Review on high-energy beam repair of surface damages in Ni-based single crystal superalloys

Abstract

The performance and durability of modern high-performance aero engines depend on the service life of hot-end turbine blades, which often dictate the engine’s overall lifespan. Ni-based single crystal superalloys are preferred materials for these components due to their superior fatigue, creep, oxidation and corrosion resistance. However, surface defects that occur during operation compromise their mechanical properties and reliability. Therefore, effective repair techniques are essential for restoring these defects and improving service performance. Although various repair methods have been developed, those capable of effectively addressing surface defects in Ni-based single crystal superalloys without damaging material properties remain limited. This review examines the potential of high-energy beam repair technologies as an innovative solution for surface defect restoration. We assess the existing repair techniques, identify their limitations and demonstrate how high-energy beams can restore material integrity while minimizing thermal damage. Key factors such as beam parameters, surface quality and defect recovery efficiency are also discussed. High-energy beam repair methods offer a promising alternative to conventional techniques, significantly enhancing the longevity and performance of repaired components. This review contributes to the optimization of repair strategies, improving the reliability and service life of turbine blades and other critical aero-engine components. Furthermore, it provides insights into the future potential of high-energy beams in advancing material repair technologies, particularly in the aerospace industry.