Development of electro-spark deposition technology for repair of Ni-based superalloy components

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The research and development of repair technology for superalloy components is of paramount importance for the large number of industries that depends on them, such as the aerospace and power generation industries. Due to the nature of superalloys, normal repair operations such as arc welding can actually cause detrimental effects to the repaired component's mechanical performances through changes of the microstructure within the heat affected zone. The use of LASER based cladding processes and additive manufacturing have become popular for the building up and repair of super alloy components. Although the use of LASER based techniques reduces the volume of the heat affected zone compared to traditional welding process, the heat affected zone remains to exist nonetheless. The proposed project aims at exploring the use of Electro-Spark Deposition (ESD) for the buildup and repair of Ni-based superalloy components. The use of ESD is expected to lead to an even smaller heat affected zone than that of the LASER based processes and thus should be less detrimental to the mechanical performances of the repaired parts. This project builds upon Huys Industries' patented and patent pending ESD technology and aims to broaden the applicability of their technology, such as for use in the aerospace and power generation industries. At the same time, this project will investigate the fundamental phenomena that takes places during the ESD process and aims to use that knowledge to optimize it for the building up of a thick, greater than several hundred microns, deposited layer. The success of this project will provide further support, in terms of trained personnel as well as transferable knowledge, to the manufacturing, aerospace, and power generation industries of Ontario and throughout Canada as well. In the course of this project, a number of highly qualified personnel HQPs will be trained, including one PhD and three MASc, and nine undergraduate co-op students. These HQPs will be trained within the world-class Centre for Advanced Materials Joining, and will have a chance to closely work with Huys' engineers.