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Materials and Processes Engineering
PROCESS SPECIFICATION
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REPAIR WELDING - NEW INVESTMENT CAST STATOR PARTS

DOCUMENT REVISION STATUS: DETERMINED BY THE LAST ENTRY IN THE "REV" AND "DATE" COLUMN
REV. DESCRIPTION SIGNATURE REV. DATE
J K L M N
REDUCED HEAT TREATMENT CYCLE FOR ALLOY GTD-222, B50A850 AND DELETED GTD-484 B50A854. (CG BECK) ADDED GTD241 (NO Ta GTD222) PER B50A972 TO THE NOZZLE CASTING SALVAGE WELD SPECIFICATION; DCI NO. 03003951. (WT KING) REVISED PRE-WELD HEAT TREATMENT REQUIREMENTS FOR GTD-222; DCI NO. 03010807. (WT KING) REVISED SOLUTION HEAT TREAT TEMPERATURE; DCI NO. 03024788. (WT KING) ADDED GTD-262; DCI NO. 08020040. (SC KOTTILINGAM)
CR TRIPEPI CR TRIPEPI CR TRIPEPI CR TRIPEPI CR TRIPEPI
1998 SEP 28 2003 MAR 17 2003 JUL 14 2003 NOV 24 2008 JUL 29
COPYRIGHT 2009 GENERAL ELECTRIC COMPANY PROPRIETARY INFORMATION - THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OF GENERAL ELECTRIC COMPANY AND MAY NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE WRITTEN PERMISSION OF GENERAL ELECTRIC COMPANY. PREPARED BY:
S.C. KOTTILINGAM
ORIG. ISSUE DATE:
DT-1C
March 1, 1976
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UNCONTROLLED WHEN PRINTED
REPAIR WELDING - NEW INVESTMENT CAST STATOR PARTS 1. SCOPE 1.1 This specification covers the repair welding procedure for investment cast nozzle segments, partitions, turbine shrouds, and other investment cast stator parts made from cobalt-base alloys, nickel base alloys and iron base alloys listed below. Repair of alloys other than those listed is not allowed. Alloys approved for repair welding are: Cobalt Base B50A489 (FSX 414) B50A374 (X40) * 1.3 Nickel Base B50A757 (Inconel 718) B50A850 (GTD-222) B50A972 (GTD241) B50A985 (GTD262) Iron Base B50A715C (CK20) B50A336 (N155) B50A100C (CK20)
1.2
The procedure applies to the repair of defects in new, non-serviced castings and parts. Weld procedure qualification, welder performance qualification, welding techniques and inspection requirements are defined. Combustion parts are specifically excluded from repair welding per this specification.
1.4 2.
APPLICABLE DOCUMENTS 2.1 The following documents shall form a part of this specification to the extent specified herein. Unless otherwise specified, the latest revision shall apply. 2.1.1 General Electric Company P3A-AG4 P3B-AG6 P3B-AG8 P8A-AG1 Fluorescent Penetrant Testing Castings-Precision Investment Radiography of Superalloy Castings Welding-General Specification
*Changed
COPYRIGHT 2008 GENERAL ELECTRIC COMPANY PROPRIETARY INFORMATION - THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OF GENERAL ELECTRIC COMPANY AND MAY NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE WRITTEN PERMISSION OF GENERAL ELECTRIC COMPANY.
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Part Specification Material Specification Process Specification 3. DEFINITIONS 3.1 3.2 3.3
As specified on applicable Part Drawing As specified on applicable Part Drawing As specified on applicable Part Drawing
For definitions pertaining to casting terminology use the List of Definitions in P3BAG6. For definitions pertaining to welding terminology use the list of Definitions in P8AAG1. Added Definitions 3.3.1 3.3.2 Fusion Zone - The volume of metal which was melted during the welding process, as determined by sectioning the weld. Heat-Affected Zone (HAZ) - That portion of metal adjacent to the weld which was not melted, but whose mechanical properties and/or microstructure have been altered by the heat of welding.
4.
ENGINEERING REQUIREMENTS 4.1 General Requirements 4.1.1 In the event of a conflict in repair welding requirements for a part, the order of precedence of requirements shall be as follows: (a) (b) (c) (d) 4.1.2 4.1.3 The drawing Other specifications referenced on the drawing This specification Any specification referenced herein.
The application of this specification shall be a general note to the drawing, or by the precision investment casting specification. Heat Treatment Atmosphere - Vacuum at 5 x 10-3 Torr maximum shall be used during heat treatment. Argon with dew point not exceeding minus 60F may only be used during cooling. Use of atmospheres other than vacuum requires prior written agreement.
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4.2
Repair Weld Procedure Sheet - Repair welding of parts may be performed only on parts for which a Welding Procedure Specification Sheet (Fig. 1) or equivalent, has been prepared and submitted to and approved by M&PE. The procedure sheet must include: the alloy specification, weld filler specification, pre-weld and post-weld heat treatment, and the other welding variables required by this specification. Welder Qualification 4.3.1 Welders shall be qualified for welding P8 or P41 through P47 base metals in accordance with one of the following recognized codes: ASME Boiler and Pressure Vessel Code, NAVSEA S9074-AQ-GIB-010/248, AWSD17.1 or NAVSHIPS 250-1500-1 prior to qualifying for welding. For qualification to this specification the welder shall make a minimum of four trial welds in the same cast part, repairing .125, .250, .500 and .750 inch diameter hemisphere-shaped voids with radiused edges (Preferred) per Fig. 23a . The part containing the trial welds must be made of the same alloy and heat treatment as the parts being considered in the qualification, except that trial welds made on age heat treated parts will qualify welds made on as-cast and solution heat treated parts, and trial welds made on as-cast parts will qualify welds made on solution heat treated parts. Welds will be made in the flat 1G position (See Para. 4.5.5). For qualification of a welder, a cross-section through each trial weld shall be crack-free as determined by examination at 200X magnification. If all trial welds are acceptable, the welder shall have unlimited qualification. Otherwise, the welder shall be qualified to make welds only up to and including the size of the largest satisfactory weld. Casting suppliers shall be responsible for welder qualification and must submit welder qualification certificates along with the 200X photomicrographs to M&PE.
4.3
4.3.2
4.3.3
4.4
Repair Welding Procedure 4.4.1 Removal of Defects Locate the defect accurately, by visual or penetrant inspection per P3AAG4 for surface defects, and by radiography per P3B-AG8 for sub-surface defects. Remove the defect by cutting (e.g., with burring tool), rather than by grinding, to minimize the depth of the machining-affected zone in the repair area. Either cutting or grinding may be used if the defects are removed prior to pre-weld solution heat treatment. However, care should be taken to avoid heat-checking of the repair area.
4.4.1.1
4.4.1.2
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4.4.1.3
Remove the amount of metal necessary to remove the defects. Inspect the repair area for removal of the defects by fluorescent penetrant inspection per P3A-AG4 prior to welding. Complete the preparation of the cavity by removing only sufficient additional metal to obtain the correct configuration of the cavity as shown in Fig. 2.
4.4.1.4
4.4.2
Welding and Heat Treatment Sequence for B50A374 (X40) Weld repairs exceeding volume limits specified in Table II are not allowed unless specified in a Weld Procedure Specification written for the specific drawing number(s) and approved by the purchaser. Solution heat treat per Heat Treat A in Table I. NOTE: Solution heat treat is recommended for optimum repairability for X40, but may be repair welded in the as cast condition.
4.4.2.1 4.4.2.2
4.4.2.3 4.4.2.4 4.4.2.5 4.4.2.6 4.4.3
Repair weld as specified in Para. 4.5 of this specification. Solution heat treat per Heat Treat A in Table I. Age heat treat per Heat Treat B in Table I. For repairs less than .4 in. by .4 in. by .4 in. (volume of 0.064 cubic inch) Heat Treat A is optional but Heat Treat B after weld.
Welding and Heat Treatment Sequence for B50A489 (FSX-414) Weld repairs exceeding volume limits specified in Table II are not allowed unless specified in a Weld Procedure Specification written for the specific drawing number(s) and approved by the purchaser. Solution heat treat per Heat Treat A in Table I. NOTE: Solution heat treat is recommended for optimum repairability for FSX-414, but may be repair welded in the as cast condition.
4.4.3.1
4.4.3.2
4.4.3.3 4.4.3.4 4.4.3.5
Repair weld as specified in Para. 4.5 of this specification. Solution heat treat per Heat Treat A in Table I. Age heat treat per Heat Treat B in Table I.
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4.4.3.6 4.4.3.7
For repairs less than .4 in. by .4 in. by .4 in. (volume of 0.064 cubic inch) Heat Treat A is optional but Heat Treat B after weld. For repairs less than 0.375 inch diameter hemisphere-shaped weld preparation (volume of .0138 cubic inch) Heat Treat A and B are optional if the part is in the age heat treated condition.
4.4.4
Welding and Heat Treatment Sequence for B50A336 (N155) Weld repairs exceeding volume limits specified in Table II are not allowed unless specified in a Weld Procedure Specification written for the specific drawing number(s) and approved by the purchaser. For B50A336A and D (Age; and Solution and Age Heat Treated Conditions):
4.4.4.1
4.4.4.2 4.4.4.3 4.4.4.4 4.4.4.5
Solution heat treat per Heat Treat C in Table I. Repair weld as specified in Para. 4.5 of this specification. Solution heat treat per Heat Treat C in Table I. Age heat treat per Heat Treat D in Table I. For B50A336B and C (As Cast; and Solution Heated Conditions):
4.4.4.6 4.4.4.7
Repair weld as specified in Para. 4.5 of this specification. Solution heat treat per Heat Treat C in Table I. For B50A336A, B, C, and D:
4.4.4.8
For repairs less than 0.375 inch diameter hemisphere-shaped weld preparation (volume of .0138 cubic inch) Heat Treat C and D are optional if the casting is in the final heat treated condition. Castings in the as-cast, or solution heat treated condition need not be solution heat treated prior to repair welding.
4.4.4.9 4.4.5
Welding and Heat Treatment Sequence for B50A715C or B50A100C (CK20) Weld repairs exceeding 1.0 cubic inch are not allowed unless specified in a Weld Procedure Specification written for the specific drawing number(s) and approved by the purchaser.
4.4.5.1
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4.4.5.2 4.4.5.3 4.4.5.4 * 4.4.6
Repair weld as specified in Para. 4.5 of this specification. Solution heat treat per Heat Treat E in Table I. For repairs less than .4 in. by .4 in. by .4 in., Heat Treat E is optional if the casting is in the solution heat treated condition.
Welding and Heat Treatment Sequence for B50A850 (GTD-222), B50A972 (GTD241) and B50A985 (GTD262) Weld repairs exceeding volume limits specified in Table III are not allowed unless specified in a Weld Procedure Specification written for the specific drawing number(s) approved by the Purchaser. Solution heat treat per Heat Treat J in Table I. An alternate heat treat cycle may be used with approval of GE M&PE and the heat treat cycle must be documented in the MPP. Repair weld as specified in Para. 4.5 of this specification. Solution heat treat per Heat Treat J in Table I. Age heat treat per the applicable Class specified on the Part Drawing and Part Specification. For repairs less than 0.25 inch diameter hemisphere-shaped weld preparation (volume of 0.004 cubic inches) Heat Treat J and L are optional if the part is in the age heat-treated condition. For GTD222 and GTD241, qualification to weld repair one alloy automatically qualifies weld repair for the other alloy. For GTD-262, a separate procedure qualification for weld repair is required. Welders qualified to weld repair GTD-222 and GTD-241 are deemed qualified to weld repair GTD-262.
4.4.6.1
4.4.6.2
4.4.6.3 4.4.6.4 4.4.6.5 4.4.6.6
4.4.6.7 * 4.4.6.8
4.4.7
Welding and Heat Treatment Sequence for B50A757 (Inconel 718) Weld repairs exceeding 3.0 cubic inches are not allowed unless specified in a Weld Procedure Specification written for the specific drawing number(s) and approved by the purchaser. Homogenize heat treat per Heat Treat F in Table I.
4.4.7.1
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4.4.7.2
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4.4.7.3 4.4.7.4 4.4.7.5 4.4.7.6 4.4.7.7
Solution heat treat per Heat Treat G in Table I. Repair weld as specified in Para. 4.5 of this specification. Solution heat treat per Heat Treat G in Table I. Age heat treat per Heat Treat H in Table I. For repairs less than 0.375 inch diameter hemisphere-shaped weld preparation (volume of .0138 cubic inch) Heat Treat F, G and H are optional if the part is in the age heat treated condition.
4.5
Welding 4.5.1 4.5.2 Unless otherwise specified, repair welds shall be made by the Gas Tungsten Arc Welding Process (GTAW). The areas to be welded must be clean. All traces of grease, dirt, pencil marks, inspection materials such as penetrant fluid and developer, heat treat scale or other foreign materials must be removed. Oily types of contamination should be removed by degreasing. Non-oily types of contamination may be removed by liquid abrasive blasting, grit blasting, or other suitable mechanical means. Castings must be at a temperature not lower than approximately 50F for welding. Materials and Process Engineering must approve preheating temperatures of greater than 100F. Argon gas backing, or an argon gas welding chamber must be used for all through defects. If copper is used in the backing fixture and is within 0.100 from the weld repair, it must be nickel or chromium plated to a minimum of 0.002 thickness. When using Argon backing gas, take preventative measures to eliminate the aspiration of air to the backside of the weld. 4.5.5 Gas Tungsten Arc Welding Electrodes: 1/16-3/32 inch diameter, 2% thoriated tungsten, pointed. Average Arc Voltage: 12-14 volts, straight polarity, direct current. Welding Current: 100 amps max. Arc shall have controlled decay to 10 amps or less before the arc is interrupted.
4.5.3
4.5.4
4.5.5.1 4.5.5.2 4.5.5.3
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4.5.5.4 4.5.5.5
Torch: Gas lens type cup must be used. Electrode stick-out must be kept at a minimum to prevent electrode melt-off. Argon Supply: Argon gas must meet the GE Material Specification D27A8C. The argon supply for both the welding torch and the back-up must be equipped with flow meters. Argon Gas Flow: The shielding gas flow at the torch should be 15 to 20 CFH unless otherwise recommended by the torch manufacturer for the selected electrode stick-out and lens cup configuration to obtain the optimum gas coverage. Welding Position: Welding shall be done in the flat position.
4.5.5.6
4.5.5.7 4.5.6
Weld Filler Alloy Unless written permission to deviate is obtained from M&PE the following filler alloys shall be used: Casting X-40 (B50A374A) FSX-414 (B50A489) N155 (B50A336) CK20 (B50A715C) or CK20 (B50A100C) INCO 718 (B50A757E&F) GTD-222 (B50A850) GTD-241 (B50A972) GTAW Weld Filler Metal FSX414LC (B50A823A) MAR-M918 (B50A824A) FSX414LC (B50A823A) MAR-M918 (B50A824A) N155 (AMS 5794) ER310 (AWS 5.9 ER310) or ER309 (AWS 5.9 ER309) INCO718 (AMS 5832) NIMONIC C263 (B50A783) NIMONIC C263 (B50A783) NIMONIC C263 (B50A783)
4.5.6.1
GTD-262 (B50A985)
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NOTE: (1) Repair welds on the gas path surfaces of FSX-414 first stage nozzles made with filler metal other than FSX414LC must be overlaid with .030 minimum of FSX414LC.
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(2) Use of L605, AMS5796, weld filler is prohibited. 4.5.6.2 4.5.7 For all GTAW, the filler wire (bare) diameter should not exceed 0.125 inches.
Welding Technique - The recommended technique for applying weld metal is as follows: For surface holes, start the weld disposition at the center of the cavity and apply filler alloy in a spiral bead towards the outer circumference of the cavity (Fig. 2). The entire spiral bead, however, should not be made in one single pass. Time must be allowed for cool-down (to less than 350F) after completing each 360 traverse or when the weld puddle reaches the weld starting point. All oxide should be removed and re-entrant and/or lack-of-fusion areas should be blended smooth before making the next pass (360 section of a spiral bead). Apply the filler alloy successive passes in the same manner until the cavity is filled. Heat input must be kept to a minimum through the use of low current employing stringer beads and using higher travel speed. For through holes (Fig. 2, 1-a, 1-b), make an initial pass with filler alloy around the entire circumference of the cavity making sure that the beveled edge is completely fused and that there is no undercut of lack of fusion on the back side of the weld. Allowing cool-down (to less than 350F) between passes, apply filler alloy in successive passes around the circumference of the remaining hole until the entire cavity has been closed. Then apply successive layers of filler alloy, following the same pattern, until the cavity is filled. Interpass cleaning practices and low heat input welding techniques must be used. For edge welds in thin sections, e.g., airfoil trailing edges, the cavity will usually be in the form of a through-going notch. If the notch is near a sidewall (Fig. 2; fillet defect repair), apply filler alloy first along the edge of the cavity nearest the sidewall and with successive passes. Fill the cavity from the sidewall toward the center of the airfoil. If the notch is not adjacent to a sidewall, apply the filler alloy along the section of maximum thickness and continue filling the cavity with successive passes until the trailing edge is complete. Allow time for cool-down between passes and grind and/or wire brush the weld deposit as necessary after each pass.
4.5.7.1
4.5.7.2
4.5.7.3
4.5.7.4
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4.5.8
Interpass Treatment After each weld pass allow the weld area to cool to less than 350F. Visually inspect the weld surface after each pass for cracks in the fusion zone and in the base material adjacent to the weld and also for oxide inclusions, etc. This should be done before the weld is cleaned; i.e., before any such defects are obscured by smearing of the weld surface. All defects in the weld must be removed before making the next weld pass. Clean the weld surface when applicable after each weld pass with powerdriven burring tool and/or circular brush with stainless steel bristles or by sand blasting, or with hand scratch brush (stainless steel bristles).
4.5.8.1 4.5.8.2
4.5.8.3
4.5.9 Post Weld Treatment - After welding, welds shall be ground or machined to the required contour of the part on both external and internal surfaces. Castings shall be post-weld heat treated as specified in Para. 4.4and Table I. If straightening is required, it shall be performed before the final heat treatment except that nozzle flow area correction may be performed after the final heat treatment. All welds shall be inspected for soundness by visual, fluorescent penetrant and radiographic methods described in the Process Specification P3BAG6, "Castings Precision Investment". 5. QUALITY ASSURANCE REQUIREMENTS 5.1 The quality requirements specified in the applicable Part Specification must be met before the part is deemed acceptable by the purchaser. These quality requirements pertain to the entire casting including the weld-repaired areas.
6.
NOTES 6.1 6.2 6.3 Figure 1 - Repair welding Procedure Specification Sheet Figure 2 - Repair Weld Preparations Weld metal volume limits refer to the weld volume remaining after blending or machining operation. The volume of welded-in patch base metal is also excluded.
/ct-07-25-08
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*TABLE I
FSX414 AND X40 HEAT TREATMENTS Solution Heat Treat A Heat to 2100F + 25F in vacuum. Hold at temperature for 4 hours. Cool rapidly (at a rate between 500F and 3000F per hour) to 1000F or below. Cool at any convenient rate to room temperature. Age Heat Treat B Heat to 1800F 25F in vacuum. Hold at temperature for 4 hours. Furnace cool to 1000F or below. Cool at any convenient rate to room temperature. N155 HEAT TREATMENTS Solution Heat Treat C Heat to 2100F + 25F in vacuum. Hold at temperature for 2 hours. Cool rapidly (at a rate between 500F and 3000F per hour) to 1000F or below. Cool at any convenient rate to room temperature. Age Heat Treat D Heat at any convenient rate to 1650F. Hold at temperature for 16 hours. Cool at any convenient rate to room temperature. CK20 HEAT TREATMENT Solution Heat Treat E Heat to 2050F + 25F in vacuum. Heat at temperature for 2 hours. Cool rapidly (at a rate between 500F and 3000F per hour) to 800F or below. Cool at any convenient rate to room temperature. INCONEL 718 HEAT TREATMENTS Homogenize Heat Treat F Heat to 2000F 25F in vacuum Hold at temperature for 2 hrs. 10 minutes. Cool at a rate of 5 to 20F per minute to 1400F. Rapid cool to room temperature. Solution Heat Treat G Heat to 1750F 25F in vacuum. Hold at temperature for 1 hour. Cool to 1100F within 23 minutes. Rapid cool to room temperature. Age Heat Treat H Heat to 1325F 25F in vacuum. Hold at temperature for 8 hours. Furnace cool to 1150F 25F for 8 hours. Hold at 1150F 25F for 8 hours. Cool at any convenient rate to room temperature. GTD-222, GTD-241 and GTD-262 Heat Treatments Solution Heat Treat J Heat to 2050 or 2100F 25F in vacuum (1) as fast as possible. Hold at temperature for 2 hours. Cool rapidly at a rate in excess of 50F per minute to 1000F or below then cool at any convenient rate to room temperature. Age Heat Treat L Heat to 1475F 25F in vacuum. Hold at temperature for 4 hours, cool Furnace cool to 1000F or below. to 1000F at rate not less than 25F per minute, then cool at any convenient rate to room temperature.
(1)
Supplier must select target solution heat treat temperature (2050F or 2100F) and record the target solution temperature in the MPP. Solution heat treat of components outside the target temperature must be submitted as a deviation even if the temperature is within the specification temperature range.
*Changed
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TABLE II
Area W
Inner and outer sidewalls ; end lugs; shank except 0.75" zone adjacent to airfoil. 1.0" band from leading edge radius; and fillet radii at sidewalls. 1.0" band from trailing edge. Airfoil not defined as Area Y, and .75" of shank adjacent to airfoil. ALLOWED MAXIMUM VOLUME OF WELDMENT PER REPAIR FIRST STAGE
Area Y Area Y(TE) Area Z
AREA Y(TE) Y&Z W
LIMIT 0.5 Cu. In. 1.0 Cu. In. 1.5 Cu. In.
SECOND AND THIRD STAGE Y(TE) Y&Z W 1.0 Cu. In. 2.0 Cu. In. 1.5 Cu. In.
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TABLE III ALLOWED MAXIMUM VOLUME OF WELDMENT PER ZONE SECOND AND THIRD STAGE NOZZLE SEGMENTS ZONE DESCRIPTION LIMIT (Cubic Inch) 0.5 in.3
OSW (Outer Sidewall) - Airfoil Fillet 0.5 Inch Flats in Either Direction (Airfoil and OSW) Extending From Center of Fillet 1.0 Inch Band from TE (Trailing Edge) 1.0 Inch Band from LE (Leading Edge) and 1.0 Inch Band from ISW (Inner Sidewall) Fillet Airfoil Not Defined By X or Y Inner Sidewall (ISW) Outer Sidewall (OSW)
X Y
0.5 in.3 1.0 in.3 1.5 in.3 1.5 in.3 1.5 in.3
Z W
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FIGURE 1
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Procedure No.: Issued: Revised: WELD REPAIR PROCEDURE Customer Casting Specification and Alloy Heat Treated Condition Required for Welding
Weld Filler and Rod Alloy and Specification Customer's Welding Specification Special Instructions
Welding Preheat Temperature Post-Weld Heat Treatment
Welding Schedule
Method: Inert-Gas-Shielded, Tungsten-Arc, Manual Equipment: Miller AC-DC Welder, Model 330A/BP or 320A/BP Electrodes: 2% Thoriated Tungsten, 1/16" - 1/8" diameter Polarity: Gas:
Current: Remarks: Approvals
Engineering Dept. Metallurgical Dept. Customers Representative
Date Date Date
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FIGURE 2 REPAIR WELDING PREPARATION
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FIGURE 2 (Cont'd.) REPAIR WELDING PREPARATION

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REPAIR WELDING - NEW INVESTMENT CAST STATOR PARTS

CR TRIPEPI CR TRIPEPI CR TRIPEPI CR TRIPEPI CR TRIPEPI

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4.4.3.3 4.4.3.4 4.4.3.5

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4.5.5.1 4.5.5.2 4.5.5.3

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Area Y Area Y(TE) Area Z

AREA Y(TE) Y&Z W

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Welding Preheat Temperature Post-Weld Heat Treatment

Current: Remarks: Approvals

Engineering Dept. Metallurgical Dept. Customers Representative

Date Date Date

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FIGURE 2 (Cont'd.) REPAIR WELDING PREPARATION

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