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Hybrid additive manufacturing plays a crucial role in the restoration of gas turbine blades, where e.g., the damaged blade tip is reconstructed by the additive manufacturing process on the existing blade made of a parent nickel-based alloy. However, inherent process-related defects in additively manufactured material, along with the interface created between the additively manufactured and the cast base material, impact the fatigue crack growth behavior in bi-material components. This study investigates the fatigue crack growth behavior in bi-material specimens of nickel-based alloys, specifically, additively manufactured STAL15 and cast alloy 247DS. The tests were conducted at 950 °C with stress ratios of 0.1 and -1. Metallographic and fractographic investigations were carried out to understand crack growth mechanisms. The results revealed significant retardation in crack growth at the interface. This study highlights the potential contributions of residual stresses and microstructural differences to the observed crack growth retardation phenomenon, along with the conclusion from an earlier study on the effect of yield strength mismatch on crack growth behavior at a perpendicular interface in bi-material specimens.
Ceramic components with complex shape cannot be produced frequently by usual ceramic forming and sintering processes. Therefore, numerous joining methods were developed and introduced in industrial scale. Nowadays, multi-stage Mo-Mn-process and active brazing are preferentially used, if temperature-stable and gastight joints are required. Unfortunately, both processes involve cost-intensive thermal processes: hydrogenous atmosphere is essential for metallization in Mo-Mn-process and active brazing takes place under vacuum. Thermal processes can be drastically simplified by using Reactive Air Brazing (RAB). Joining under air atmosphere is an interesting alternative, especially to join oxide ceramic components among themselves. So far, main disadvantage of RAB is low strength of join connections.
Aim of this investigation was the development of high-strength, thermal shock resistant and gastight ceramic-ceramic joints by RAB. Therefore,
- commercial, silver and copper oxide containing RAB soldering composition was modified by addition of ceramic particles with low thermal expansion coefficients (TEC). Hence, thermal misfit between TEC of solder and ceramic components was significantly reduced.
- RAB soldering paste was replaced with newly developed RAB composite tapes, produced by ceramic “doctor blade” technology. Thereby, improved potential exist to tailor the brazing layer relating to composition, thickness and thickness uniformity.
Gastight alumina-alumina, alumina-zirconia and zirconia-zirconia joints with strongly improved strength were produced by novel composite tapes. No strength degradation of joints was observed after thermal cycling up to 700°C.