Verification Programme

To demonstrate how overaged (i.e. "engine-run") microstructures can be recovered to the "as-new" condition using E&CT Recovery heat treatments.

Verification Programme Overview

testing diagram
Data will be presented from stress rupture testing and microstructural analysis carried out on "as-new" overaged and "recovered" samples.

Stress Rupture Testing

Stress Rupture TestingA furnace chamber surrounds each specimen keeping the samples at a constant temperature.

The test runs until the sample ruptures. The hours to rupture are recorded. This gives an indication of the strength of the material.





Summary of Stress Rupture Testing Results

verification graph

Values obtained clearly demonstrated that Marm-002 EA and DS overaged material was fully recovered back to the ‘as-new’ condition.

Microstructural Analysis - Overaged Material

Overaged DS and EA materials were confirmed to have heavily degraded microstructures comprising the following features:
  • Gamma prime coarsening and agglomerisation.
  • Increased spacing between gamma prime precipitates.



Microstructural Analysis - Recovered Condition

The microstructures of the DS and EA materials were found to be similar to that os "as-new" material. They comprised the following features:

Conclusions

Stress Rupture Testing

Values obtained clearly demonstrated that Marm-002 EA and DS overaged material was fully recovered back to the ‘as-new’ condition using RWG proprietary heat treatments.

Microstructural Analysis

Optical and Scanning Electron Microscopy demonstrated that ‘overaged’ EA and DS microstructures were fully recovered back to the ‘as-new’ condition.

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Component Repair

The Rolls Wood Group Component Repair Division was established in November 1992 to provide a dedicated component repair service for the Rolls Wood Group engine Projects. The facility provides an in-house capability for over 90% of the repair processes required for the Rolls-Royce RB211, Avon, Olympus and 501 gas generators.

Before & after HP NGV's

The Component Repair Division operates from 2 site locations in Aberdeen, Scotland (Wellheads and Kirkhill) and is designed around a 'cellular production' concept, with 3 distinct production zones established to enhance the quality and turn-times of the components being processed.

The Wellheads site incorporates approximately 22,000 sq feet of floor space and the Kirkhill site covers a space of 14,000 sq feet.

The Repair Division Capabilities are as follows:

  • Thermal Spray Systems:
    HVOF Sulzer Metco DJ 2600/2700
    Plasma - F4 and F4 90 Deg
    Flame - 6P11 Abradables.
  • Hot End Coatings:
    Sermaloy J
  • Machining:
    Vertical Boring, Turning, Surface Grinding, Milling, Drilling, Creep Feed Grinding and Salvage Fitting.
  • Protective (Paint) Coatings:
    SermeTel W, Teflon, Polymide, Epoxy Resin, LHRSE, HHRSE & Dense Pack.
  • Inspection:
    Fluorescent Dye Penetrant, Dimensional, Visual and Ultrasonic turbine blade wall thickness inspections.
  • Calibration Department
  • Welding and Brazing:
    TIG Welding, Arc Welding, Acetylene Gas Welding, Torch Brazing, Resistance Welding Spot, Seam & Circumferential & Dot riveting.
  • The Laboratory supplies a comprehensive quality control service for all production activities.
  • Metal Forming:
    Polishing, Hand Grinding and Fettling, Hydraulic Presses and Shears, Belt Sanding & Superpolishing.
  • Chemical Treatment:
    Chromate Conversion Coatings. Ferric Chloride etch, Nitric Acid Stripping of Braze & Abradables, Stripping of Platinum Aluminising and Sermaloy J, HVOF, Plasma & flame spray coating.
  • Heat Treatment:
    Degussa, Vacuum and Carbolite Furnaces perform Solution, Brazing,  Ageing and Diffusion Heat Treatments and the Curing of Protective Coatings.
  • Plating:
    Selective Plating Process - Silver, Copper 7 Nickel Cobalt.