal treatment. This preliminary action ensures that when cracks form during heating, the braze material is already in position to fill and seal them, preventing leakage and maintaining component reliability without sacrificing manufacturing capability for complex geometries
2Reliability
If conventional repair methods are used to heal cracks, then component reliability is improved, but manufacturing complexity and cost increase due to multiple processing steps
Solution Approach 1:
The patent combines the thermal treatment process with the crack repair function into a single integrated operation. The braze material is applied beforehand and activates during the same heating cycle used for thermal treatment, eliminating the need for separate cleaning and brazing operations. This merging reduces process complexity while maintaining component integrity
3Manufacturing precision
If fluoride ion cleaning is performed before braze repair, then crack surface preparation is improved, but manufacturing time and process complexity increase
Solution Approach 1:
The patent extracts and eliminates the fluoride ion cleaning step from the traditional repair process. By applying braze material to expected crack locations before thermal treatment, the method relies on the braze material's ability to flow into and fill cracks during heating without requiring prior oxide removal, significantly reducing processing time while maintaining adequate surface preparation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively seals cracks in situ during heat treatment, enhancing the mechanical integrity and longevity of turbine components, reducing scrap and repair costs by eliminating the need for separate braze repair cycles and fluoride ion cleaning processes.
Implementation Method 1
a high temperature vacuum brazing process could be implemented to heal the surface cracks
Implementation Method 2
heats the additively manufactured component to one or more desired heating temperatures
Data Source
AI summary
A manufactured article is comprised of an additively manufactured component having sequentially joined layers of metallic powder. A braze material is disposed on at least a portion of an outer surface of the component. The braze material is located in expected crack locations in the outer surface. At least one crack formed in the outer surface, during a heat treatment, is filled with the braze material. The additively manufactured component comprises a metallic material from a precipitation hardened nickel-based superalloy, which forms a γ′ phase.