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The Liburdi Group of Companiesproviding specialized Technologies, Systems, and Services forTurbine, Aerospace and Industrial Applications.
Materials Engineering ServicesManufacture and Repair SupportFailure AnalysisRemaining Life AnalysisMetallurgical Laboratory AnalysisMaterials SeminarsWelding Process Development
Metallurgical ProcessesLPM™ Powder Metallurgy Process GTAW, PAW and Laser Welding ProcessesLFX™ Welding FluxesLOM™ and LSR™ Coating ProcessesCVD & PVD Coating SystemsOverlay Coating ProcessesPlasma Spray ProcessesChemical Stripping ProcessesVacuum Heat TreatmentsHot Isostatic PressingLaser Processing
Gas Turbine ServicesComponent RefurbishmentRejuvenation Heat TreatmentsEfficiency and Power UpgradesComponent Redesign and ModificationWinGTAP™ and LGTP-Health™ Diagnostic and Performance Software
Turbine Fleet Management
Precision Welding EquipmentLAWS™ Automated Welding SystemsLaser, Plasma, GTAW Automated WeldingDabber® Welding SystemsLVS™ Machine VisionLST™ Laser Seam TrackingLRC™ PC Based ControllersAutomated Machining SystemsOrbital Tube and Pipe Welding Systems Pulsweld®, Dimetrics®, Hobart® Power SourcesMerrick® Engineering SystemsMachine PAW torchesWeldline® SeamersPrecision Welding Lathes and wire feed unitsCustom Industrial Welding SystemsNuclear Welding Systems
Liburdi Engineering provides a diverse range of turbine services,metallurgical analysis, mechanical design, performancemonitoring, repair development and corporate research anddevelopment. Our services in the turbine industry complimentthose offered by the original engine manufacturers while providing the added benefit of an independent engineeringanalysis and advanced, life extending, refurbishment processesand coatings.
Since 1979, Liburdi has pioneered in the development of metallurgical processesand technologies required for reliable analysis and refurbishment of aero andindustrial gas turbine components. Through innovation and dedication to quality,Liburdi has become a recognized leader in turbine repair and life extensiontechnologies, as well as a supplier of automated equipment used to weld, machineand coat aerospace and industrial components. Liburdi provides a comprehensiverange of products and support services including:
automation
Liburdi Automation is the manufacturer of high precision, vision based LAWS™, Dabber® and Pulsweld® power sources,multi-axis articulated motion systems and controllers forapplications in turbine, aerospace, nuclear, industrial andautomotive industries.
Liburdi Dimetrics® manufactures an extensive range of orbitalwelding products and precision lathes, seamers and positionersusing advanced technologies acquired from Dimetrics®,Hobart®, Merrick Engineering®, Weldline® and enhanced byLiburdi. These specialized GTAW, PAW and GMAW systemsand controllers are used extensively for precision welding oftube and pipe, medical devices, industrial, nuclear powergeneration and automotive components.
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Liburdi’s offices and main manufacturingand service facilities located near Toronto,Ontario and Charlotte, North Carolina.
Facilities located in Hamilton, Ontario and in Charlotte, NorthCarolina, provide a complete range of component refurbishmentand advanced life extending processes for the latest class ofhigh performance aero and industrial turbines including –alloy rejuvenation, LPM™ Powder Metallurgy, automatedwelding processes, and unique coatings for erosion, oxidationand corrosion resistance.
turbine services
Liburdi Engineering provides comprehensive metallurgical services ranging from analysis ofservice failures to the development of new technologies, such as advanced welding and joiningmethods, rejuvenation heat treatments, and protective coating processes. Liburdi’s seminarson turbine materials and welding metallurgy provide unique insight and training for operatorsand engineers.
Turbine Component Life Trend AnalysisMetallurgical examination of hot gas path componentsassessed for remaining service life includes characterizingthe type of damage and quantifying the extent of materialdegradation so that an informed and cost effective repair or replacement decision can be made.
Components are examined for:• oxidation/corrosion attack• coating thickness and integrity• microstructural degradation• reduced creep strength• dimensional changes
Liburdi has developed techniques which have become therecognized industry standard with the issue of “Gas TurbineBlade Life Assessment and Repair Guide” co-authored byLiburdi and published by EPRI. We continue to developadvanced techniques for correlating microstructural andcoating changes with service exposure which, along witheffective use of Finite Element Technology, enhances thevalue of the information derived from the components.
Repair Process SpecificationsDetailed specifications define repair requirements andensure that repairs of acceptable quality and enduranceare achieved. Liburdi has developed specifications for useby prominent industry organizations such as EPRI andCTTC. Similar specifications are developed for the turbineoperator and are also used for the repairs performed byLiburdi.
Welding and Joining Applications AnalysisOur team of specialists analyze weld processes andmicrostructures and provide solutions in support ofcustomers’ applications for aerospace and advancedmanufacturing. This unique expertise allows us to quicklyunderstand the metallurgical requirements and modify theparameters for optimum quality and speed. Applicationsrange from superalloy to steel, as well as copper andaluminum alloys for a wide range of critical products.
Laboratory FacilitiesLiburdi has a fully equipped metallographic laboratoryincluding facilities for mechanical testing and non-destructivechemical analysis. Our affiliation with McMaster Universityprovides the latest in metallurgical analytical equipment,including:
• Scanning Electron Microscopes (SEM)• Transmission Electron Microscopes (TEM)• Scanning Transmission Electron Microscopes (STEM)• Secondary Ion Mass Spectroscopy (SIMS)• X-ray Diffraction (XRD) etc.
Component Failure Analysis
The Liburdi team applies an interdisciplinary approach tothe analysis of turbine failures. Our staff includes engineersexperienced in engine and component design, aero-dynamics and performance analysis, repair and coatingtechnologies, as well as metallurgy and materialsexpertise. By analyzing a failure or reduced componentlife from several perspectives, we are able to identify theproblem and its cause, and to further advise on how toprevent its re-occurrence.
Our metallurgical engineers and technologists are fullyexperienced in the materials and high strength superalloysused in today’s gas turbine engines. We have developed aunique understanding of the behavior of these complexalloys and specialize in the analysis of their service behavior.
Metallurgical Engineering
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Stainless steel tube weld using high speed DC pulsingService exposed GTDIII alloy showing coarsening ofgamma prime structure and grain boundaries.
New material structure for GTDIII alloy showing fullduplex gamma prime structure.
High cycle fatigue striationsand disc failure.
7.5kHz
Our mechanical engineering services are specifically tailored to gas turbines. This allows us to perform a thorough independent analysis of problems and, where required, to modify or redesign components. Our work scope can vary from stress analysis on rotating blades todetermine repair limits to a detailed examination of performance and temperature distributionfor the complete engine.
This unique capability has been made possible by the experience and talent of our engineersin the field of engine design. To assist in our analysis, we use advanced computer programsfrom industry proven sources or developed at Liburdi. Our computer analysis capabilityincludes:
• Finite Element Heat Transfer, Stress and Frequency Analysis• Cooling Flow and Compressible Flow Network Analysis• Computational Fluid Dynamics• Rotor Dynamics• Turbine Mean Line Aerodynamic Analysis• Design, Off-Design and Transient Performance Analysis
Turbine Upgrades and ModificationsWhen redesign is required, we can provide completedrawings and specifications, and manufacture themodifications in our facility. In many cases theseimprovements have been adopted and used underagreement by the original engine manufacturer.
Our cooling engine modifications have achieved significantimprovements in component life extension, unit reliabilityand efficiency, and enjoy a proven track record over theyears. Benefits are gained through the use of modern designmethods and the introduction of elements such as highperformance gas seals, cooling flow distribution, highstrength materials and coatings.
Our turbine upgrades include steaminjection and supercharging for poweraugmentation, conversions for gasexpander use, performance improvingtransition and seal redesign, andaugmented disc and blade cooling forextended creep life.
Turbine Engine Performance SoftwareOver the years, Liburdi has developed advanced, high precisionengine performance models for use in developing performanceimprovements. These programs are similar to those used by theengine designer and enable a detailed, stage-by-stage analysis tobe carried out over the full operating range in support of Liburdi’sengine modification and performance upgrade activities. We alsowork with the engine manufacturers and provide tailored systemsfor their engineers to use. Detailed models are developed specificallyfor each engine model in order to provide this high level of accuracy.
WinGTAP LGTP™ PerformanceSoftwareThe LGTP™ Performance Software is packaged inan easy to use Windows format and is used byengine manufacturers, packagers and facilitydevelopers to predict on-site performance for thefull range of on-design and off-design operation.The software is configured specifically for eachengine model, either industrial frame or aero-derivative, and can include heat recovery cycles forcombined cycle and co-generation installations.
LGTP-Health™ PerformanceDiagnostic SoftwareThe LGTP-Health™ Software is based on the LGTP™ Performance Softwarewith additional capabilities for engine health monitoring and diagnostics.The software is installed in the engine control room for operationsmonitoring by our customers to identify and determine the source ofperformance degradation as well as determine the operating cost of theperformance degradation.
Mechanical Design & Engine Performance
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LGTP-Health™ Diagnostic analysis of G.E. Frame 7 Engine
LGTP™ performance analysis ofGE LM2500+DLE Engine.
Finite Element Analysisapplied to improve bladeairflow cooling andexhaust diffuser design.
The repair and manufacturing facilities offered by Liburdi are supported by the extensiveexperience of our mechanical and metallurgical engineering team. Each job is individuallyreviewed by experienced engineers who are responsible for specifying the design of the repair,establishing safe limits for the extent and type of repair permitted, and for ensuring theintegrity of the part. The result is advanced technologies and experienced supervision for allprocesses to ensure quality and reliability.
Quality Assurance to the HighestStandardsIn addition to ISO9000, Liburdi is DOT/FAAapproved for aero component repairs and OEMapproved by engine manufacturers and theirapproved overhaul facilities. We have authoredrepair specifications for operator groups such asEPRI and CTTC. Liburdi repairs components forthe engine manufacturer and directly for the engineowner/operator. Liburdi’s advanced processes areapproved and used by the OEM for new partmanufacture of the latest engine designs.
Component Repair Specialists • Industrial frame blades and vanes for extended life• Aero derivative blades and vanes for extended life• Combustors and transition repairs• LAWS™ automated systems for advanced high
strength welding• LPM™ powder metallurgy for superior strength repairs • Fuel nozzle restoration, re-manufacturing, flow check,
re-certification• Advanced CVD, PVD and Plasma Spray coating
systems selected specifically for the type of service
Coating Stripping and Re-CoatingLiburdi’s stripping facility employs the latesttechnology and precise controls for reliable strippingof components – both internal and external coatings.Multiple stripping tanks are used with chemicalsolutions and procedures designed specifically foreach of the coatings in common use – diffusionaluminides, MCrAlY, TBC. Liburdi has developedadvanced CVD coating systems for aluminide coatingof internal and external surfaces.
Automated Welding
By combining our understanding of materialsbehavior with advanced automated weldingrepair techniques, we are able to develop newrepair processes for component life extension.Automated welding enables the use of highstrength and oxidation resistant weld metals not possible with conventional welding.
Rejuvenation Heat Treatments
Since 1979 we have been the leaders in introd-ucing HIP and rejuvenation heat treatments tofully restore properties of high hour blades.Proven processes have been developed for allblade alloys used in the past as well as the latestDirectionally Solidified and Single Crystal alloys.
CVD and Overlay Coatings
Advanced systems for applying diffusion aluminidecoatings to the external and internal airfoil surfaces aswell as a wide range of MCrAlY overlay coatings areapplied to suit the specific engine service environment.
LPM™ Powder Metallurgy Process
This unique patented process is used extensively as analternative to welding for high strength, distortion-freerepairs for both blades and vanes. The process is OEMapproved and enables a wide range of alloys to be usedfor crack repair and surface build-up. The LPM™ repairshave consistently outperformed conventional weld orbraze repairs on numerous engine rainbow tests.
Component Refurbishment & Life ExtensionAdvanced Technologies for Component Life Extension
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LAWS-1000™ System welding HPT blade with oxidationresistant weld alloy for longer overhaul life.
Rejuvenated bucket with improvedcoating after 24,000 hrs ofcogeneration service.
Vane repairs with LPM™ used to reinforce fillets and build up wall thickness.
turbine services
The unique Liburdi Powder Metallurgy, LPM™, is a patented, advanced joining and claddingprocess for blades, vanes and other superalloy turbine components. LPM™ offers superiorstrength and performance compared to conventional weld and diffusion braze repair methods.The LPM™ process uses mechanical means to remove the crack-damaged areas. Inspectionsensure that all weakened material has been removed before the LPM™ materials are applied at room temperature using either a moldable putty or a flexible tape composition. The parts are then heat treated in a vacuumfurnace to produce a liquid phase sintered, metallurgical bond with the base alloy. The process is very versatile and materials can be formulated from a wide variety of high strength superalloy powders selected for the specific application,e.g. IN738, Rene80, Mar M247, X40. Compositions can also be designed for wear resistance using Chrome Carbide or abrasive tip materials.
Blade RepairsFor nickel based blade superalloys such as IN738 and GTD111,matching powder alloys are used for strength approaching the original component. The strength far exceeds that of conventional weld alloys for high reliability and more extensiverepairs. For the latest high performance engines, the process is used by theOEMs to apply an “engineered” blade tip of abrasive oxidation-resistant alloy tohigh strength (single crystal) airfoil castings and for closing the cavities that areused to support the internal ceramic core during the casting process.
Vane and Nozzle Segment Repairs
For cobalt based vanes such as X40 and FSX414 alloys, high strength nickelbased LPM™ powder alloy is used for strength exceeding the original component.In this way, the parts are upgraded by strengthening the damaged areas forfuture extended service life. LPM™ reconstructed vanes will often outperformthe original cast part.
• LPM™ is able to repair crack sensitive alloys without the heat affected zone cracks associated with welding
• LPM™ is able to repair structural areas of vane segments without the local distortion which can be associated with welding.
• When used to restore worn or eroded airfoil or shroud surfaces, the LPM™ isapplied in a flexible tape form to restore the original surface with a controlled thickness of new superalloy material.
• LPM™ is used to reconstruct badly damaged vanes and is superiorto coupon replacement.
Advanced ManufacturingThe LPM™ materials are also used for new component manufacturing.Typical applications include hard facing of Z notches for shroudedblades, abrasive tips for single crystal blades, closure of corecavities and repair of new castings.
Advanced Coating TechnologyLiburdi Engineering has pioneered in the developmentof several unique vapor coating processes capableof depositing wear-resistant and oxidation-resistantcoatings. In addition to providing these coatingservices, Liburdi designs and builds CVD and PVDcoating systems for installation at customers’facilities.
Titanium Nitride Hard CoatingsThe Reactive Ion Coating RIC™ process is a plasmaassisted, electron beam evaporization Physical VapourDeposition (PVD) process used to deposit hard, erosion-resistant Titanium Nitride coatings. The RIC™ is applied to compressor airfoils in jet engines and some industrialturbines to protect against erosion and the resulting lossesin engine efficiency and power. The superior erosionresistance of the RIC™ coating is OEM approved for newblade manufacture for Allison T56 engines operating inthe harshest military desert environments. The coating,while extremely hard, is very thin and provides a smoothersurface finish for improved aerodynamic efficiency overthe life of the overhaul cycle. A three times life improvementhas been achieved on T64 and T56 engines operating insevere environments.
Aluminide CVD CoatingsThe Liburdi LOM™ coating process is a ChemicalVapor Deposition (CVD) process which applies a high purity aluminum coating over the exterior and if required internal surfaces of turbine blades. Theunique process enables very complex shapes andinternal passages to be successfully coated withtight control over uniformity of coating thickness. Theprocess can be combined with modifying elementssuch as platinum or Yttrium to produce high performancemodified aluminide coatings for specific applications.
Aluminide and MCrAlY Overlay CoatingsLiburdi has developed a group of coatings using a unique slurry application technology for turbineblades and vanes. The application process is usedto produce modified diffusion aluminides such asSilicon Aluminide as well as MCrAlY coatings with-out relying on conventional pack or high velocityspray processes.
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Vane repair with extensive material removedprior to LPM™ application.
LPM™ repaired vane after 24,000 hrs ofcogeneration serviceoutperformsconventional weldrepairs in rainbowtests.
RIC™ Titanium Nitride Coating Process
LOM™ Process for CVDaluminide coatinginternal and externalblade surfaces.
Properties of LPM™ wide gap repairs aresuperior to conventional weld repairs.
IN738
LPM
IN625
LPM™ – Liburdi Powder Metallurgyturbine services
Liburdi introduced the first LAWS™ robotsystem designed specifically for turbine blades and vanes in 1990. Since that time the product has evolved into a family of gantry and rectilinear robotic architectures,each with the latest LRC™ Controller andLiburdi Vision System. These systems are now the industry standard and are used inaero manufacturing and overhaul facilitiesaround the world. Liburdi has a uniqueunderstanding of the application of thisequipment since the LAWS™ systems are operated in its own repair andmanufacturing facility and therefore Liburdi can provide “Turn-Key” solutions including tooling and process development for most applications.
LAWS™ Automated Welding Systems
The LAWS™ systems provide superior control of the weldprocess for improved quality and consistency comparedto manual welding of crack-sensitive alloys. Power sourcesranging from Micro Plasma to Laser can be used, dependingon the application.
The LAWS™ systems are used for shrouded blade Z notchhard facing, unshrouded HPT blade tip repair, compressorblade tip and leading edge restoration, and for manufacturinga variety of cases and circumferential air seals.
Liburdi’s Automated Laser System can be configured for a variety of aerospace and industrial applications, such as HPT blades, shrouded LPT blades, compressor blades and seals. The unit is capable of achieving near-net-shape weld geometry and can be supplied with wire or powder delivery systems.
Dabber® Automated Welding SystemsThe acquisition of the advanced welding products of Hobarthas added the Dabber® automated systems to Liburdi’sproduct line. An industry standard for over two decades,the Dabber® has now been enhanced with new technologyfor the most demanding applications of close spaced, thinedge seal restoration.
Liburdi Vision System LVS™
The Liburdi Vision System captures a 3-Dimensional imageto precisely characterize the motion, shape and thicknessof each surface to be welded. The LVS™ directs the torchpath and adjusts the weld parameters for consistent weldsof the highest metallurgical quality for difficult to weld alloys.
Pulsweld® Power SourcesThe Pulsweld® line of GTAW and PAW power sources offersboth high precision and guaranteed repeatability to meetthe most demanding applications. The 50/100 amp MicroGTAW/PAW system is designed for low heat input welding,while modular high speed systems ranging from 200 to1200 amps are available to satisfy larger power requirements.For difficult to weld materials such as aluminum, the
patented Pulsweld® Variable Polarity VP™ technology utilizes its unique cathodic cleaning action to provide
enhanced tolerance to surface oxide and contaminants toachieve superior welds.
Precision Torches and AccessoriesThe custom line of GTAW and PAW torches from Liburdiare recognized as the best precision machine and manualtorches in the industry. The micro plasma torches areengineered for repeatability and reliability and are the idealsolution for exacting welding applications.
Systems Integration forAdvanced ManufacturingThe Liburdi team directs its extensiveexperience to design fully integrated systemsto meet the specific requirements of the mostchallenging manufacturing applications.Single source responsibility for all robotics,integration, power sources, vision, software,tooling, weld development, NDT andmetallurgical qualification of weld samples.This same expertise is dedicated to ongoingsupport for customers and their manufacturingoperations. Our applications range from largeaerospace systems for VPPA welding oflaunch vehicles to micro plasma welding ofautomotive devices.
Automated Welding Systems
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LAWS-1000™ LAWS-500™
automation
LTP-75 Machine Torch
Dabber®
LAWS-5000™
LAWS-4000™
The Liburdi Dimetrics® and Hobart® line of precision GTAWpower sources are designed for tube and pipe welding usingautomated orbital weld heads and welding lathes. Precisepower output is available from models ranging from 150 to 500amps. The MicroPAW® power source is available as a 20 ampsystem designed for low heat, precision plasma welding ofsmall components, medical instruments, hermetically sealedvessels, fine wires and bellows.
Orbital and Industrial Welding SystemsLiburdi Dimetrics® manufactures an extensive rangeof automated orbital welding products, precisionlathes, and controls for GTAW, PAW and GMAWwelding applications ranging from fine, thin wall tubewelding to thick wall, high deposition pipe welding.
Orbital Tube and Pipe Heads Heads are designed for every application. Tube-to-tubeand tube-to-sheet weld heads for the full range of tubediameters and specialized needs – high purity, narrowprofile, low clearance profile, liquid and gas cooled,with/without removable cassette, and with small or largewire spools.
Welding Support Services (DTS)Liburdi Dimetrics® provides a full range of cus-tomer and technical support services including field and factory service, in-house or on-site training programs, application consultation andengineering, and orbital tube and pipe rental equipment.Welding and maintenance technicians are also available for on-site, short or long term project support. Our in-house welding store provides same day shipment ofwelding accessories and consumables such as weldwire, electrodes, torch tips, gas cups, and LFXTM
welding fluxes for complete customer support.
Precision ControlsLiburdi Dimetrics® orbital tube and pipe welding controllersare microprocessor based and available with multi-segmentcurrent control, AVC, wire pulsing/oscillation, and real-timedata logging capability. For heavy wall applications, thesystems feature advanced hot wire and narrow groovetechnologies for high deposition welding. Unique VariablePolarity features are also available for welding aluminum.
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Gold Track® V Hot Wire CCTM
The Gold Track® V Hot Wire CCTM Automated Welding Systemproduces high quality GTA welds with overall speeds comparable to those of GMAW systems. Its patent pendingprocess automatically adjusts the wire current as the operatorincreases or decreases the wire feed rate, maximizing depositionrates and reducing overall welding time. The system is availablein our standard single hot wire configuration, or in a dual hot wire setup for bi-directional applications.
Gold Track® V Automated Welding SystemThe Gold Track® V provides an impressive 500 Ampere ofpower at 100% Duty Cycle. The legendary built in Gold Track®
Controller allows synchronized control of 4 to 6 servos andcan operate all pipe and tube heads.
Model "F" Weld Head The field-proven Model "F" head is available in MIG, TIG andhot wire configurations. The full function (travel, AVC, wirefeed, oscillation) head is renowned for reliability and accuracy.The patented zero backlash traction driven carriage can beeasily mounted on various tracks with quick disconnects.
Weld Catalyst Novel LFXTM and LDWTM formulations for
enhanced weld penetration
Gold Track VP for aluminum applications
MTW-160 Portable Tube Welding SystemMerrick Weldline®
Seamer
Integrated Welding Lathe
Low Profile “F”MIG Head
Gold Track® V availableon cold and hot wireand VP models
Dual Hot Wire “F” Head
Quick Clamp Track DLP 1.4 Low Profile Head
1⁄2˝
304 ss
CANADA1-905-689-07341-905-689-0739
U.S.A.1-704-892-88721-704-892-4713
EUROPE+31.341.418899+31.341.424153
Sales and Service:Phone:
Fax:E-Mail:
For further information on existing and future products, call us or visit our Website at: www.liburdi.com
automation
turbine services
