UNIQUE POLYMER SYSTEMS is dedicated to providing advanced repair and protection solutions for critical components in industrial settings. This case study details the successful repair of turbine blades using our UPS 200 EG CERAMIC REPAIR PASTE and UPS 210 CR EFFICIENCY FLUID CERAMIC.

The leading edges of turbine blades in a critical system were showing the onset of corrosion and wear damage. These issues, if left untreated, could lead to further deterioration, potentially affecting the turbine's efficiency and performance. Immediate repair and protection were required to extend the blades' service life and maintain optimal operation.

The challenge was to effectively restore the lost material on the turbine blades and apply a protective coating that would resist future corrosion and wear. The solution needed to ensure the blades could withstand the harsh operating conditions they are subjected to.

UNIQUE POLYMER SYSTEMS provided a comprehensive repair and protection solution using UPS 200 EG and UPS 210 CR. The repair process involved the following steps:

Surface Preparation

- The turbine blades were abrasive blast cleaned to achieve a surface cleanliness level of SA2.5 with a 75-micron profile, in accordance with ISO 8501/4 Standard SA2.5 (SSPCSP10/NACE 2). This preparation ensured that the repair materials would adhere effectively to the substrate.

Application of UPS 200 EG CERAMIC REPAIR PASTE

- The pitted and damaged sections on the leading edges of the turbine blades were rebuilt using UPS 200 EG. This step restored the structural integrity of the blades, filling in areas where material had been lost due to corrosion and wear. 

Application of UPS 210 CR EFFICIENCY FLUID CERAMIC

- The blades were then coated by brush with UPS 210 CR. The material was applied in two coats to achieve a nominal total dry film thickness of 500 microns. This coating provided robust protection against future corrosion and wear, ensuring the long-term performance of the turbine blades.

The repair process successfully restored the turbine blades to their original condition, with enhanced protection against future wear and corrosion. The application of UPS 200 EG and UPS 210 CR provided a durable solution, extending the service life of the turbine blades and maintaining their efficiency.

This case study demonstrates the effectiveness of UNIQUE POLYMER SYSTEMS' products in repairing and protecting critical components in industrial systems. Our advanced materials and precise application process provided a cost-effective solution, ensuring the turbine blades remain operational and efficient for years to come.