ETN Global

SGT-A35 User Group

2018 Meeting
April 26-27, Barcelona, Spain

MRO Presentation
Liburdi Turbine Services Inc

Lloyd Cooke, P. Eng

1
 Liburdi Group of Companies
• Liburdi Engineering Ltd
• Liburdi Turbine Services Inc.
• Liburdi Automation Inc.
• Liburdi Dimetrics Corp

Dundas, Ontario Canada

Stoney Creek, Ontario, Canada

• Amsterdam
• St Petersburg, Russia
• Abu Dhabi, UAE
Mooresville, NC, USA
2
 Liburdi Group of Companies
Turbine Services Engineering Automation Dimetrics

• Industry Leader in • Component Life Analysis • Industry Leader in • Pioneer in development

development of • Failure Analysis automated welding of orbital welding
advanced component • Coating Evaluation systems for turbine, systems
repairs and Selection aerospace, industrial, • Portable tube welders
• Worlds only source and tub mill applications • Goldtrack ® welding
• Component Design
for Rejuvenation • Pulsweld system systems
technologies • Engine Health and renowned for accuracy
Performance • Precision welding
• Blades, Vanes, and and repeatability systems for tube and
Combustor Components • Training Seminars • Every major turbine OEM pipe, medical devices,
• GE, Rolls-Royce, Siemens using our systems power plant, nuclear, and
Westinghouse, Alstom, & automotive
Solar
“Synergy In Technology“ Across The Group 3
Turbines Served
Liburdi Turbine Services is the leading provider
of advanced-technology component repairs, extending lives
of critical gas turbine components

Aero-Derivative Light Industrial Heavy Duty

GE – LM2500 Siemens – TB5000 F-Class - 6FA, 7FA, W501F, V84.3A

GE – LM1600 Siemens – SGT100 Typhoon GE Frame 3, 5, 6B , 7EA, 9E, GE10
GE – LM6000 Siemens – SGT400 Tornado Siemens W101, W191, W251, W501
SGT-A05 501K Solar - Centaur Siemens V84, V94
SGT-A20 Avon Alstom 11N, GT24/26
Also FAA Commercial Aircraft
SGT-A35 RB211 PW2000, V2500,
Industrial Spey 4
Materials and Repair Seminar

Slides selected from 2 day seminar

Basic Gas Turbine Materials and Repair

Seminar/Workshop
Seminar presented each year at various locations worldwide

5
 GT Component Repairs – Why ?
• Maintenance, after fuel, is the main operating cost over the life cycle of a
gas turbine engine
• Spare part replacements and repairs of hot section components
represent the major cost portion of all Maintenance
• Typically a component repair will cost 10% - 30% of the replacement new
part cost
• Therefore, repairs represent the main cost savings opportunity for the
operator
• Repair is ecologically favourable; less resources and energy required

6
Why are they referred to as Superalloys?

•Unlike other metals such as steel – they retain their strength at

high temperatures

•Because they have remarkable mechanical strength up to 80%

of their incipient melting point.

•They exhibit the highest surface stability at elevated

temperatures.

•They are also “Exotic” as they can contain up to 14 elements.

7
Overview of why Superalloys
are used in Gas Turbines
• Excellent mechanical properties in the service range that gas
turbine materials operate in, even after prolonged service
• Excellent creep strength
• Useful mechanical strength
• Good fatigue and thermal fatigue properties
• Adequate ductility and toughness (low crack growth rates)
• Useful thermal expansion characteristics
• Excellent resistance to oxidation and corrosion
• Alloy additions form self-healing protective scales
• Fabricability (forging, casting, welding, machining, coating)

8
Superalloy elements - and Why?
• Alloy “Solvent” must be stable throughout the intended operating
temperature range and be able to dissolve large amounts of
“Solute”. Usually a mixture of nickel and cobalt
• Protective scale formers added for oxidation protection; provided
by aluminum & chromium,
• Heavy “refractory” elements added for solution hardening,
molybdenum, niobium, rhenium, tantalum, tungsten
• Precipitation forming elements added for strengthening
aluminum, titanium, niobium
• Grain boundaries are strengthened (or controlled) carbon,
hafnium, zirconium, boron
• Deleterious “tramp” elements are rigorously limited - sulphur,
lead, silver

9
Compositions and Properties
Nickel Based Alloys
•Sheet alloys like solid-solution HasteloyX, Nimonic263, IN617
have low aluminum + titanium content have excellent
formability, used for combustor section fabrications and
lightly loaded combustion liner segments.

•Forged alloys like Udimet520, Nimonic105, X750 have a

moderate aluminum + titanium content, have good mechanical
properties but are forgeable. Used for low and intermediate
temperature blades.

•Cast alloys like CMSX2, GTD111, IN738, MM247 have a high

aluminum + titanium content, have excellent mechanical
properties at elevated temperature and are used for highest
temperature blades. Lower ductility means forming is not
possible
10
What are the Materials?
Piping, tubing,
Compressor Combustor Turbine Stationary valves, etc.
Some 300SS 300SS 300SS, 400SS, C242, C1023 Steel
403, 410, 422, Hastelloy-X, RA-33 N-155, M509, HS-188,L605
450 Stainless L-605 Compressor
X-40, X-45, FSX-414, ECY-768
IN718 IN-600, IN-617 Casings
IN738, R80, GTD222, GTD444
Ti64 titanium MarM002 Grey Cast Iron
Nimonic 75, Nimonic 263
Carbon Steel
M152 Haynes 230
Aluminium
Turbine Shells
Ductile Cast Iron
Stainless Steel
Nickel Alloy
Compressor
Wheels/Disks
Ni-Cr-MO-V
Forging
Turbine
Wheels/Discs
Ni-Cr-MO-V Steel
Cr-Mo-V Forging
Turbine Rotating 12Cr Stainless
N105, N108, N115, Waspalloy, U-500, Discalloy
U520, U700,U710, U720, INX750, IN738, A286
Rene80, GTD111, Mar-M247, Mar-M002, IN718
PWA1483, CMSX4, ReneN5 11
Precipitation Strengthening
Achieved by adding elements to form second phases within the
metallic grains.
In nickel superalloys;
Aluminum & titanium added to form ´, Ni3(Al, Ti)
Niobium additionally added to form ˝, Ni3(Al, Ti, Nb).

´ effective for
strengthening to
Al 2000oF (1090oC).

˝ only effective
for strengthening to
 Ni 1200oF (650oC).

Added elements occupy specific locations with the lattice

This leads to coherency between the phases 12
Precipitation Strengthening:
Gamma Prime (´) Strengthening
Aluminum & titanium added to form ´, Ni3(Al, Ti)
Niobium additionally added to form ˝, Ni3(Al, Ti, Nb).

Cuboidal primary
´ phase

Spherical
secondary ´
phase

13
Casting Technologies

Equiaxed (EQ)
Conventionally Cast (CC) Directionally Solidified (DS) Single Crystal (SC or SX)
[polycrystalline - random] [polycrystalline - textured] [monocrystalline]

MarM002 MarM002DS RR2200

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Equiaxed Grain Structure
Directional Solidified Grain Structure
Single Crystal Structure

MarM002

15
 Cast Nickel Based Alloy Compositions

Alloy Ni Cr Co Mo W Ta Nb Al Ti Fe Mn Hf C B Zr Others

Alloy 713C 74 12.5 0.0 4.2 0.0 0.0 2.0 6.1 0.8 0.0 0.0 0.0 0.12 0.012 0.10

B-1900 64 8.0 10.0 6.0 0.0 4.0 0.0 6.0 1.0 0.0 0.0 0.0 0.10 0.015 0.10

C-1023 58 15.5 10.0 8.5 0.0 0.0 0.0 4.2 3.6 0.0 0.0 0.0 0.16 0.006 0.00

GTD-111 60 14.0 9.5 1.5 3.8 2.8 0.0 3.0 4.9 0.0 0.0 0.0 0.10 0.01 0.03

GTD-222 51 22.5 19.0 0.0 2.0 1.0 0.8 1.2 2.3 0..0 0.0 0.0 0.10 0.010 0.01

IN-100 60 10.0 15.0 3.0 0.0 0.0 0.0 5.5 4.7 0.0 0.0 0.0 0.18 0.014 0.06 1.0 V

IN-738LC 61 16.0 8.5 1.7 2.6 1.7 0.9 3.4 3.4 0.0 0.0 0.0 0.11 0.010 0.05

IN-939 48 22.5 19.9 0.0 2.0 1.4 1.0 1.9 3.7 0.0 0.0 0.0 0.15 0.009 0.09

IN-792 61 12.4 9.0 1.9 3.8 3.9 0.0 3.1 4.5 0.0 0.0 0.0 0.12 0.020 0.10

MarM-002 61 9.0 10.0 0.0 10 2.5 0.0 5.5 1.5 0.0 0.0 1.5 0.14 0.015 0.05

MarM-247 60 8.3 10.0 0.7 10 3.0 0.0 5.5 1.0 0.0 0.0 1.5 0.10 0.015 0.05

CMSX- 2 66 8.0 4.6 0.6 7.9 5.8 0.0 5.6 0.9 0.0 0.0 0.0 0.00 0.000 0.00

PWA-1483 61 12.8 9.0 1.9 3.8 4.0 0.0 3.6 4.0 0.0 0.0 0.0 0.07 0.0 0.0

Rene-N5 62 7.0 8.0 2.0 5.0 7.0 0.0 6.2 0.0 0.0 0.0 0.2 0.0 0.0 0.0 3.0 Re

CMSX-10 62 3.0 6.0 1.0 6.0 8.5 0.3 6.0 0.8 0.0 0.0 0.1 0.0 0.0 0.0 6.0 Re

16
 Cast Nickel Based Alloy Compositions

Alloy Ni Cr Co Mo W Ta Nb Al Ti Fe Mn Hf C B Zr Others

Alloy 713C 74 12.5 0.0 4.2 0.0 0.0 2.0 6.1 0.8 0.0 0.0 0.0 0.12 0.012 0.10

B-1900 64 8.0 10.0 6.0 0.0 4.0 0.0 6.0 1.0 0.0 0.0 0.0 0.10 0.015 0.10

C-1023 58 15.5 10.0 8.5 0.0 0.0 0.0 4.2 3.6 0.0 0.0 0.0 0.16 0.006 0.00

GTD-111 60 14.0 9.5 1.5 3.8 2.8 0.0 3.0 4.9 0.0 0.0 0.0 0.10 0.01 0.03

GTD-222 51 22.5 19.0 0.0 2.0 1.0 0.8 1.2 2.3 0..0 0.0 0.0 0.10 0.010 0.01

IN-100 60 10.0 15.0 3.0 0.0 0.0 0.0 5.5 4.7 0.0 0.0 0.0 0.18 0.014 0.06 1.0 V

IN-738LC 61 16.0 8.5 1.7 2.6 1.7 0.9 3.4 3.4 0.0 0.0 0.0 0.11 0.010 0.05

IN-939 48 22.5 19.9 0.0 2.0 1.4 1.0 1.9 3.7 0.0 0.0 0.0 0.15 0.009 0.09

IN-792 61 12.4 9.0 1.9 3.8 3.9 0.0 3.1 4.5 0.0 0.0 0.0 0.12 0.020 0.10

MarM-002 61 9.0 10.0 0.0 10 2.5 0.0 5.5 1.5 0.0 0.0 1.5 0.14 0.015 0.05

MarM-247 60 8.3 10.0 0.7 10 3.0 0.0 5.5 1.0 0.0 0.0 1.5 0.10 0.015 0.05

CMSX- 2 66 8.0 4.6 0.6 7.9 5.8 0.0 5.6 0.9 0.0 0.0 0.0 0.00 0.000 0.00

PWA-1483 61 12.8 9.0 1.9 3.8 4.0 0.0 3.6 4.0 0.0 0.0 0.0 0.07 0.0 0.0

Rene-N5 62 7.0 8.0 2.0 5.0 7.0 0.0 6.2 0.0 0.0 0.0 0.2 0.0 0.0 0.0 3.0 Re

CMSX-10 62 3.0 6.0 1.0 6.0 8.5 0.3 6.0 0.8 0.0 0.0 0.1 0.0 0.0 0.0 6.0 Re

17
Hot Section Coating Requirements
COATING SELECTION COATING PROCESSES

• Effectiveness • Functional Coatings

• Addresses the need • Diffused aluminides
• Multiple capabilities • MCrAlY overlays
• Stability • Ceramic TBC overlays
• Microstructure • Coating Processes
• Self-renewing • Pack Cementation
• Mechanical Durability • Slurry / Paints
• Suitability • Chemical Vapor Deposition
• Processability • Thermal Spraying
• No “side effects” • Physical Vapor Deposition
• Cost / value

18
 Cyclic Oxidation Mechanism
• Aluminum oxide scale formed on surface of nickel base alloys – the
scale is a barrier to additional oxidation and is protective
• During thermal cycling, the difference in thermal expansion coefficients
(metal>>oxide) between the oxide and metal leads to stresses at the
interface
• Spalling will result – therefore scale adhesion is necessary for good
oxidation performance

Quasi-linear oxide growth under cyclic oxidation

19
Nickel Aluminide Diffusion Coatings
• Aluminum content forms a protective oxide scale on surface.
Thickness of coating provides a reservoir of aluminum, but
coatings need to be periodically replaced.

• Nickel content is derived from base material. This diffusion

creates a “metallurgical bond”. Presence of other alloying
elements in base material is a consideration.

• 1950’s First Introduced Pack Aluminides

• 1977 Introduced Platinum Aluminides

• Used Extensively on turbine airfoils since 1970’s

Silicon Alumindes - Sermaloy J, LSR SiAl,

Platinum Aluminides LSR PtAl,

20
 Nickel Aluminide Diffusion Coatings
Compositions & Microstructures
Silicon Aluminide Platinum Aluminide

Nickel Aluminide Platinum Aluminide Chromium Aluminide

Ni Al (Pt, Ni) Al (Cr, Ni) Al

• Aluminide coatings showing aluminum rich beta phase

surface layer and diffusion zone into the base metal

• Modified Aluminides use the addition of Platinum, Silicon,

Chromium to enhance the coating oxidation or corrosion
resistance
21
• Coating thickness as diffused - .001 - .003 inches 30-80um
 MCrAlY Overlay Coatings

• Introduced in 1970’s for turbine blades to balance oxidation

and corrosion protection.
• M = Metal (Nickel-Cobalt-Iron Alloy)
plus Chromium, Aluminum, Yttrium, trace elements
• Thick (0.005”-0.010”) - used extensively on industrial frame
blades and vanes
• May have over-coating of diffusion aluminide to improve
oxidation protection (GT33 Plus)
• Also used as Bond Coating for Thermal Barrier Coatings
• Applied by physical means; typically thermal spraying.

22
 MCrAlY Overlay Coatings
• Overlay coatings are applied by thermal spray which results in minimal
reaction with the substrate
• This allows greater freedom to tailor coating composition than in diffusion
coatings

Typical thickness
0.005 to 0.010”

Comparison of diffusion and overlay coatings

23
MCrAlY Composition
There are three main classes of MCrAIY’s in use:

The specific alloys are tailored to the specific application:

• Higher chromium and/or cobalt for hot corrosion
applications
• Higher aluminum for oxidation resistance
• Other elements can be added, Si, Hf, Ta, Ru…..
24
MCrAlY Microstructure

NiCoCrAlY Coating NiCoCrAlY with over-aluminizing

• The microstructure of MCrAlY coatings consists of aluminide

particles in an austenite matrix
• MCrAlY may be over-aluminized with diffusion aluminide to
increase the aluminum content of the surface for better
oxidation resistance
25
Thermal Spray Microstructures

LPPS Coating HVOF Coating APS coating

Low Pressure Plasma Spray High Velocity Oxy Fuel Air Plasma Spray

• Dense and uniform coatings are preferred for MCrAlY coatings as they
better isolate the base metal from gas infiltration
• Except as bond-coatings under TBC’s, in these applications the
porosity and defects allow differential thermal expansion
• Clean and rough interfaces promote better adhesion.
26
Comparative Oxidation and
Corrosion Performance

PtAl

Silicon Al

Cyclic oxidation resistance at 1125˚C on GTD111 Alloy

27
Thermal Barrier Coatings (TBC)

• Thermal Barrier Coatings are applied over an MCrAlY bond coating. Bond
coating provides oxidation/corrosion resistance; TBC provides thermal
insulation layer
• Repair surface must be clean of oxides/contamination to ensure good bond
and adhesion of MCrAlY bond coat. The bond coat is usually applied with a
rough surface to assist in the bonding of the TBC top coat.
• TBC is applied by Air Plasma Spray (APS) on large and loss-critical
hardware like combustor components and vanes.
• TBC is applied as Electron Beam Physical Vapour Deposition (EBPVD) in
a low pressure chamber on small and critical components like blades.

28
Comparison: EBPVD and Thermal Spray;
Two Different TBC Microstructures
• Columnar microstructure
• Excellent strain tolerance
• Requires a flat bond coat
• Yttria Stabilized Zirconia bonds to
Aluminum Oxide interface scale
• Deposited at >900˚C
• Porous, lamellar microstructure
• Good strain tolerance due to porosity
and sub-critical microcracks
• Requires a rough bond coat surface
for Yttria Stabilized Zirconia’s
mechanical bonding
• Deposited at <300˚C
29
Commercial Coatings – Partial List
• Simple Aluminides Pack – PWA 273, Codep, RT21, AEP

• Simple Aluminides CVD – PWA275, RT47, LOM

• Chrome Aluminides – RB505, PWA63

• Silicon Aluminides – PWA73, Sermaloy J, LSR

• Platinum Aluminides – LDC-2E, RT22, RT44, 1595

• NiCoCrAlY – GT33, PWA211, PWA286, ATD63, SV20

• CoNiCrAlY – GT29, ATD70

• Thermal Barrier Coatings – Zircoat, DVC-TBC, GPX

• Compressor Airfoil Coatings – SermatelW, 5380DP, CC1, Ceral3450

30
Thermal Mechanical
Fatigue (TMF) Damage
• Transient thermal strains during start-up and shutdown cycles
combined with the steady state thermal and centrifugal loads
generate a complex low cycle fatigue load on turbine parts –
thus TMF life is a function of start/stop cycles

Transient Thermal Strain in a Vane Segment

31
Thermal Mechanical
Fatigue (TMF) Damage

32
Thermal Mechanical
Fatigue (TMF) Damage

A Intergranular TMF Crack in Udimet 520 Alloy (50X)

33
High Cycle Fatigue (HCF)
• High cycle fatigue in turbines is most frequently excited by
an engine order fatigue load
• It should be recognized that, at these frequencies, millions
of cycles can be accumulated in a few hours
• As such, turbine components are not designed with a HCF
life – they should have infinite life under normal operating
conditions
• Conversely HCF damage can be accumulated very rapidly
under non-design conditions

34
High Cycle Fatigue (HCF)

HCF Fracture Features – crack initiation

35
High Cycle Fatigue (HCF) (Cont.)
• High cycle fatigue fractures typically show the cyclic growth of
the crack with each cycle by the formation of fatigue striations
on the crack surface
• Beach marks may be formed by episodic
crack growth

HCF Fracture Features

36
Microstructure - ´ Aging
• The metal temperatures in the hot section are high enough
that growth of ´ particles takes place by diffusion to
minimize the interfacial energy
• The particle growth takes place at constant volume fraction
(ie. there are fewer larger particles)

Change in Alloy IN738 after 24,000 hours

37
 Creep Damage
• Grain boundary sliding during creep deformation leads to
the formation of voids along the boundaries and eventually
to inter-granular failure
• Since creep is a time, temperature and stress dependent
mechanism, there is a finite life until rupture
• Creep lifing of components is determined on this basis,
using the calculated temperature and stress for the
component and the Larson-Miller curve for the alloy
• For engines operating under non-standard conditions a
different creep life can be predicted

38
 Creep Damage (Cont.)

Creep Voids along grain boundary 20X Magnification 5,000X Magnification

• Inter-granular Cracking and Creep Void

Formation on the Fracture Surface of a
Failed Blade

39
 Environmental Attack: Oxidation

• At High Temp an alloy or coating will reach a point

where alloying elements cannot diffuse to the
surface fast enough to maintain a protective oxide
layer (Al2O3)
• At this point, oxygen diffuses into the substrate
and reacts to form internal-oxides and a significant
alloy depleted layer is evident
• Time to reach this point is a function of;
– hours of operation and
– Start/stop cycles, since oxide spalling Oxidation may appear as
accelerates the process white or black roughened
areas, often correlated to
design features

40
Environmental Attack Hot Corrosion

• Alkali sulphate salts deposit on the component surfaces (salt

+ sulphur)
• Sulphur is usually present as a contaminant in the fuel
• Salts of sodium and potassium may be present as
contaminants in fuel, air or water
• Fluxing of the protective oxide layer results in reaction with
the alloy at a greatly accelerated rate
• Oxides of vanadium and lead have a similar contamination
effect, vanadium is particularly detrimental to TBC coatings

41
Environmental Attack - Hot
Corrosion (Cont.)
• Distinctive scale morphologies associated with each
temperature range have been identified, but attack with
features of both scales is commonly identified

Type I Attack Type ll Attack

42
 Environmental Attack - Hot Corrosion (Cont.)

• Hot corrosion occurs most

Hot Corrosion Oxidation
rapidly at two temperatures
where different
Type II
mechanisms operate:
Sulphur
Type I Oxidation • Low temperature (Type II)
Corrosion Rate

Dependent
rate hot corrosion takes place
Sulphur most rapidly at
Independent approximately 700˚C
(1300˚F) and only in high
Sulphur environments
Na2SO4
Dewpoint • High temperature (Type I)
hot corrosion occurs at
700 800 900 approximately 875˚C
Temperature [°C] (1600˚F)
43
43
 Coating Degradation - Depletion

• In service, beta NiAl phase diffuses to the surface to replenish surface

aluminum oxide formers
• Coating life determined by remaining aluminum rich beta phase – when
beta is exhausted coating thickness rapidly diminishes to point of failure

44
Coating Degradation - Cracking

• Coatings can be brittle relative to the base metal

• Coating cracks in coating can some times drive
into the base metal
45
Coating Degradation - TBC's

TBC Long Term Failure Mechanisms

46
 Metallurgical Sectioning Plan

• Sectioning plan is important, must include

were the damage is expected.
• based on observation and experience
• determine local effects of:
–Temperature
–Stress
–Oxidation
–Corrosion
–Prior repairs
–etc.

47
47
Mechanical Testing
• Stress-Rupture, Creep, Tensile Test Bars
• Compare to new material specifications
• Compare to minimum serviceability limits

48
48
Common Repair and Refurbishment
Operations
• Strip remaining coating

• Pre-repair heat treatments – stress relief and prepare for welding

• Fluorescent Dye Penetrant Inspection (FPI) to identify cracks

• Grind to remove cracks and depleted material adjacent to crack

• Weld to repair cracks and restore dimensions

• Margins and blend to original dimensions/profiles

• Pre- coatinf FPI Inspection

• Recoat gas path surfaces

• Final FPI, Dimensional Inspections

49
Chemical Stripping of Coating
• The repair of coated components requires that old spent
coating be removed from the parts

• Strong, often heated, mineral acids mixtures (H2SO4, H2SO4

HCl, H2NO3 etc.) used to dissolve aluminide phases in the
coating

• The acid compositions are designed and controlled to

selectively remove coating without attacking the substrate
alloy

50
Chemical Stripping: Metallurgical Effects

• Excessive exposure • What should

happen
to the stripping
solutions can lead to
inter-granular attack
of the base metal

• So the process and

handling must be
designed to
minimize exposure
to the solutions • What can happen

51
 Chemical Stripping: Control

• Appropriate selection and control of stripping solutions for

coatings and alloys

• Qualification of process for specific alloys in the appropriate

condition

• Increasing need to strip internal coatings as well as external

coatings – advanced component design now includes internal
coatings

• Non-destructive testing

52
How Compositions Affect Weld Repair
- Nickel based Alloys
• Solid-solution superalloys, HastX, Haynes230, IN617 IN625 (zero to low
aluminium+titanium) are weldable
• Superalloys with high gamma-prime (´) content (high
aluminium+titanium) are difficult to weld because of cracking
• In many cases there is no matching filler metal in wire form, so you may
have to resort to powder as filler metal. This limits available welding
techniques.
• IN625 solid solution alloy has been an industry choice to weld some of
the cast, high gamma prime (´) content superalloys. However it is
relatively weak which limits welding to low stress areas of low to
intermediate temperatures

53
53
 Welding Challenges
Welding of gamma prime
(´) strengthened
superalloys is difficult
compared to welding of
cobalt base alloys or
stainless steel alloys.
• Fusion Zone cracking
MM002
• HAZ cracking
(microfissuring)
• Post weld heat treat
cracking (strain age
cracking)

54
 Gas Tungsten Arc Welding
(GTAW) or “TIG”
• Arc established between the non consumable
tungsten electrode and the work piece.
• The process uses shielding gas (typically Argon
or Helium) and filler metal.
• Most common method for manual welds
• Process advantages include:
– Producing superior quality welds, free of
defects.
–.
GTAW (TIG) welding using DCEN (Direct
Current, Electrode Negative)

Ref (Welding Handbook, Vol.2, 8th edition, AWS)

55
Laser Beam Welding (LBW)
• LASER (light amplification by stimulated
emission of radiation)
• Heat is generated by a concentrated
beam of coherent, monochromatic light.
• The laser beam is directed by fibre-optic
cables or mirrors and then focused to a
spot using lenses.
• High energy density welding
• Low total heat input gives small fusion
zone for clean welds

Laser welded impeller - titanium 56

 Enabling Technologies
Technologies that enable Advanced Repairs
To extend service life, achieve multiple service intervals

Blade Alloy Liburdi Powder LAWS ® Automated High

Rejuvenation Metallurgy LPM ® Welding Performance
FSR® Series 3000™ Weld Alloys Coatings
Returning Higher strength Laser, PAW, GTAW TBC
turbine blades than welding and Oxidation resistant MCrALY Coatings
back to “zero-hour” life reconstruction of Series 3000TM LSR® Aluminides
wall thickness Alloys

57
New Advanced Repairs for
SGT-A35 Industrial RB211 Components
Time Line of Advanced Repairs Introduced by Liburdi
1995 – RB211-24C HPT Blades
1997 – RB211-24C/G IPT Blades
2002 – Rolls-Royce (now Siemens) Authorizes Liburdi Advanced Repairs
2003 – RB211-24C HPT NGV
2003 – RB211-24G HPT NGV
2003 – RB211-24C/G IPT NGV
2004 – RB211-24G HPT Seal Segments
2004 – RB211-24C HPT Seal Segments
2005 – RB211-24C/G IPT Seal Segments
2008 – RB211 Compressor Vane Repair/Upgrades
– RB211 Stage 5 Stage 6 OGV Repairs in development
– RB211 DLE Combustor Repair in development
– RB211-24GT Blade Repairs in development

58
LTS SGT-A35 RB211 Applications

RB211 service experience with “new” repair technologies

•HPT Blade Sets – 300 sets repaired since 1995

•IPT Blades Sets – 200 sets repaired since 1997

•HPT NGV Sets – 120 sets repaired since 2003

•IPT NGV Sets – 100 sets repaired since 2003

•HPT Seal Seg Sets – 125 sets repaired since 2004

•IPT Seal Seg Sets – 100 sets repaired since 2005

•HPC Compressor 1,2,3,4,5 Vane sets - 90 sets since 2008

59
 RB211 HPT and IPT Blades
Advanced Weld Repair
Advanced Weld Repair
after 24,000 hours service
• no shroud metal loss
• L3667 Weld Alloy
Sets now achieve 24,000 hours intervals
and service intervals through to 120,000+ hours

New Blades 24,000 hrs service Conventional CM64 Weld after 13,000 hrs
• - metal loss leads to weld repair extensive metal loss

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FSR® Full Solution Rejuvenation
for RB211 Blades Alloys MarM002, MarM002DS
• Full Solution rejuvenation heat treat – not partial
• Proprietary vacuum heat treatments
• Restore MicroStructure and Properties (creep strength)

As-New After 12,000 Hours After 24,000 Hours FSR Rejuvenated

Examples of micrographs at 10,000x magnification

showing effects of service hours,
And recovery of original microstructure with FSR heat Treatments

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RB211 HPT NGV Reconstruction Repair
Original braze joint •Incoming damage –
requires burned leading and
repair/restoration trailing edges , thin
airfoils, burned outer
shroud surfaces, shroud
braze joints deteriorated

•Previously NGVs were

considered not repairable
and were replaced with
new.

Severely burned
trailing edges

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RB211 HPT NGV Reconstruction Repair

• LPM® high strength

alloy as-applied to
leading edge, mid
airfoil, and trailing
edges

• LPM® material after high

temperature vacuum heat
treatment to ”cast” material to
the airfoils 63
RB211 HPT NGV Reconstruction Repair

• Airfoils machined to original contours, all cooling holes re-

established by EDM machining, airfoils re-coated , and shrouds
coated with TBC coatings.
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RB211 IPT NGV Reconstruction Repair
• NGVs with thin airfoils and through-going impact damage were
previously retired and replaced with new.
• LPM Powder Metallurgy process enables the airfoil surfaces to
be reconstructed to original dimensions using Superalloy materials

• LPM® used to repair cracks,

burned surfaces, and thicken
airfoils to original
specifications

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RB211 IPT NGV
Reconstruction by LPM®
• Airfoil thickness restoration in 2007 by LPM® process
• NGV ran in engine 179-822 for 24,281 service hours
• After service, NGV stripped and inspected – LPM reconstruction alloy is
etched to be visible – entire trailing portion of airfoil had been
reconstructed and ready for a second service interval

66
RB211 HPT Seal Segment Reconstruction

• Incoming seal segs have thin and distorted backing

plates, plus rubs (grooves) into backing plate –
previously considered scrap and replaced with new

• Seal Segments are now being re-formed, and

thickened to original dimensions using LPM process –
parts can be returned for continued service 67
RB211 HPT Seal Segment Reconstruction

• Reconstructed backing
plate – dimensions
checked and new
honeycomb being
applied

68
 RB211 IPT Seal Segment Reconstruction
• Incoming seal segs distorted (out
of round), seal slots misaligned,
backing plates thin due to oxidation
– parts were previously declared
scrap and replaced with new

• Backing plate is re-formed, then

thickened and machined to original
dimensions. Seal slots filled and re-
machined to original dimension and
location, new honeycomb added –
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RB211 HP Stg 1, 2, 3, 4,
Compressor Vane Repairs
Including Stage 5 MOD 1275

70
Power Turbine Applications

71
Power Turbine Applications
RT45, RT48, RT56, RT62 Power Turbine Repairs
• Liburdi has introduced a full menu of repairs for the Siemens
(RR) Power Turbines as follows:

• PT Blades (full FSR Rejuvenation Repairs) - since 1998

• PT Vanes – since 1992
• PT Diffuser, Nose Cone, Blade and Nozzle Casing,
Diaphragm – since 2015
• 100+ sets pf Siemens Power Turbine parts restored to
zero-hour condition.
• Zero-hour restoration for extended service to 200,000+
hours

• Job Experience – 100 sets repaired

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Advanced Weld Repairs for
PT Cases, Diffusers, Rings
RT – 48 RT – 56 RT – 62
(LT-1391, LT-1460, LT-1470, LT-1504) (LT-1531, LT-1462, LT-1458) (LT-1459, LT-1476)

RT48 RT48S RT56 RT62

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Advanced Weld Repairs for PT
Cases, Diffusers, Rings

74
PT Stationary Component Repair
Comprehensive Inspection and repairs of assembly
including – example
Inner Nozzle and Diffuser Assembly
Stage 2 Blade Casing
Downstream Retaining Ring
Stage 2 Nozzle Casing
Outer Inlet Diffuser Casing
Diffuser Casing
Inner Inlet Diffuser
 Inspect for service damage
 Test for alloy and coating composition
 Recommend most cost-effective repair
 Replace missing metal to restore strength
 Bolt holes repaired, dowels replaced
 Correct dimensional variations, distortions, restore flatness
 Correct fit-up for smooth assembly
 Heat-treatment to re-strengthen alloy
 Re-coat to protect component
 Inspect for release and issue certificate

75
Comprehensive Repair of
Complete Assembly
• Initial disassemble, clean, and incoming inspections,
• Report of damage and repair requirements
• Repair and final inspections
• Re-assemble
• Certificate of Conformance, pack and ship

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Stage 1 and 2 Power Turbine Vane Repairs

• Incoming clean, inspect, report

• Pre and Post Repair Heat treatments
• Weld repair cracks
• Weld repair any FOD missing material
• Correct distortion
• Reconstruct alignment spigot
• Final Inspections FPI, Dimensional
• Certification of Conformance
• Sets restored to “Zero-Hour” condition -
similar to new parts – additional service
interval to 200,000+ hours

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Stage 1 and 2 Power Turbine Blade Repairs

• Incoming clean, inspect, report

• Pre and Post Repair Heat treatments
• Weld repair shroud, platform cracks
• Blend airfoil damage
• FSR® Full Solution Rejuvenation® Heat
Treatments
• Weld and re-machine to restore z-notch
dimensions
• Final Inspections FPI, Dimensional
• Certification of Conformance
• Sets restored to “Zero-Hour” condition - similar to
new parts – additional 100,000 hours service
interval to 200,000+ hours

78
RB211 On-Condition Maintenance

79
RB211 On-Condition Maintenance

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ETN Conference Issues

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