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Method of repairing damaged turbine rotor wheels using differentially controlled temperatures
| Details |
Inventors: Nolan, John Francis; Crawmer, Gerald Richard; Emeterio, Eloy Vincent;
Assignee: General Electric Co. (Schenectady, NY)
Primary Examiner: Cuda; Irene
Assistant Examiner:
Attorney, Agent or Firm: Nixon & Vanderhye
A method of repairing a turbine rotor wheel having a damaged dovetail includes removing the damaged dovetail from the turbine wheel, leaving a turbine wheel body and welding a ring about the turbine wheel body in place of the removed damaged dovetail. During the welding process, including during preheating, welding or stress relieving, the temperature of the wheel body and ring is differentially controlled to introduce residual stresses in the ring. After welding a dovetail is formed in the ring for receiving turbine bucket dovetails. As a result, the ring has residual compressive stresses in a cold condition of the turbine whereby reduced net stresses in the ring in the location of the new dovetail during hot turbine operating conditions are reduced. |
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DETAILED DESCRIPTION In accordance with one aspect of the present invention, there is provided a dovetail repair for a turbine rotor which, instead of a weld buildup repair, provides a ring replacement, typically a forging, for the entirety of the damaged dovetail and which forged ring can be formed of the same or improved materials in comparison with a replacement rotor material wherein the same or improved resistance to the various failure mechanisms is obtained.
The replacement ring, forged or cast, is beneficially virtually free of defects and which defects might otherwise be extant in repaired dovetail characterized by a weld buildup of the same or similar material.
Also, the material of the replacement ring is not a function of the welding process or the weld material employed to secure the ring to the rim of the wheel body after the damaged dovetail has been removed.
Consequently, the forged replacement ring can be formed of materials which provide optimum properties for resistance to one or more of the different types of failure mechanisms.
For example, for rotors formed of Ni--Cr--Mo--V or Cr--Mo--V or 12 Cr, a 12 Cr material such as 12% CrCb or an Inconel-based material can be employed.
The weld material can be any weld material which is compatible with both the base material and the forged ring material, for example, a 12 Cr--Ni--Mo.
The nature of the weld material is less significant to the welding process employed in this invention because the weld is formed along a relatively low stress area of the wheel and the only purpose of the weld is to join the wheel and the ring.
That is, the weld material is not required to be as resistant to high stresses as is the dovetail per se.
The substantially defect-free replacement forged ring can be welded to the rim of the wheel body by a fine-line welding technique.
Characteristic of the fine-line welding technique is the provision of a substantially linearly extending non-beveled extremely narrow groove which does not introduce significant porosity or slag into the weld material and which is relatively unsusceptible to welding problems when welding on materials usually considered difficult to weld on
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