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Customer Challenge

High Pressure NGV of an aero engine had exhibited cracks on its land and at the adjacent seal slots. This occurrence required a weld repair process to be developed in order to restore component to its original design intent. The repair process had to address below challenges:

  • Acceptable welding achievement at Thermal Barrier Coating (TBC) region of damage
  • Achievement of acceptable material properties due to change in microstructure at weld region
  • Evade possibility of weld failure

Scope

  • Create repair solution, support customer approval process and publish manuals

Solution

  • Repair solution for validation trials
  • Weld parameters
  • Final repair process and control parameters for buy-off by customer specialists
  • Engine Manuals with approved procedures

Benefits

  • Trial welding on sample blade to prove repair process
  • Engineering Analysis to justify acceptability of absence of TBC at weld region
  • Trial blade lab tested for micro structure

Features

  • Trial welding on sample blade to prove repair process
  • Engineering Analysis to justify acceptability of absence of TBC at weld region
  • Trial blade lab tested for micro structure.

Results

  • An usual alternative repair method of Wide Gap Brazing would have resulted in phenomenal increase in repair cost