Gas Turbine Metallurgy, Coatings and Repair
Held in conjunction with the
Location: Fairmont Singapore Raffles
City Convention Centre
The gas turbine is one of the most
technologically advanced energy conversion devices. The first working models
were introduced in 1939 in both aviation and in electric power production and
had turbine inlet temperatures on the order of 1100 F and employed uncooled, heat resisting steel turbine blades. Today
turbine inlet temperatures are in the range of 2700 F (1500 C) for the G &
H class utility combustion turbines and in excess of 3000 F (1650 C) for
commercial flight engines. These remarkable increases in the gas turbine firing
temperature have been made possible in part by substantial advances in hot
section airfoil materials, coatings and manufacturing technology during the
past seventy years.
This workshop will discuss the development
history, manufacturing processes, application and refurbishment of the high
temperature materials and coatings used in gas turbine engines with particular
emphasis on hot section superalloy component
manufacture and refurbishment. The metallurgy of nickel and cobalt based superalloys will be discussed and the many steps involved
in investment casting manufacture, from wax pattern & ceramic core
production, shell build, equiaxed, DS or single
crystal vacuum casting and post cast operations will be reviewed. This will
include review of advances in cooling configurations, casting imperfections,
inspection methods and general acceptance criteria. Specific challenges related
to making large F, G & H-class components and sophisticated air cooled,
single crystal aero-engine airfoils will be noted. The widespread use of
thermal barrier coatings has brought great focus to the issue of coating
selection. The various types of gas turbine hot section coatings, their
selection criteria and manufacturing method used will be discussed.
The benefits of repair and refurbishment of
engine run parts is well established. The increased complexity and high
replacement cost of hot section components has placed greater importance on
development of innovative component repair schemes. Participants will learn
methods of assessing component damage experienced from service exposure,
typical degradation modes observed and the techniques used to analyze the remaining
life of components removed from service. The various component repair
technologies utilized to restore components will be discussed in detail (ie dimensional checks, coating removal techniques, HIP and
rejuvenation heat treatments, weld repair, diffusion brazing processes and
component re-coating) as will quality assurance methods and procedures to
verify the refurbished components meet industry standards. The workshop
includes many case study examples of component refurbishment and the last section
is devoted to a workshop where attendees develop component repair solutions.
Participants are encouraged to submit questions in advance regarding repair
issues faced in their jobs.
After completing the course the participants
should be able to explain:
Typically technical staff, engineers and
technicians responsible for various aspects of gas turbine design, upgrade,
manufacture, repair, analysis, operations, or maintenance will attend. A must
for GT repair shop personnel, insurance companies, coatings suppliers, GT OEM
designers and technical staff.
This seminar will cover superalloy
materials, airfoil manufacture, protective coatings, component
damage experienced from service exposure, techniques used to analyze the
remaining life of components removed from service, component repair
technologies, and quality assurance of repairs. The seminar includes many case
study examples and the last section of the seminar is devoted to a workshop
where attendees develop component repair solutions. Participants are encouraged
to contact the instructors prior to the course with potential applications or
problems that can be discussed as case studies.
Course Outline
o
Gas Turbine
Engine Designs
o
Typical Gas
Turbine Components, Materials and Coatings
o
Gas Turbine
Airfoil Materials, Coatings and Airfoil Design Trends
o
Superalloy Metallurgy
o
Evolution of Superalloy Materials Technology
o
Production of Superalloys
o
Investment
Casting of Equiax, DS and Single
o
NDT Inspection,
Criteria and Acceptance Standards
o
Superalloy Surface
Stability
o
Comparison of
Oxidation/Corrosion protection
o
Manufacturing
Methods and Requirements
o
Diffusion vs.
Overlay Coatings
o
Thermal Barrier
Coatings
o
Metallurgical
Effects of Service
o
Creep
o
High Cycle Fatigue
o
Low Cycle
Fatigue
o
o Environmental
Degradation
o
Cost Benefit of
Repairs
o
Repair Market
Trends
o
The Future for
Industrial Frame GT Repairs
o
Timing and
selection of components for analysis
o
Micro structural
analysis
o
Mechanical
testing –Stress Rupture bars
o
Coating
Evaluation
o
Hot Corrosion
Attack
o
Failure Analysis
o
Component
Management Program
o
Determine Damage
Mechanisms, the Extent of Damage, Root Cause of Damage, and
Corrective/Preventive Action
o
Typical Damage
o
Coating
Stripping
o
Dimensional
Checks
o
Re-Coating
Selection and Processes
o
HIP and
Rejuvenation Heat Treatments
o
Superalloy Weld Processes
o
Diffusion
Brazing
o
QA Certification
o
Quality Plan
o
QA Inspections
o
NDE Defect
Criteria
o
Dimensional
Specification
o NDE Inspections
o Case studies presented by the instructors to
illustrate the process of component repair & refurbishment. The class will
then be divided into teams and given components for which they will determine
the best process
o Round table discussion regarding the latest repair
trends and student questions.
Jeff serves as President and Principal
Metallurgical Consultant for Material Processing Technology LLC (MPT), a firm
that he founded in 2002 to provide metallurgical engineering consulting
services in the field of high temperature materials and coatings for gas
turbine engines. MPT specializes in technology assessment, process improvement
and product commercialization for gas turbine materials, coatings and component
repair.
He holds B.S. and M.S. degrees in
Metallurgical Engineering from the
He is active as a technical session
organizer for the Manufacturing, Materials and Metallurgy (3 M) committee of
the International Gas Turbine Institute of ASME, and is a past 3 M committee
Chairman. He has served on the National Materials Advisory Board committee on
Coatings for High Temperature Structural Materials, is a member of ASM Intl
Metals Handbook Advisory Committee and ASTM’s G02 committee on wear and erosion.
He holds ten
As a graduate of