Development of procedures and modelling for gas turbine component repair

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Currently the repair of gas turbine components for aerospace and some land based industries such as power generation, is close to a $1 billion business in Canada. Of this figure some $200 million is taken up with replacement of Directionally Solidified (DS) and Single Crystal (SX) components and some $25 million sub-contracted outside of Canada due to lack of technical expertise within the country. This issue will be addressed in the proposal where the repair of directionally solidified and single crystal components forms a major part of the research. Overall the main thrust of the proposal is to increase the technical knowledge of engineers within Canada relative to cost-effective repair of gas turbine components. With hot end components being valued at up to $600, 000 for the replacement of the first stage turbine blades on the CF-6 engine for example, increased technology and suitable repair schemes will ensure that the business is kept within Canada. This not only leads to increased knowledge, but also increased competitiveness for Canadian companies in the worldwide repair business. In this context, Standard Aero is a major player in the repair business, but still has to send sophisticated DS and SX components outside of Canada for repair. Furthermore, cost-effective repairs on other cast components will increase their competitiveness in the repair business. Our other partner in the research program is Bristol Aerospace, a company having a long time involvement in the repair business. Bristol has a different product mix from Standard Aero and is thus more concerned with sheet metal and casting repair of Ni-based Superalloys and also repairs of titanium components for the hot end of the turbine. The two approaches used by these companies are thus complimentary and cover a wide technology base for the repair of gas turbine components. Support for the program should ensure that Canadian companies remain competitive in gas turbine component repair and also will be able to solicit further repair from companies outside Canada. This will lead to increased business, jobs for Canadian engineers and the training of HQP's at the University.