Repaired spline and seal teeth on mated components

Abstract

Repaired spline and seal teeth of a mated component are disclosed. The splines are repaired by using a low energy input weld to deposit a repair material on the non-worn, non-pressure face of the splines while minimizing the HAZ grain size. The splined area of the component is remachined to the original spline contour by removing original material from the worn, pressure face of the splines and excess repair material to produce a mated component with radially re-clocked splines that have original component material on the pressure face of the teeth.

1 . A component of a gas turbine engine configured to matingly engage a complementary component of the gas turbine engine comprising: 
 a plurality of splines radially spaced about the component, 
 wherein each spline has a pressure face and a non-pressure face opposite the pressure face;  
 wherein the pressure face of at least one repaired spline has a surface remachined from original spline material; and  
 wherein the non-pressure face of the at least one repaired spline has a surface comprised of a layer of repair material metallurgically bonded to the original spline material.  
   
   
   
       2 . The gas turbine engine component of  claim 1 , wherein the original spline material comprises a superalloy selected from the group consisting of nickel-based, cobalt-based, iron-based and combinations thereof.  
   
   
       3 . The gas turbine engine component of  claim 1 , wherein the original spline material comprises a nickel-based superalloy comprising about 18 weight percent chromium, about 19 weight percent iron, about 5 weight percent niobium+tantalum, about 3 weight percent molybdenum, about 0.9 weight percent titanium, about 0.5 weight percent aluminum, about 0.05 weight percent carbon, about 0.009 weight percent boron, a maximum of about 1 weight percent cobalt, a maximum of about 0.35 weight percent manganese, a maximum of about 0.35 weight percent silicon, a maximum of about 0.1 weight percent copper, and the balance nickel.  
   
   
       4 . The gas turbine engine component of  claim 1 , wherein the repair material has a same composition as the original spline material.  
   
   
       5 . The gas turbine engine component of  claim 1  wherein the layer of repair material has a thickness of less than about 15 mils.  
   
   
       6 . The gas turbine engine component of  claim 1  wherein the at least one repaired spline has a heat affected zone with a grain size of less than about ASTM number 10.  
   
   
       7 . The gas turbine engine component of  claim 1  wherein the non-pressure face of the at least one repaired spline has a remachined surface.  
   
   
       8 . The gas turbine engine component of  claim 1 , wherein the component is a gas turbine engine shaft configured to connect a compressor and a turbine of the gas turbine engine to provide a common axis of rotation for the compressor and the turbine.  
   
   
       9 . The gas turbine engine component of  claim 1 , wherein the component is heat treated at a temperature of about 1100° F. to about 1400° F.  
   
   
       10 . A gas turbine engine shaft configured to connect a compressor and a turbine of a gas turbine engine to provide a common axis of rotation for the compressor and turbine, the shaft comprising: 
 a plurality of splines radially spaced about the shaft; 
 wherein each spline has a pressure face and a non-pressure face opposite the pressure face;  
 wherein the pressure face of at least one spline comprises original spline material; and  
 wherein the non-pressure face of the at least one spline has a surface comprised of a layer of repair material metallurgically bonded to the original spline material, wherein the pressure face and non-pressure face are remachined to provide a repaired spline and wherein the repaired spline has a heat affected zone with a grain size of less than ASTM number 10.