A laser powder bed fusion–based methodology for repairing damaged nickel-based turbine blades: Investigation of interfacial characteristics and hot isostatic pressing treatment

Di Wang; Zhenyu Liu; Guowei Deng; Xin Zhou; Sheng Li; Haoliang Wang; Yongqiang Yang; Changjun Han

doi:10.1016/j.matchar.2024.113948

A laser powder bed fusion–based methodology for repairing damaged nickel-based turbine blades: Investigation of interfacial characteristics and hot isostatic pressing treatment

Di Wang
, Zhenyu Liu
, Guowei Deng
, Xin Zhou
, Sheng Li
, Haoliang Wang
, Yongqiang Yang
, Changjun Han^*

^*Corresponding author for this work

Research output: Journal Publications and Reviews › RGC 21 - Publication in refereed journal › peer-review

18 Citations (Scopus)

Abstract

This study presents a methodology for repairing a damaged nickel-based turbine blade via laser powder bed fusion (LPBF) additive manufacturing. Specifically, the CM247LC nickel-based alloy was utilized to repair a damaged SRR99 nickel-based blade with LPBF, followed by hot isostatic pressing (HIP) post-treatment. The LPBF repair process achieved crack-free metallurgical bonding at the CM247LC/SRR99 interface with large epitaxially grown grains. Furthermore, HIP facilitated the formation of γ/γ’ phases with comparable dimensions at the interface as well as in the CM247LC and SRR99 regions through recrystallization. Additionally, the columnar grains in the LPBF-printed CM247LC region transformed into coarse equiaxed grains after HIP, accompanied by precipitation of nanoscale Hf-rich carbides. Meanwhile, microcracks in the LPBF-printed CM247LC region and shrinkage pores in the cast SRR99 region were effectively eliminated. The LPBF-printed CM247LC exhibited an 8.62% higher hardness compared to that of SRR99. The repaired samples showed an ultimate tensile strength of 791 MPa, with fracture occurring at the SRR99 side, indicating a reasonable metallurgical bonding strength at the CM247LC/SRR99 interface. The findings offer a novel alternative for the industrial application of repairing damaged nickel-based turbine blades.

© 2024 Elsevier Inc. All rights reserved.

Original language	English
Article number	113948
Number of pages	13
Journal	Materials Characterization
Volume	212
Online published	3 May 2024
DOIs	https://doi.org/10.1016/j.matchar.2024.113948
Publication status	Published - Jun 2024
Externally published	Yes

Funding

This research is supported by the Basic and Applied Basic Research Foundation of Guangdong Province (Grant Nos. 2019B1515120094, 2022B1515020064, 2022A1515010304), the Central University Basic Research Fund of China (Grant Nos. 2022ZYGXZR009), and the Foundation of Equipment Pre-research Area (Grant Nos. JZX7Y20220163200901).

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

SDG 9 Industry, Innovation, and Infrastructure

Research Keywords

Additive manufacturing
Laser powder bed fusion
Nickel-based alloys
Repair
Turbine blade

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10.1016/j.matchar.2024.113948

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@article{72792cf4b4734bf8bfe14b1d420b3522,

title = "A laser powder bed fusion–based methodology for repairing damaged nickel-based turbine blades: Investigation of interfacial characteristics and hot isostatic pressing treatment",

abstract = "This study presents a methodology for repairing a damaged nickel-based turbine blade via laser powder bed fusion (LPBF) additive manufacturing. Specifically, the CM247LC nickel-based alloy was utilized to repair a damaged SRR99 nickel-based blade with LPBF, followed by hot isostatic pressing (HIP) post-treatment. The LPBF repair process achieved crack-free metallurgical bonding at the CM247LC/SRR99 interface with large epitaxially grown grains. Furthermore, HIP facilitated the formation of γ/γ{\textquoteright} phases with comparable dimensions at the interface as well as in the CM247LC and SRR99 regions through recrystallization. Additionally, the columnar grains in the LPBF-printed CM247LC region transformed into coarse equiaxed grains after HIP, accompanied by precipitation of nanoscale Hf-rich carbides. Meanwhile, microcracks in the LPBF-printed CM247LC region and shrinkage pores in the cast SRR99 region were effectively eliminated. The LPBF-printed CM247LC exhibited an 8.62\% higher hardness compared to that of SRR99. The repaired samples showed an ultimate tensile strength of 791 MPa, with fracture occurring at the SRR99 side, indicating a reasonable metallurgical bonding strength at the CM247LC/SRR99 interface. The findings offer a novel alternative for the industrial application of repairing damaged nickel-based turbine blades. {\textcopyright} 2024 Elsevier Inc. All rights reserved. ",

keywords = "Additive manufacturing, Laser powder bed fusion, Nickel-based alloys, Repair, Turbine blade",

author = "Di Wang and Zhenyu Liu and Guowei Deng and Xin Zhou and Sheng Li and Haoliang Wang and Yongqiang Yang and Changjun Han",

note = "Publisher Copyright: {\textcopyright} 2023",

year = "2024",

month = jun,

doi = "10.1016/j.matchar.2024.113948",

language = "English",

volume = "212",

journal = "Materials Characterization",

issn = "1044-5803",

publisher = "Elsevier Inc.",

}

A laser powder bed fusion–based methodology for repairing damaged nickel-based turbine blades: Investigation of interfacial characteristics and hot isostatic pressing treatment. / Wang, Di; Liu, Zhenyu; Deng, Guowei et al.
In: Materials Characterization, Vol. 212, 113948, 06.2024.

Research output: Journal Publications and Reviews › RGC 21 - Publication in refereed journal › peer-review

TY - JOUR

T1 - A laser powder bed fusion–based methodology for repairing damaged nickel-based turbine blades

T2 - Investigation of interfacial characteristics and hot isostatic pressing treatment

AU - Wang, Di

AU - Liu, Zhenyu

AU - Deng, Guowei

AU - Zhou, Xin

AU - Li, Sheng

AU - Wang, Haoliang

AU - Yang, Yongqiang

AU - Han, Changjun

PY - 2024/6

Y1 - 2024/6

N2 - This study presents a methodology for repairing a damaged nickel-based turbine blade via laser powder bed fusion (LPBF) additive manufacturing. Specifically, the CM247LC nickel-based alloy was utilized to repair a damaged SRR99 nickel-based blade with LPBF, followed by hot isostatic pressing (HIP) post-treatment. The LPBF repair process achieved crack-free metallurgical bonding at the CM247LC/SRR99 interface with large epitaxially grown grains. Furthermore, HIP facilitated the formation of γ/γ’ phases with comparable dimensions at the interface as well as in the CM247LC and SRR99 regions through recrystallization. Additionally, the columnar grains in the LPBF-printed CM247LC region transformed into coarse equiaxed grains after HIP, accompanied by precipitation of nanoscale Hf-rich carbides. Meanwhile, microcracks in the LPBF-printed CM247LC region and shrinkage pores in the cast SRR99 region were effectively eliminated. The LPBF-printed CM247LC exhibited an 8.62% higher hardness compared to that of SRR99. The repaired samples showed an ultimate tensile strength of 791 MPa, with fracture occurring at the SRR99 side, indicating a reasonable metallurgical bonding strength at the CM247LC/SRR99 interface. The findings offer a novel alternative for the industrial application of repairing damaged nickel-based turbine blades. © 2024 Elsevier Inc. All rights reserved.

AB - This study presents a methodology for repairing a damaged nickel-based turbine blade via laser powder bed fusion (LPBF) additive manufacturing. Specifically, the CM247LC nickel-based alloy was utilized to repair a damaged SRR99 nickel-based blade with LPBF, followed by hot isostatic pressing (HIP) post-treatment. The LPBF repair process achieved crack-free metallurgical bonding at the CM247LC/SRR99 interface with large epitaxially grown grains. Furthermore, HIP facilitated the formation of γ/γ’ phases with comparable dimensions at the interface as well as in the CM247LC and SRR99 regions through recrystallization. Additionally, the columnar grains in the LPBF-printed CM247LC region transformed into coarse equiaxed grains after HIP, accompanied by precipitation of nanoscale Hf-rich carbides. Meanwhile, microcracks in the LPBF-printed CM247LC region and shrinkage pores in the cast SRR99 region were effectively eliminated. The LPBF-printed CM247LC exhibited an 8.62% higher hardness compared to that of SRR99. The repaired samples showed an ultimate tensile strength of 791 MPa, with fracture occurring at the SRR99 side, indicating a reasonable metallurgical bonding strength at the CM247LC/SRR99 interface. The findings offer a novel alternative for the industrial application of repairing damaged nickel-based turbine blades. © 2024 Elsevier Inc. All rights reserved.

KW - Additive manufacturing

KW - Laser powder bed fusion

KW - Nickel-based alloys

KW - Repair

KW - Turbine blade

UR - https://www.scopus.com/pages/publications/85192241900

UR - https://www.scopus.com/record/pubmetrics.uri?eid=2-s2.0-85192241900 &origin=recordpage

U2 - 10.1016/j.matchar.2024.113948

DO - 10.1016/j.matchar.2024.113948

M3 - RGC 21 - Publication in refereed journal

AN - SCOPUS:85192241900

SN - 1044-5803

VL - 212

JO - Materials Characterization

JF - Materials Characterization

M1 - 113948

ER -

A laser powder bed fusion–based methodology for repairing damaged nickel-based turbine blades: Investigation of interfacial characteristics and hot isostatic pressing treatment

Abstract

Funding

UN SDGs

Research Keywords

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