Repair welding of cracked turbine shroud using matching composition consumables

Abstract

Repair welding of a crack in the III-stage shroud of a high pressure turbine, was carried out using matching composition ER 410 filler wire by the gas tungsten arc welding (GTAW) process with ultra high purity argon as shielding and backing gas. The development of the repair welding procedure involved laboratory studies for the selection of a suitable ER410 filler wire, optimisation of welding parameters and PWHT. Mock up welding under simulated on-site constraints confirmed the feasibility to produce in situ sound weld joint. In situ repair welding and localised PWHT was carried out successfully. NDT and in situ metallography of the repair-welded region confirmed adequate tempering of the martensitic weldment during the localised PWHT.     

沾化电厂1、2号机除氧器环焊缝缺陷分析与处理

<正> 0 概 述 沾化电厂1、2号除氧器环焊缝存在大量宏观裂纹和连续未焊透缺陷,在运行过程中发生多处泄漏现象,被迫降压运行,效率大大     

Recent developments in repair welding technologies in Japan

Abstract

Developments in some difficult repair welding technologies in Japan during the past decade are reviewed. The topics covered include the repair welding of bridges in service, the temper bead method which makes it possible to omit post-weld heat treatment (PWHT) of repaired pressure vessels, the seal welding of a reactor vessel in which stress corrosion cracks were detected, low heat input repair welding of neutron irradiated stainless steel and nickel based alloys, the prevention of solidification cracking in repair welding of aged heat resistant cast steels, the development of welding materials for the mending of single crystal nickel based superalloy turbine blades, underwater repair welding of nuclear reactors, the reduction of residual stresses in repair welding, and an ultrasonic testing method for nickel based weld metals. The local PWHT of creep resistant ferritic steel tubes is also reviewed.     

Adhesively Bonded Patch Repair of Composite Laminates

Damaged composite laminates repaired using adhesively bonded patches have been studied. A special adhesive element is developed to examine the stress distribution in the bonded region. Utilizing the adhesive element, one is able to incorporate the regular elements in the laminate and patch. It has the advantage of reducing the adhesive bonding problem to a two-dimensional in-plane problem, and avoiding the need for refined meshes in the adhesive. The special adhesive element is derived based on the assumption of constant shear stress through the thickness of the adhesive. The damaged area of the composite laminate is simulated as a hole. The repair efficiency is evaluated by comparing the stress concentration factor in the damaged hole before and after repair. The effects of the thickness, size and material properties of both patch and adhesive on the stress distribution are presented through a parametric study. Numerical results indicate that a stiffer and thicker patch is able to carry higher loads, and, consequently, reduce the load across the damaged area yielding less stress concentration in the damaged hole. For a high shear modulus and thin thickness of the adhesive layer, less loads are transferred to the patch resulting in a high stress concentration in the damaged hole.     

Shear bond strengths of five intraoral porcelain repair systems

In fixed prosthodontics, fracture of the porcelain veneer is not an uncommon problem under clinical conditions due to, e.g., malfunction, trauma or technical failures. To avoid time-consuming and cost-intensive renewal of the entire restoration, repair of the chipped veneer is desirable. The aim of this in vitro study was to evaluate the shear bond strengths of five intraoral porcelain repair kits based on different chemical bonding systems. 45 metal plates veneered with feldspathic porcelain were fabricated. The surface treatment was performed using five porcelain repair systems based on tribochemical silica coating (Cojet), mechanical roughening (Silistor, Cimara, Ceramic Repair) or etching (Clearfil Repair) followed by application of silane coupling agents (five specimens each). Cylinders of composite resin of Charisma and Pertac Hybrid were bonded using Cojet, Silistor, Cimara and Ceramic Repair, and of Clearfil AP-X with Clearfil Repair onto the porcelain specimens. After thermocycling (5000 cycles, 5–55°C) shear bond strength was measured according to ISO 10477 followed by assessment of the failure mode. Statistical analysis was carried out with one-way ANOVA and Bonferroni–Dunn's multiple comparisons post-hoc analysis for test groups (α = 0.05). Shear bond strengths higher than 10 MPa were found for all test groups except for Ceramic Repair with Pertac Hybrid (8.1 ±1.3 MPa), which was significantly lower than all other groups (P < 0.05). Highest shear bond strength was found for Silistor with Charisma (23.1 ± 5.8 MPa), which was significantly higher (P < 0.05) than all other groups except Cojet with Charisma (17.8 ± 3.6 MPa) and Clearfil Repair (20.3 ± 5.0 MPa). Cojet and Silistor with Charisma, Cimara, as well as with Clearfil mainly showed cohesive or mixed failure modes (cohesive and interfacial). Bond strengths of the combinations Silistor-Charisma, Clearfil Repair-Clearfil AP-X and Cojet-Charisma were superior to all other combinations used in the present tests.     

Fracture mechanics testing of the bond between composite overlays and a concrete substrate

This paper presents a methodology for assessing the bond strength of composite overlays to concrete utilizing a fracture toughness test. The principles and practices of existing ASTM standards for determining the fracture toughness of adhesive bonds between double cantilever beam (DCB) metallic and composite specimens (D 3433-93 and D 5528-94a) have been extended to cover the case of an elastic composite layer bonded to a rigid concrete/masonry substrate. In the theoretical section, the dominant loading conditions, relevant ASTM standards, and the development of energy release rate concepts for analyzing a disbonding composite layer modeled as an elastic cantilever beam are presented. The experimental section covers specimen fabrication and preparation, experimental setup, test procedures, post-test evaluation of the specimens, and data processing. The discussion of test results focuses on explaining the variability in measured strain energy release rate, and identifies trends between the measured strain energy release rate and the fraction of the fracture surface retaining cement paste after disbonding. It was found that good-quality composite-to-concrete bond is associated with high fracture toughness of the adhesive and location of the crack path in the concrete substrate. Strict enforcement of surface preparation and adhesive handling procedures was found to play an important role in promoting good bond strength and high fracture toughness. The fracture toughness test developed in this paper can be used for screening various composite-repair systems, to assess the effect of different environmental attacks, and as a quality control tool.     

The effect of patch geometry on the static and fatigue behaviors of defective aluminum panels repaired with a composite patch

In this study, 6.125-mm cracked Al 7075-T6 plates unpatched and repaired with 4-ply boron/epoxy composite patches of several geometries have been investigated under both static and fatigue loads. The stress distributions around the crack tip for these specimens were calculated using the finite element method. It was shown that Rose's model was not adequate to calculate the stress intensity factor for different patch geometries where patch dimensions were on the order of those of the cracked structure. A new definition based on the stress near the crack tip was introduced. Also, based on the experimental data, a new definition for relative repair efficiency was introduced, and the effects of patch geometry on the static tensile and fatigue behaviors of the repaired structures were examined experimentally. Combining the results of static tensile and fatigue tests, it was concluded that the geometry of the patch had large effects on the properties of the repaired structures, the effects not included in Rose's model.     

Atmospheric corrosion of zinc Part 2: Marine atmospheres

Abstract

This paper summarises the results obtained in the MICAT (Mapa Ibero-Americano de Corrosão Atmosférica (Latin American Map of Atmospheric Corrosion)) atmospheric corrosion project (an Iberoamerican project on atmospheric corrosion, involving 14 countries and 75 atmospheric test sites) for zinc specimens exposed in the Latin American region for 1–4 years at 23 pure marine and 19 mixed marine (i.e. SO₂ polluted) sites. The atmospheres at these sites were characterised climatologically and in terms of their pollution levels so that their corrosivity could be expressed in accordance with ISO standards. Morphological and chemical characterisation of the zinc corrosion product layers (ZCPLs) was performed using scanning electron microscopy coupled with energy dispersive spectrometry (SEM–EDS), X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), and soluble salt evaluation techniques. The results obtained show that the corrosion rate of zinc is a function of both the chloride pollution level and the time of wetness. Some synergetic effects of Cl^- and SO₂ were demonstrated, although some special types of behaviour were also observed.     

Laser cladding repair of turbine blades in power plants: from research to commercialisation

Abstract

Reliable and efficient power generation is a major global issue due to both political and environmental concerns. Nevertheless, many critical components, particularly the blades of the low pressure (LP) side of power generating steam turbines, are subject to failure due to severe erosion at the leading edges. Since taking machines offline for maintenance and removal of damaged blade for repair is extremely expensive, increasing the service life of these critical components offers significant economic and political benefits. Conventional techniques to increase service life include brazing of an erosion shield at the leading edge of the turbine blade, open arc hardfacing, and cladding with erosion resistant materials using gas tungsten, manual metal or plasma transferred arc welding. The authors have been investigating since 2001 the use of laser cladding technology to deposit a high quality and erosion resistant protection shield on the leading edge of LP blades. The project has demonstrated the feasibility of in situ repair of turbine blades in trials conducted at a power station using a fibre delivered diode laser and a robot. A company, Hardwear Pty Ltd, was established in late 2005 to commercialise this technology and has to date carried out successfully several commercial contracts involving the repair of 340 LP blades.     

Residual stresses and distortions in welded structures: a perspective for engineering applications

Abstract

In this paper, some of the historical developments and recent advances in understanding welding induced residual stresses and distortions are discussed in the context of their impact on today's engineering applications. With recent rapid advances in computational simulation techniques, the complex thermomechanical phenomena associated with typical welding processes can be effectively dissected into solvable problem sets for both fundamental understanding and specific engineering applications. Although a great deal of research is currently still ongoing to advance our fundamental understanding of the complex thermophysical and thermomechanical phenomena, an engineering perspective is provided to demonstrate how an engineer can make use of the current state of knowledge to derive effective practical solutions when dealing with day to day problems in the areas of residual stresses and distortions in welded structures. First, some of the fundamental mechanical considerations associated with residual stress and distortion developments are presented. Then, some of the computational modelling requirements for engineering applications are discussed in the light of recent developments. Finally, application examples are presented to demonstrate how an effective engineering solution can be sought by taking advantage of today's advanced modelling techniques with appropriate engineering assumptions.