# US 10,864,607 B2 · Method for manufacturing or for repairing a component of a rotary machine as well as a component manufactured or repaired using such a method

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- Number: US 10,864,607 B2
- Document ID: US10864607B2
- Status: Granted
- Kind: B2
- Application number: 15/699,060
- Filed: 2017-09-08
- Published: 2018-03-22
- Granted: 2020-12-15
- Earliest claimed: 2016-09-22
- Assignees: Sulzer Management AG
- Applicants: Sulzer Management AG
- Inventors: Robin Rettberg; Thomas Kränzler; Enno Danke
- Web page: https://patentgrep.com/patent/US10864607B2

## CPC

- B22F 5/009: {of turbine components other than turbine blades (of turbine blades B22F5/04)}
- B23K 9/044: {Built-up welding on three-dimensional surfaces}
- B23K 9/167: and of a non-consumable electrode
- B23K 9/173: and of a consumable electrode
- B23K 10/027: {Welding for purposes other than joining, e.g. build-up welding}
- B23K 26/342: Build-up welding
- B23P 6/007: {using only additive methods, e.g. build-up welding}
- B23P 15/006: {turbine wheels}
- B23P 15/04: turbine or like blades from several pieces
- B33Y 80/00: Products made by additive manufacturing
- F01D 5/048: {Form or construction}
- F04D 29/023: {especially adapted for elastic fluid pumps}
- F04D 29/026: {especially adapted for liquid pumps}
- F04D 29/2222: {Construction and assembly (F04D29/2211 takes precedence)}
- F04D 29/284: {for compressors}
- B22F 7/08: with one or more parts not made from powder {(B22F7/062 takes precedence)}
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B23K 2101/001: {Turbines}
- B23K 2103/04: Steel {or steel} alloys
- B23K 2103/08: Non-ferrous metals or alloys
- B23K 2103/10: Aluminium or alloys thereof
- B23K 2103/14: Titanium or alloys thereof
- B23K 2103/26: {Alloys of Nickel and Cobalt and Chromium}
- B23K 2103/42: {Plastics other than composite materials}
- B23P 2700/06: Cooling passages of turbine components, e.g. unblocking or preventing blocking of cooling passages of turbine components
- B33Y 10/00: Processes of additive manufacturing
- F05D 2220/30: in turbines
- F05D 2230/10: by removing material
- F05D 2230/31: Layer deposition
- F05D 2230/60: Assembly methods
- F05D 2230/80: Repairing, retrofitting or upgrading methods
- Y02P 10/25: Process efficiency
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23P: METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS (arrangements for copying or controlling B23Q)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- F04D: NON-POSITIVE-DISPLACEMENT PUMPS (engine fuel-injection pumps F02M; ion pumps H01J41/12; electrodynamic pumps H02K44/02)
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A method for manufacturing a component of a rotary machine, the component extends in an axial direction and a radial direction vertical thereto, and has an inner channel, extending from a first end in a center of the component to a second end at a radial limiting surface of the component and which is partially closed. A blank includes the center of the component and is limited by an outer surface in the radial direction. The maximum dimension of the outer surface in the radial direction is smaller than the dimension of the limiting surface in the radial direction, A first subtractive process step is performed such that a part of the channel is manufactured by a machining process, with the part extending from the first end of the channel to the outer surface of the blank. Afterwards the channel is finished by a build-up process on the blank.

## Claims

### Claim 1

A method for repairing a component of a rotary machine, the component extending in an axial direction and a radial direction vertical thereto, and comprising a plurality of inner channels, each inner channel extending from a first end in a center of the component to a second end at a radial limiting radial surface of the component, the second end of the channel opening in the radial limiting surface of the component, adjacent channels being respectively separated by a separating wall, the method comprising:
identifying damaged areas of the component at the limiting radial surface or at one of the channels or at one of the separating walls;
manufacturing a blank by a machining removal or by a separating removal of the damaged areas, the blank comprising the center of the component; and
replacing the removed damaged areas by a build-up process on the blank to manufacture the final form of the component.

### Claim 2

A method for manufacturing a component of a rotary machine, the component extending in an axial direction and a radial direction vertical thereto, and having at least one inner channel extending from a first end in a center of the component to a second end at a radial limiting surface of the component and which is at least partially closed, that the method comprising:
providing a blank comprising the center of the component, and the blank being limited by an outer surface in the radial direction, the maximum dimension of the outer surface in the radial direction being smaller than a dimension of the limiting surface in the radial direction;
performing a first subtractive process step in which a part of the channel is manufactured by a machining process, with the part extending from the first end of the channel to the outer surface of the blank; and
afterwards finishing the channel by a build-up process on the blank by application of at least part of a shapeless or a neutrally shaped material, at least one material is used for the build-up process, the at least one material being different from a material of the blank.