Structural Braze Tape for High-Strength Superalloy Repair
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Solution Overview
Problem
Conventional boron or silicon braze repairs for gas turbine engine components made of nickel or cobalt superalloys have lower structural strength and poor dimensional control due to the composition of braze alloys and the amorphous nature of braze slurry.
Innovation Solution
A structural braze tape with a composition free of boron and silicon, comprising a nickel or cobalt-based superalloy alloy layer, a boron-free braze material layer, and a flux layer with fluoride, which allows for improved flexibility, dimensional control, and cleansing of impurities during the brazing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional boron or silicon braze alloys are used for repair, then the braze material can be applied to superalloy components, but the structural strength of the repaired area is lower than that of the original component
Solution Approach 1:
The patent changes the chemical composition parameters of the braze alloy by eliminating boron and silicon elements and replacing them with alternative alloying elements such as nickel, chromium, and cobalt. This parameter change transforms the braze material from a conventional low-strength composition to a high-strength composition that can match or exceed the structural strength of the original superalloy component.
Solution Approach 2:
The patent creates a composite braze material system that combines multiple metallic elements (nickel, chromium, cobalt, and other alloying elements) in specific proportions. This composite material approach allows the braze alloy to achieve superior mechanical properties and structural strength that cannot be obtained with conventional single-phase braze materials.
2Ease of manufacture
If braze slurry is used for repair, then the material can be applied to damaged areas, but dimensional control of the repaired area is difficult due to the amorphous nature of the slurry
Solution Approach 1:
The patent changes the physical state parameter of the repair material from an amorphous slurry to a structured tape form. This parameter change enables precise dimensional control while maintaining ease of application, as the tape can be accurately positioned and applied to the damaged area without the flow and settling issues associated with slurries.
3Productivity
If conventional braze materials are used, then the repair process can be completed, but impurities remain in the repaired area affecting the quality of the braze joint
Solution Approach 1:
The patent extracts and removes harmful boron and silicon elements from the braze material composition. By eliminating these elements that generate impurities during the brazing process, the resulting braze joint has fewer inclusions and impurities, improving the overall quality and integrity of the repair.
Solution Approach 2:
The patent changes the chemical composition parameters of the braze material to exclude elements that form harmful impurities. This parameter change ensures that during the brazing process, fewer unwanted compounds and inclusions are formed, resulting in a cleaner, higher-quality braze joint.
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 structural braze tape achieves a braze joint with structural strength approaching that of the original superalloy substrate, enabling effective repair and creation of components with similar integrity, while providing better dimensional control and reduced impurities.
Implementation Method 1
The composition may include a fluxing agent that cleanses impurities during the brazing operation
Implementation Method 2
The assembly is heated and then cooled to produce a braze-repaired component
Implementation Method 3
Braze materials may be used in the production and repair of gas turbine engine components
Implementation Method 4
The assembly is heated and then cooled to produce a braze-repaired component
Data Source
AI summary
A braze tape (12) useful with superalloy materials. In one embodiment, the tape includes a layer (14) containing superalloy powder (22) in a binder (24), and a layer (16) containing boron and silicon free braze material powder (32) in a binder, joined together by a layer (18) of double-sided adhesive fluorocarbon polymer tape, such as a double-sided adhesive polytetrafluoroethylene or Teflon® tape (46).