"Basic Gas Turbine Metallurgy and Repair Technology Workshop"

Saturday, June 6, 2009
World Marriott Resort & Convention Center
Orlando, Florida

Overview and Objective
This workshop will explain super-alloy metallurgy as it applies to gas turbine components. We will look at component damage experienced from gas turbine service exposure and the techniques used to analyze the remaining life of components removed from service. We will compare and contrast protective coatings, component repair technologies, and repair quality assurance techniques. The workshop includes many case study examples, and the last section is devoted to a workshop where attendees develop component repair solutions. Participants may submit questions in advance regarding repair issues faced in their jobs.

After completing the course the participants should be able to explain:

1. What makes super-alloys especially suited for gas turbine components
2. How different damage mechanisms (oxidation, corrosion, erosion) affect the component
3. How high cycle fatigue & low cycle fatigue damage is caused, prevented, and repaired
4. Various heat treatments used in repairs, and why they are important
5. Advantages & disadvantages of the many types of protective coatings
6. Critical quality control steps in component repair
7. How to reliably extend the service life of valuable components

Instructors
Lloyd Cooke, Director, Operations, Liburdi Turbine Services;
Warren Miglietti, Technical Expert-Reconditioning, Power Systems Mfg., LLC (An Alstom owned Company);
Doug Nagy, Industrial Component Repair Manager, Liburdi Turbine Services.

Who Should Attend
A must for GT repair shop personnel, GT designers and technical staff, Operations and maintenance engineers and technicians responsible for gas turbine component repairs, and insurance companies!

Course Schedule

Saturday, June 6 8:00 a.m. to 5:00 p.m.
Section I:	Introduction: Why repair and refurbish parts? The Future for Industrial Frame GT Repairs Repair Market Trends Cost Benefit of Repairs Industry Trends
Section II:	Gas Turbine Nomenclature: A review of typical gas turbine components and the respective environment they withstand. Industrial Gas Turbine Nomenclature Industrial and Aero-derivative Typical Gas Turbine Component Materials Design Differences Advanced Design Turbine Blade Data Operating Modes – Industrial Engines – Industrial Frame Engines Inspection and Maintenance Intervals
Section III:	Materials and Metallurgy: Gas Turbine materials and their properties. The Future for Industrial Frame GT Repairs Repair Market Trends Overview of Why Superalloys are Used in a Gas Turbine Overview of Superalloy Production Routes Investment (Lost Wax) Casting Processing and manufacture of materials Superalloys Compositions and Properties Solid Solution Strengthening Precipitation hardening Grain boundary strengthening and control
10:00 a.m. – 10:15 a.m.	Coffee Break
Section IV:	Gas Turbine Coatings: This section covers the typical coatings utilized in Gas Turbines such as Anti-Corrosion, Wear Surface and Thermal Barrier Coatings. 4.1 Applications • Coating Microstructure • Coating Performance • Selection of Coatings 4.2 Coating Processes • Slurries and Paints • Pack Process • Chemical Vapor Deposition •Thermal Spraying • Physical Vapor Deposition
Section V:	Degradation Characteristics in Gas Turbine Components: Degradation modes such as creep, LCF, etc. and their effects on Gas Turbine Components. Metallurgical Effects of Service Creep –High Cycle Fatigue –Low Cycle Fatigue Environmental Attack –Oxidation –Corrosion Coating Degradation, Depletion, Cracking, TBC's Mechanical Damage Thermal Mechanical Fatigue (TMF) Damage Microstructure - y´Aging Dissolution of y´ in an Over-temperature Incident Microstructure -Carbide Aging Environmental Attack: Oxidation, Hot Corrosion. Aqueous Corrosion
12:00 p.m. – 1:00 p.m.	Group Lunch
Section VI:	Component Evaluation: The evaluation of used components and determination of the repair/refurbishment process will be discussed. Timing and selection of components for analysis Micro structural analysis Mechanical testing –Stress Rupture bars Coating Evaluation Hot Corrosion Attack Failure Analysis Component Management Program Determine Damage Mechanisms, the Extent of Damage, Root Cause of Damage, and Corrective/Preventive Action
Section VII:	Refurbishment & Repair Processes: Procedures and techniques used to restore components to industry standards. Typical Damage Coating Stripping Dimensional Checks Re-Coating Selection and Processes HIP and Rejuvenation Heat Treatments Superalloy Weld Processes Diffusion Brazing
3:15 p.m. – 3:30 p.m.	Coffee Break
Section VIII:	Quality Assurance: Methods and procedures to verify components meet industry standards. QA Certification Quality Plan QA Inspections NDE Defect Criteria Dimensional Specification NDE Inspections
Section IX:	Vendor Selection & Verification GT Repair Shop Selection and Qualifications – What to Look For.
Section X:	Case Studies & Problem Solving: Case studies presented by the instructors to illustrate the process of component repair & refurbishment. The class will then be divided into teams and given components for which they will determine the best process.
Section XI:	Round Table Discussion: Round table discussion regarding the latest repair trends and student questions.
Wrap-up and Evaluation