Introduction of Thermal Spray Technology in Gas Turbine Maintenance and Application

       Gas turbine repair

 Gas turbine power generation is becoming a hot spot in China's power generation industry. Today, the level of development of the gas turbine industry has become a national industrial advanced level

With the continuous development of low-pollution emission technology for gas turbines, natural gas-burning gas turbines and their combined cycles have become the new darling of power generation equipment in the 21st century, such as

The new peak of development has become the pursuit of China's dynamic people. Solving the problem of heavy gas turbines being controlled by others is the country’s need, and it is also the need of all Chinese power people.

The developed countries in the West strictly control high-tech exports to China, and high-power gas turbine technology is undoubtedly their key protection object, whether it is the production of new units or

Or the manufacturing and maintenance technology of key components.

1 Gas turbine maintenance technology

1.1 Main maintenance technology

The aviation-derived gas turbine has excellent performance, advanced production technology, complex process structure, and very strict requirements on repair technology and process, and must be returned to the factory for overhaul

The main process technology used includes 7 aspects:

1.1.1 Disassembly and assembly technology

The gas turbine returning to the factory for maintenance must first have the ability to disassemble and assemble. It must be efficient while avoiding secondary damage to the gas turbine. This technology requires

People, and equipped with a large number of special tooling.

1.1.2 Parts cleaning technology

Cleaning is mainly used to remove the attachments on the surface of the parts, including: rust layer, oxide scale, dirt, carbon deposits, oil stains, paint and silica gel, etc., and the cleaning effect is up to

The requirements for flaw detection, the cleaning methods include: organic solution cleaning, chemical solution cleaning, steam cleaning, high-pressure water cleaning, sand blowing cleaning and vibration finishing

The washed parts need to be dried in the drying box.

1.1.3 Detection technology

Testing technology is mainly used to detect cracks on the surface and inside of parts, including visual inspection, size measurement, fluorescent testing, magnetic testing, eddy current testing and X

Injury technique. Fluorescence flaw detection is mainly used for the detection of surface cracks on parts; magnetic flaw detection is used for surface and near surface crack detection of ferromagnetic parts; eddy current flaw detection is used for detection; X-ray flaw detection is used for defect detection of a small number of welding repair parts. The progress of signal and image processing technology and the automation of the system have improved the detection capabilities and

Calculate component life and accurately calculate component inspection interval. In recent years, tremendous progress has been made in the miniaturization of probes, greatly improving endoscopic monitoring

Sex.

1.1.4 Welding technology

The welding technology mainly includes inert gas shielded welding, electronic welding, plasma welding, linear welding, vacuum welding, laser welding, brazing and so on. Among them, plasma arc welding can be

The parts have the performance of new parts and are mainly used for repairing sealing devices; tungsten inert gas welding is used for surfacing of knife-edge type sealing parts, and its heat-affected zone is extremely small; high-tech brazing

Alloys, cobalt brazing alloys, make the parts even more wear-resistant than the original; laser welding can ensure a higher-precision measurement, in order to measure the deformation and diameter of the connection area

control.

1.1.5 Coating technology

Gas turbines generally use high-temperature coating technology to achieve the purpose of improving performance, improving reliability and extending service life. Among the key components of the hot end, the turbine blade

Barrier coating; the inner cavity of the blade uses anti-oxidation and anti-thermal corrosion coating; the turbine ring uses a sealing coating; the blade tip uses a wear-resistant coating. The spraying technology of the coating mainly has real

Rapid plasma spraying and physical and chemical vapor deposition, etc. Because the processing cost of superalloy and blade is much higher than the cost of coating, so in the repair process,

Removing the coating and repairing it is of great significance for safe use while ensuring the original performance of the blade substrate.

GE Aviation reduced the scrap rate of blades by 2% after using the chromium-rich coating in the repair plant in Singapore. The platinum-aluminum coating can improve the blade performance under high temperature and severe conditions.

The layer can prevent the molten salt from eroding the coating substrate at high temperatures.

1.1.6 Finishing technology

Mechanical processing and repairing techniques include: turning processing, boring and milling processing, and grinding processing. Turning is mainly used to increase the diameter of the sealing ring and other parts before and after spraying.

Precision machining after replacement of flanges of similar parts; boring and milling processing is mainly used for repairing parts holes, grooves, bosses and journals; grinding processing is mainly used for parts

Precision machining after repair.

1.1.7 Commissioning technology

Test run is a crucial part of gas turbine maintenance, and it is a test of the effect of gas turbine repair, which directly affects the use of gas turbines. Gas turbine test bench

The meter must be able to perfectly simulate on-site working conditions and must have strict noise control.

1.2 Research and development of maintenance technology

The main purpose of the research and development of maintenance technology is to continuously reduce the life-cycle cost of the gas turbine, and to restore or even improve the performance of the gas turbine. In view of this, OE

The research and development of maintenance technology is very important. For example, GE Aviation invests 30~9~140 million US dollars in the research and development of maintenance technology every year.

More than 15,000 kinds, and even some parts have doubled the warranty period after repair. It mainly focuses on the research and development of 7 maintenance technology fields, including: launch

Management, testing methods, processing technology, welding technology, the use of cold metal gas spray accumulation technology for material repair and other related advanced technologies.

As a user, Lufthansa Airlines develops maintenance technology for the purpose of dealing with frequent failures, saving costs and improving efficiency. At present, in the gas turbine maintenance side

There are also 3D printing technology and comprehensive fault diagnosis technology. As the geometry of gas turbines becomes more and more complex, it will rely more on robots to carry out repeatability.

Made.

Material-Equipment-Process-Solution

We have accumulated a lot of experience in the coating application direction, and we are currently reproducing these successful cases. We will lead you to complete the coating manufacturing conversion process

Production start; reliable supply solutions from materials, equipment and processes; coating test on your site or our technical center

Coating quality and efficiency.



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