Method for Repairing Monocrystalline Materials

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This patent describes a method for repairing monocrystalline (single-crystal) metallic components, especially those made of nickel- or cobalt-based superalloys used in high-temperature applications such as turbine blades. The process involves polishing the damaged area, heating the entire component in a vacuum to high temperatures (just below melting), and then applying a matching alloy powder coating using vacuum plasma spraying. This maintains or restores the original single-crystal orientation at the repair site, resulting in a repaired zone that preserves the superior mechanical properties of the original material.

Use CasesContent extracted from patent full text and abstract with AI.

• Repair of single-crystal turbine blades in gas or jet engines (aerospace and power generation).
• Restoration of high-value, single-crystal components in power plants.
• Extension of service life for expensive or hard-to-manufacture monocrystalline parts.
• Repair of turbine blades with internal cooling channels or complex features.
• Repair of high-temperature components in chemical processing or energy sectors.

BenefitsContent extracted from patent full text and abstract with AI.

• Restores the original single-crystal structure and orientation at the repair site, preserving mechanical properties such as strength and creep resistance.
• Avoids the creation of undesirable polycrystalline regions, which can compromise component performance and durability.
• Reduces the need for total part replacement, saving costs and resources, especially for expensive single-crystal parts.
• Minimizes residual stresses in the repaired area, reducing the risk of further damage or failure.
• Enables effective repairs even in complex areas (such as near cooling holes or channels), which are difficult to address with traditional welding or cladding methods.

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Inventors & Applicants

Patent Abstract

The invention relates to a method for coating a monocrystalline substrate surface of a component, which comprises a monocrystalline alloy, with a coating material. The surface to be coated is polished, and the substrate is transferred into a vacuum chamber where the entire substrate is heated externally to temperatures which correspond to at least half the melting temperature of the substrate in °C but which lie below the melting point of the substrate. The coating material is then applied onto the surface to be coated in the form of a powder by means of a vacuum plasma spraying process, wherein a powder with an average particle size ranging from 10 to 100 µm is used. The working pressure lies between 1 and 200 mbar, and an argon/hydrogen mixture is used as the working gas. Thus, at least one region is generated in the applied layer directly on the boundary surface of the coating material and the polished substrate surface, said region having the same monocrystalline orientation alignment as the substrate lying therebelow.