Component repair using brazed surface textured superalloy foil

Abstract

A superalloy component such as a gas turbine engine blade ( 40 ) having a ceramic thermal barrier coating ( 41 ) is repaired using a textured repair foil ( 30 ). A degraded region of the thermal barrier coating is removed ( 14 ) and the underlying superalloy material surface is prepared ( 16 ) for re-coating. The repair foil is includes a layer of boron-free braze material ( 34 ) and a layer of superalloy material ( 32 ) having a textured surface ( 36 ). The foil is brazed ( 18 ) to the prepared surface during a solution heat treatment effective to homogenize the braze ( 20 ). A new area of thermal barrier coating ( 46 ) is applied over the foil with a bond that is enhanced by the texturing of the foil surface.

1 .- 20 . (canceled) 
     
     
         21 . A foil comprising
 a layer of alloy material; and   a layer of braze material on a side of the alloy material;   wherein the layer of alloy material comprises a layer of superalloy material adjacent the braze material and a layer of bond coat material on the layer of superalloy material.   
     
     
         22 . A gas turbine engine component comprising
 the foil of  claim 21 , and   a layer of thermal barrier coating material disposed over the layer of bond coat material.   
     
     
         23 . A foil comprising
 a layer of alloy material; and   a layer of braze material on a side of the alloy material;   wherein the braze material comprises a ternary alloy comprising a composition in wt. % of: Cr 15-25%; Ti 15-25%; balance Ni.   
     
     
         24 . A gas turbine engine component comprising
 the foil of  claim 23 , and   a layer of thermal barrier coating material disposed over the layer of alloy material.   
     
     
         25 . A foil comprising
 a layer of alloy material; and   a layer of braze material on a side of the alloy material;   wherein the braze material comprises a composition in wt. % within the following ranges:   Cr 12-16%;   Ti 13-16%;   Al 0-2.5%;   Co 2-4%;   W 3-5%;   Mo 0-2%;   Ta 0-2%;   balance Ni.   
     
     
         26 . A gas turbine engine component comprising
 the foil of  claim 25 , and   a layer of thermal barrier coating material disposed over the layer of alloy material.   
     
     
         27 . A foil comprising
 a layer of alloy material; and   a layer of braze material on a side of the alloy material;   wherein the braze material comprises a composition in wt. % within the following ranges:   Cr 15-18%;   Ti 10-15%;   Al 0-2.5%;   Co 2-4%;   W 3-5%;   Mo 0-2%;   Ta 0-2%;   balance Ni.   
     
     
         28 . A gas turbine engine component comprising
 the foil of  claim 27 , and   a layer of thermal barrier coating material disposed over the layer of alloy material.   
     
     
         29 . A foil comprising
 a layer of alloy material; and   a layer of braze material on a side of the alloy material;   wherein the braze material comprises a composition in wt. % within the following ranges:   Cr 15-19%;   Ti 8-10%;   Al 0-2.5%;   Co 14-18%;   Mo 12-16%;   balance Ni.   
     
     
         30 . A gas turbine engine component comprising
 the foil of  claim 29 , and   a layer of thermal barrier coating material disposed over the layer of alloy material.