Patent ID: 9272365
Filing Date: 2016-03-01
CPC Classification: B23K,F01D,F05D,Y10T

Claim Text:
1. A method for multi-layer cladding of epitaxial grain superalloy components, that maintains epitaxial grain growth in newly clad layers, comprising: introducing filler material on a component superalloy substrate surface; focusing a laser beam on the filler material and substrate; transferring optical energy at a selected optical energy transfer level from the laser to the filler material and substrate that fuses the filler material to the substrate as a filler layer without causing thermal degradation to the substrate; moving the substrate and laser beam relative to each other, fusing the filler material to the substrate along a first deposit path, in a first cladding layer and first path direction on the substrate surface, and varying optical energy transfer rate, compensating for changes in component surface topology, while maintaining uniform energy transfer at the selected optical energy transfer level; forming an adjoining first cladding layer second deposit path on the substrate surface, which overlaps the first deposit path, by moving the laser beam and substrate relative to each other in a second path direction that is opposite the first path direction, and increasing energy transfer rate during the second deposit path formation in an overlapping first and second deposit path region, while maintaining uniform energy transfer at the selected optical energy transfer level; forming a second cladding layer third deposit path, overlying the first cladding layer second deposit path, by moving the laser beam and substrate relative to each other in a third path direction that is generally opposite the second path direction, and varying optical energy transfer rate, compensating for changes in component surface topology, while maintaining uniform energy transfer at the selected optical energy transfer level; and forming an adjoining second cladding layer fourth deposit path, overlying the first cladding layer first deposit path, which overlaps the third deposit path, by moving the laser beam and substrate relative to each other in a fourth path direction, which is opposite the first and third path directions, and increasing energy transfer rate during the fourth deposit path formation in an overlapping third and fourth deposit path region, while maintaining uniform energy transfer at the selected optical energy transfer level; such that weld solidification crystal alignment in the deposited cladding layers is generally perpendicular to the substrate surface from the substrate and through each successive clad layer.