Blitz Repair for Turbines

Dr. Mack, you and your team have developed a new method. Can you explain how your new turbine repair method works?

Our method involves using a laser to apply and melt ceramic powder onto a surface. The laser beam and powder feed move away from the surface at a speed of a few millimeters per second, forming tightly packed micro-columns a few tenths of a millimeter in size.

This structure is highly heat-resistant and can endure frequent temperature fluctuations.

What problem does this new laser process solve?

Gas and aircraft turbines operate at extreme temperatures, reaching up to 1,500 degrees Celsius. Turbine components survive these conditions because they are coated with protective ceramic layers.

However, these layers wear out over time, necessitating the dismantling of components, removal of old layers in an acid bath, reapplication of new coatings, and reassembly. This traditional process takes days to weeks.

Our laser method allows for on-site repairs of minor damages without removing parts. Lasers could be mounted on robots to perform these repairs, saving significant time and money.

What are the next steps for this technology?

The process is currently patent-pending. We've received positive feedback from industry stakeholders, but we still need a cooperation partner to help us develop this method to market readiness.