Laser cladding in repair of IN738 turbine

blades
C. Chen*1, H. C. Wu2 and M. F. Chiang1
Laser cladding with additive powder can be used for repairing high cost components such as
industrial turbine blades. Repair of damaged blades is important for electrical power companies
to reduce operating costs. The repair of IN738 gas turbine blades using laser cladding is
reviewed. A laser cladding system for blade repair and the associated heat treatment procedures
before and after repair are discussed. In general, laser cladding with IN625 powder does not
require preheating and can be used for repairing IN738 blades in low stress areas. For laser
cladding with a higher strength material, e.g. IN738 powder, preheating to high temperatures is
necessary to avoid cracking. In a process simulation, test coupons were employed to compare
the microstructures and mechanical properties of the IN738 clad region and base metal. Blade
repairs with IN738 additive powder were found to be stronger but much more difficult to process
than those with IN625 powder. Therefore, extreme caution is required when repairing IN738
blades in high stress areas using a matching filler metal.
Keywords: Laser cladding, Weld repairs, IN738 nickel base superalloy, Turbine blades

Introduction distortion, which has been widely used to repair

damaged blades and to build up three-dimensional
Nickel base superalloys were developed mainly for high (3D) metal parts.10,11 Despite the high capital invest-
temperature applications, and IN738 is one of the most ment required for the laser system and associated
widely used materials for hot sections in industrial gas auxiliaries, the choice of lasers as a heat source to
turbines. In power generation plants, gas turbines from perform repair welding seems to be cost effective in the
various manufacturers, such as GE, Siemens, Alstom long term. A recent study indicated that the use of
and MHI, use IN738 as a durable blade material. The preheating to y800uC in laser welding can avoid
sophisticated blade design, in an effort to increase cracking of IN738 welds.12 Similarly, preheating can
efficiency, inevitably leads to a high blade cost. During be applied to the cladding repair process of the blades
service, turbine blades may suffer different degrees of with IN738 additive powder. The use of filler metal with
surface damages or form cracks, resulting in a reduced matching composition can extend the blade repair to
blade lifetime. These service defects could be as a result high stress areas if cracking can be avoided.
of erosion, corrosion, tip rubbing, foreign object Nevertheless, appropriate precautions must be taken in
damage, fatigue, creep, etc.1 The cost of replacing an the blade repair procedures, including preweld heat
IN738 blade is quite expensive, often more than $15 000 treatment, control of the preheat temperature and heat
for a first stage gas turbine blade. Hence, the refurbish- input, prevention of oxidation, use of proper post-weld
ment of damaged blades has become increasingly heat treatment and careful X-ray inspection to guaran-
important for aging turbines in power generation plants. tee sound repairs. This paper reviews the repair of IN738
IN738 alloy is not generally considered weldable due blades based on the laser cladding technique and reports
to its crack sensitivity.2 However, various attempts have some results of research into cladding repair involving
been made to overcome this issue, e.g. the use of ductile the IN738 alloy.
filler metal,3 the reduction of heat input4 and preheating
to high temperatures.5,6 The advantages of laser repair
techniques over conventional welding methods to IN738 turbine blades
refurbish crack sensitive superalloys have been reviewed IN738 is a cast Ni–Cr–Co base superalloy, which can
elsewhere.7–9 Laser cladding is a low heat input process withstand high temperature and has high strength, in
with a minimal heat affected zone (HAZ) and little addition to good hot corrosion properties. It is
strengthened by precipitation of the ordered Ni3(Al,Ti)
1
c9 phase and solid solution strengthening from the
Department of Materials Science and Engineering, National Taiwan
University, Taipei 106, Taiwan alloying elements. There are two versions of the alloy,13
2
Taiwan Power Research Institute, Taiwan Power Company, Shu-Lin, IN738C (y0?17 wt-%C) and IN738LC (y0?11 wt-%C);
Taipei 238, Taiwan the latter is mainly used for investment casting of
*Corresponding author, email [email protected] turbine blades in hot sections. The nominal composition

ß 2008 IHTSE Partnership

Published by Maney on behalf of the Partnership
140 International Heat Treatment and Surface Engineering 2008 VOL 2 NO 3/4 DOI 10.1179/174951508X446484
 Chen et al. Laser cladding in repair of IN738 turbine blades

1 Photographs showing a GE MS7001EA gas turbine and b first stage IN738 blade

of IN738LC alloy (wt-%)13 is Ni–16Cr–8?5Co–3?5Ti– spraying of MCrAlY coatings after repair, diffusion
3?5Al–2?5W–1?75Mo–1?6Ta–0?7Nb. Figure 1 shows a heat treatment, inspection methods, etc., are beyond the
GE gas turbine, in which IN738 is used as the blade scope of this paper.
material for the first, second and third stages of the
turbine rotor assembly. The temperature is the highest in Laser cladding technique
the first stage (y850uC) and gradually decreases in
subsequent stages. Owing to differences in service Cladding or welding repair of damaged metal compo-
temperatures, the blade design is also different between nents is one of the important applications in laser
stages and manufacturers. For example, there are materials processing. It is characterised by the short
cooling holes in the first and second stage blades but interaction time of the cladding material with the intense
not in the third stage blades in Fig. 1. Additionally, laser beam to deposit metal of controlled thickness on
the selected area. During the process, a thin layer of the
thermal barrier coatings14 are required for the first
substrate is also melted, and a strong metallurgical bond
and second stage blades to minimise hot corrosion in
is formed between the deposited layer and the substrate.
service, which also complicates the repair procedure
It is often used to enhance surface properties, such as the
substantially.
wear and corrosion resistance of metal components. In
The damaged or cracked areas of the blade can be
laser cladding, the addition of filler metal is necessary to
identified by various methods, including visual, fluor-
rebuild the damaged component to its original dimen-
escent liquid penetration and radiographic inspections.
sions. Depending on the applications, the thickness
Such areas occur mainly in the upper portion (bucket and width for each deposited layer are typically 0?2–0?8
airfoil in Fig. 1b) of the blade and should be machined and 1–3 mm respectively. A series of overlapping passes
off and replaced with a suitable filler metal. Obviously, and multiple layer depositions can generate a large clad
welding and cladding are the most commonly used area as well as different 3D structures. The filler metal,
repair methods. However, the weldability of IN738 is solid wire or alloy powder can have compositions
poor due to the formation of hot cracks in the weld different than that of the component to be repaired.
metal as well as liquidation cracks in the HAZ.15 In Thus, the mechanical properties of the deposit built-up
addition, strain age cracking in the HAZ of the weld and the interfacial region of weld repairs should be
might also occur during the post-weld heat treatment.16 evaluated carefully to ensure specific requirements are
In the welding of heat sensitive materials, the use of high met. For instance, ductile filler metals (low strength
power density sources, such as electron and laser beams, materials) are frequently utilised for repair welding to
is helpful for reducing the heat input. A laser beam, minimise the strain imposed on the hardened HAZ and
which can be transmitted through air, is convenient for to compensate for weld metal shrinkage.19 Currently,
most engineering applications. In a broad sense, the laser repair of damaged IN738 blades with IN625 (a
cladding can also be regarded as a welding process. relatively soft nickel base alloy) is normally performed at
For this reason, the terms welding and cladding are room temperature. However, this method is limited to
often used interchangeably in the repair process. Repair the repair cladding of IN738 blades in the low stress and
cladding or welding of IN738 blades with laser beams tip regions20 due to the lower strength of IN625.
cannot be performed ‘in situ’, since the thermal barrier Several techniques are commonly used to feed
coatings on the blades must be removed and high additive materials during the process, including pre-
solution temperatures are involved in both preweld and placed powder, wire feed and blow powder techniques as
post-weld heat treatments. The blade repair procedure is described elsewhere.21–23 The blow powder technique,
quite complicated for IN738, as presented else- according to the powder delivery design, can be
where.1,17,18 The emphasis of this paper is the repair further divided into lateral and coaxial powder feed
of IN738 blades using the laser cladding technique. methods.24–26 Laser cladding with lateral (off-axis) wire
Other steps, such as the removal of the blade coating or powder feeding is inconvenient and can less readily
before repair, drilling of cooling holes, vacuum plasma accommodate an irregular cladding path. As a result,

International Heat Treatment and Surface Engineering 2008 VOL 2 NO 3/4 141
Chen et al. Laser cladding in repair of IN738 turbine blades

2 Schematic diagrams showing a near coaxial and b coaxial cladding nozzles

the coaxial and near coaxial powder feeders are the made induction coil is often required to fit the shape of
major powder delivery methods used in repair cladding the region to be repaired, which further complicates the
as well as in 3D laser metal forming11 of damaged repair procedure. During laser cladding, metal powder is
components with complex shapes. Metal powders with susceptible to oxidation at high temperatures, which
particle sizes in the range of 45–90 mm are suitable for may lead to an unacceptable porosity level in the clad
the laser cladding process; however, finer powders may region. Therefore, effective shielding is essential to
be required if a lower power is used. Figure 2 shows ensure good repair quality. Other than that, various
schematic diagrams of typical near coaxial and coaxial in-process monitoring sensors or control devices29 can
powder feeders. The former (Fig. 2a) is used in laser be added to the system to improve the quality of weld
engineered net shaping systems.27 In both nozzles, the repairs.
focal point of laser beams relative to the workpiece can
be adjusted. For processing with a coaxial powder feeder Heat treatment and laser repairing
(Fig. 2b), the focus of the powder stream and the
efficiency of the powder deposition are improved by
Blade analysis and heat treatment
controlling the shroud gas around the circumference at Figure 4 shows micrographs of the first and second stage
the nozzle outlet. A longer interaction time between the blades after 35 000 h of service. It can be seen that the
powder and laser beam, in addition to greater reflection microstructures are different between the airfoil
of the laser by the powder stream, can be expected with a (Fig. 4a) and root (Fig. 4b) portions, indicating that
coaxial nozzle. Consequently, the attenuation of laser the temperature variation along the length of the blade
beams is greater with the coaxial powder feeder, leading was significant. Apparently the upper portion of the
to a reduced HAZ in the substrate. This can be helpful blade experienced considerably higher temperatures
especially for repairing heat sensitive IN738 alloy. than the root during service, resulting in a coarsening
of the microstructure. Figure 4a reveals the coarsening
Basically, a laser cladding system for blade repairs
of c9 in general and the formation of a continuous path
consists of several key components as illustrated in
of c9 at the grain boundaries with scattered carbides. The
Fig. 3. It includes a high power laser, beam delivery and
carbide reactions are complex; however, MCzc
focusing units, a powder feeder, a cladding nozzle, a NC
table or a robot, a heating apparatus and an inert
shielding device or vacuum chamber. Two types of
continuous wave lasers, namely, CO2 and solid state
lasers, with powers in the kilowatt class, are generally
used. The former has a wavelength of 10?6 mm, which is
considerably longer than the latter, e.g. 1?07 mm for an
ytterbium fibre laser. The coupling coefficient, i.e. the
absorbed intensity/the laser intensity incident on the
surface, is greatly improved with solid state lasers.28
Moreover, fibre lasers with flexible beam delivery can be
easily attached to a robot, thereby avoiding the need for
complicated beam guiding devices, as with a CO2 laser.
As mentioned earlier, a high temperature preheat is
necessary to obtain crack free IN738 welds. Owing to
the limited space, an induction heater is suitable for fast
heating of the workpiece before laser cladding. The use
of induction heating to preheat the region to be repaired
requires proper design of the induction coil and good
temperature control. This is crucial for the cladding
repair of IN738 blades using IN738 powder. A custom 3 Laser cladding system for blade repairs

142 International Heat Treatment and Surface Engineering 2008 VOL 2 NO 3/4
 Chen et al. Laser cladding in repair of IN738 turbine blades

a near top of leading edge in first stage blade after 35 000 h of service; b root of same blade as in a; c near top of lead-
ing edge in second stage blade after 35 000 h of service; d typical microstructures of used blades after 1180uC/
2 hz850uC/16 h heat treatments
4 Micrographs (SEM) of IN738 blades: note that white particles are MC carbides

RM23C6zc9 is most likely to occur in service.30 This is Figure 5a shows the formation of a microcrack in the
supported by the SEM/EDS analysis of Cr rich areas HAZ of a repaired blade with IN625 powder using a
(dark areas indicated by arrows) along the grain heat input of 100 J mm21 and a powder flow rate of
boundaries in Fig. 4a. Likewise, the degree of c9 11 g min21. The size of such a liquation crack is less
coarsening in the airfoil of a second stage blade is than 20 mm, which is undetectable with X-ray inspec-
significantly lower than that in a first stage blade due to tions. However, severe HAZ cracks in the blade would
the lower exposure temperature, as shown in Fig. 4c. result if a higher heat input were employed. Figure 5b
Long term exposure has been reported to cause MC shows a large HAZ crack along the grain boundary of
carbide degeneration and the precipitation of M23C6 at the repaired blade with a 150 J mm21 heat input, in
the grain boundaries, resulting in weakening of the which no crack was found in the relatively soft clad
boundaries.31 However, the used blades after a suitable layer. Although a decreased heat input certainly helps to
heat treatment, e.g. 1180uC/2 hz850uC/16 h, have reduce the size of HAZ cracks, complete elimination is
microstructures similar to those of new blades. They difficult. When IN738 powder is used for repairing
consist of c9 of either cubical (0?5–1 mm) or spherical IN738 substrates without preheating, cracking in the
(,0?1 mm) particles, along with MC carbides and c9/c laser clad layer as well as in the HAZ is inevitable, as
eutectics located mainly at the grain boundaries as shown in Fig. 5c. It seems that cracking was initiated in
shown in Fig. 4d. the clad layer and then extended into the HAZ.
The temperature and stress along the length of the To ensure adequate strength of the repaired regions,
blade are varied, so that service degradation of the blade blade repairs with matching filler metal and preheating
is not expected to be uniform. The change in micro- at elevated temperatures are essential to the repair
structures might lead to HAZ cracking in the repaired process. To simulate the laser repair process, a near U
IN738 alloy.32 In order to unify the microstructure, a groove (5 mm wide, 20 mm long and 2 mm deep) for the
preweld treatment is necessary before repair welding of IN738 specimens (3?8 mm thick) was introduced and
IN738 blades. A full solution heat treatment at 1180uC then filled with IN738 powder in nine passes. The
for 2 h is recommended for IN738 alloy.33 However, a processing parameters included a laser power of
solution treatment at a lower temperature, e.g. 1120uC 1700 W, a scan rate of 1000 mm min21 and a powder
for 2 h in vacuum,34 seems to be acceptable. flowrate of 12 g min21. After cladding, the specimens
Additionally, the preweld solution treatment is known were subjected to 1180uC/2 hz850uC/16 h post-weld
to improve the weldability of c9 strengthened nickel base heat treatments. Figure 6 shows the cross-sectional view
superalloys.35 and the associated microstructures of various regions of
the weld repair. Metallographic examination (Fig. 6a)
Laser clad IN738 specimens and X-ray inspection revealed no porosity or cracks in
After the preweld treatment (1180uC/2 h), a surface the repaired specimen. Comparing the left halves of
build-up using IN625 filler metal is frequently performed Fig. 6b and d, the clad region obviously exhibits finer
on damaged IN738 blades at room temperature. dendrites than the base metal due to rapid cooling in the

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Chen et al. Laser cladding in repair of IN738 turbine blades

hardness of an IN625 clad region is y250 HV, which is

substantially lower than that of the base metal. This
limits the use of IN625 for repair to low stress areas
only. In addition, tensile tests were also performed on
IN738 clad specimens at 850uC. The yield and ultimate
tensile strengths of the weld repair were about 510 and
705 MPa respectively. The fracture locations of repaired
specimens occurred at both laser clad and base metal
regions, with the tensile elongation near 7%. Tensile
results for the repaired specimens with IN738 cladding
powder are within the range of data from the IN738
alloy tested at elevated temperatures.5,36
The fatigue crack growth rate (FCGR) test was also
performed on weld repairs in an MTS system using the
alternating current potential drop technique.37 The U
groove specimens described in the previous section were
also used to conduct the FCGR test. To reveal the crack
growth behaviour in different regions of a weld repair,
the crack growth direction was oriented normal to the
cladding direction in the compact tension specimen.
Both laser clad and base metal specimens were solution
treated at 1180uC for 2 h and then aged at 850uC for
16 h. Figure 7 displays the FCGR (da/dN) v. DK curves
for the repaired and base metal specimens tested at
850uC, in which the FCGRs of the clad and base metal
regions are comparable and within almost the same
databand. The da/dN v. DK curves at 850uC are, in fact,
parallel to those at room temperature but with higher
FCGRs.
Figures 8–10 give some examples of blade repairs
using the laser cladding technique with either IN625 or
IN738 powder as additive materials. Figure 8 shows a
damaged IN738 blade before and after repair. Figure 9
illustrates the refurbishment of blade tips with the 3D
laser metal forming technique. These two examples used
IN625 powder as filler metal during the laser cladding
process. Note that preheating is not necessary for the
repair of IN738 blades with IN625 powder, while a
5 Micrographs (SEM) showing interfacial regions of weld
preheat temperature of near 800uC is required for
repairs processed with a IN625 powder and 100 J mm21
repairs that use IN738 powder. Although IN738
heat input, b IN625 powder and 150 J mm21 heat input
cladding powder can be applied to low stress areas
and c IN738 powder and 110 J mm21 heat input: note
instead of IN625 powder in Figs. 8 and 9 with
that weld repairs were carried out at room temperature
preheating, the major application of IN738 as filler
with powder flowrate of 11 g min21
metal for repairing IN738 blades should be for high
stress areas. Figure 10 demonstrates a successful case of
laser cladding process. The HAZ (Fig. 6c) extends repair cladding on a high stress area of the blade using
y250 mm from the fusion line and has similar structures IN738 powder. It should be emphasised that not all
to the base metal (cast alloy), except for the smaller MC damaged blades can be repaired with IN738 filler metal.
carbides. Carbides are usually located at the dendritic As a result, blade repairs using IN738 filler metal should
boundaries; they are relatively small in the clad region be evaluated carefully, and extreme caution should be
(0?5–1 mm), somewhat large in the HAZ (1–2 mm) and taken. Other than that, hot isostatic pressing (hipping)
considerably larger in the base metal (5–10 mm). In can also be performed on the repaired blade to heal or
addition, fine and coarse c9 precipitates in the matrix reduce creep cavities and cladding defects, if any. Thus,
(right halves of Fig. 6b–d) are similar, regardless of the the mechanical properties of the used blade and the
regions. It is noted that the strength of IN738 at elevated quality of the repaired region can be improved by
temperatures is attributed to such fine c9 precipitates hipping.
(20–50 nm in diameter).

Weld repair properties and blade repair Summary

examples Important factors in the laser repair of IN738 blades
Microhardness measurements were also made on the using the laser cladding technique have been highlighted.
weld repair (Fig. 6a) of the IN738 specimen after post- The application of laser cladding to perform surface
weld heat treatment. The average hardness values of the build-up and 3D laser metal forming of damaged IN738
IN738 clad, HAZ and base metal regions are similar, in blades has been described. This is particularly important
the neighbourhood of 410 HV. However, this was not for the power generation plants with aging gas turbines,
the case for weld repairs using IN625 filler metal. The since obtaining new blades may be difficult due to long

144 International Heat Treatment and Surface Engineering 2008 VOL 2 NO 3/4
 Chen et al. Laser cladding in repair of IN738 turbine blades

a cross-section; b microstructure in repaired region; c HAZ microstructure; d base metal microstructure

6 Weld repair using laser cladding technique
lead times or even impossible due to obsolescence. Laser
cladding has proven to be a promising method to repair
damaged IN738 blades with IN625 powder. For
cladding with IN738 powder (a higher strength mate-
rial), preheating is an additional requirement for
repairing IN738 blades. Experimental results indicated
that the microstructure, hardness and fatigue crack
growth rates of the IN738 clad region were comparable
to those of the base metal after a suitable post-weld heat
treatment. In contrast, the IN625 clad region exhibited a
considerably lower hardness than the base metal.
Consequently, the use of IN625 is limited to low stress
areas. Blade repairs in high stress areas require the use of
IN738 cladding powder, which complicates the repair
process as a result of the need for high preheating
temperatures. Since the repairability depends on the
7 FCGR (da/dN) v. DK curves for repaired and base metal
specimens tested at 850uC

a second stage (Siemens) blade; b first stage (GE) blade

8 Damaged IN738 blade (Siemens, first stage) a before 9 Refurbishment of blade tip with 3D laser metal forming
and b after laser cladding technique

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