Forschungs- & Entwicklungsinformationsdienst der Gemeinschaft - CORDIS

A braze repair process developed for SX/DS alloys in Rolls-Royce gas turbine engines

Rolls Royce, a UK based company, is a world leader in the manufacture of both aero and industrial gas turbine engines. Some of the most critical components of gas turbine engines are turbine blades and nozzle guide vanes (NGV's). These components, made of the highest quality Nickel super alloys, are very expensive. In recent years newer versions of these super alloys with enhanced high temperature properties, have entered service. These are single crystal (or SX) and directionally solidified (or DS) super alloys.

One of the principal results of this project is a new braze repair process for repair of cracks in SX and DS super alloy componets of gas turbine engines. SIFCO is the principal owner of this result. By a consortium agreement, the result is available to the other members of the SCARF Consortium, including Rolls-Royce, some of whom will exploit it in different market segments, or in different gas turbine engine applications.

Because of its pre-eminent market position in the repair of Rolls-Royce aero engine components, R-R will initially focus on the application of the new wide gap crack repair technology from the SCARF project to this engine type. (This does not exclude the possibilities of other applications to other gas turbines).

After the completion of the SCARF project, once the properties of the SCARF braze repair system have been fully characterised, R-R will seek to have this new braze repair technology approved by it's own internal repair approvals systems. Detailed test and characterisation data relating to the new braze process, and to the properties of the braze repaired component will be required. That is why the test and characterisation work carried out in the SCARF project is important. It provides much of the data, which will subsequently be required by the "approvals” body.

When the necessary approvals have been obtained R-R will then be in a position to provide an improved repair service for its customers (operators and over haulers of R-R aero engines) who until now do not have a satisfactory approved repair source for service damaged SX/DS components from R-R engines. The availability of a relatively cheap repair service for very expensive SX and DS turbine components, which have suffered crack damage during service, will confer major cost benefits to R-R's customers.

R-R grows its business by continuously developing and marketing new, high performance gas turbines, and by reassuring it's customers that cost effective repair technologies exist for the critical engine components. An integral part of this is the ongoing provision to customers of new or improved repair options to prolong the service life of engine components at minimum cost.

Hence the exploitation of this result will occur seamlessly as part R-R's ongoing business growth and development.

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Reported by

Rolls-Royce Aero Engine Services Limited
DE24 8BJ Derby
United Kingdom
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