The drive for high-efficiency gas turbines necessitates new materials for the hot-section components, i. e. single-crystal (SX) or directionally solidified (DS) components. Their high intrinsic value and elevated replacement costs call for high-tech repair solutions. Although modern gas turbines are extremely reliable, wear of the stages - in particular those under severe thermo mechanical load - is unavoidable (Figure 1). Blade repair (instead of replacement) helps to save costs, especially for the latest versions with their directionally solidified or even monocrystalline structure. To satisfy these demands, Sulzer Elbar introduced a novel laser powder welding technology (LPW) in spring 2001. This process facilitates not only the rebuilding of substrate material with higher creep-resistant filler alloys, but also the reproduction of single-crystal structures. Additionally, it delivers a broad range of capabilities to expand the repair limits of conventional cast (CC) components and for the repair of future types of gas turbine components.
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