A nickel-based braze alloy composition includes nickel, about 1 weight % to about 5 weight % boron (B); and about 1 weight % to about 20 weight % germanium (Ge). The composition is free of any silicon. Superalloy articles having a crack or other type of void or gap may be filled with the nickel-based braze alloy composition. Methods for filling such a gap are described.

Combining a precipitation-hardening nickel-base alloy with a steel or titanium substrate makes it very easy to repair parts, the nickel-base alloy having good erosion-resistant properties. A method for producing is disclosed. In particular for repairing, a component having a substrate, in particular turbine blades made of steel or titanium, in particular made of martensitic or precipitation-hardening chromium-rich steels, with a localized deposition weld or with an affixed shaped part, in which a precipitation-hardening nickel-based alloy is used as the localized deposition weld or as the shaped part, in which a laser powder deposition weld or an arc deposition weld is performed.

Combining a precipitation-hardening nickel-base alloy with a steel or titanium substrate makes it very easy to repair parts, the nickel-base alloy having good erosion-resistant properties. A method for producing is disclosed. In particular for repairing, a component having a substrate, in particular turbine blades made of steel or titanium, in particular made of martensitic or precipitation-hardening chromium-rich steels, with a localized deposition weld or with an affixed shaped part, in which a precipitation-hardening nickel-based alloy is used as the localized deposition weld or as the shaped part, in which a laser powder deposition weld or an arc deposition weld is performed.

Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

Methods provided for remotely stopping a crack in a component of a gas turbine engine are provided, along with methods of remotely cleaning a surface area of a component of a gas turbine engine. The method can include inserting an integrated repair interface attached to a cable delivery system within a gas turbine engine; positioning the tip adjacent to a defect within a surface of the component; temporarily attaching the tip adjacent to the defect within the surface on the component; and drilling a hole into the base of the defect. An integrated repair interface is also provided.

A method for forming a secondary component from an original component having an original shape includes separating the original component into a parent component and a replaced portion, and forming a replacement coupon using an additive manufacturing system. The replacement coupon is shaped to substantially match the original shape of the replaced portion. The method further includes coupling the replacement coupon to the parent component to form the secondary component. The method also includes at least one of (i) removing the replacement coupon from a build plate of the additive manufacturing system prior to application of any heat treatment to the as-built replacement coupon, wherein the replacement coupon maintains a near-net original shape of the replaced portion after removal, and (ii) entering the secondary component into normal duty with no hot isostatic press treatment of the replacement coupon having been performed.

A method for design in indenter apparatus for plastically straining a workpiece including a weld nugget, adjacent heat affected zones, and the adjacent parent-metal portions or new metal portions, throughout the weld nugget volume and heat affected zone, to produce threshold levels of uniform plastic strain which meet or exceed plastic strain levels that provide, when the weld nugget and heat affected zone is heat treated, a recrystallized grain structure metallurgically comparable to the grain structure of the parent-metal. The indenter provided by the optimization methods may be used to advantageously in a method for the repair of damaged rotors, including integrally bladed rotors, in gas turbine engines, such as in aircraft engines. Blades for gas turbine engines, including integrally bladed rotors, may be advantageously provided constructed by the methods taught.

A method comprises inspecting a ceramic matrix composite component assembled in a gas turbine engine to determine an extent of damage to the ceramic matrix composite component, determining a repair technique to repair the damage to the ceramic matrix composite component based on the extent of damage to the ceramic matrix composite component, and repairing the ceramic matrix composite component using the repair technique.

A repair method (72) for extending a service life of a power turbine disk (12) having corrosion damage, wherein the power turbine (14) includes stages (16, 18, 20, 22) and interstage gaps (26, 28, 30, 32). The method (72) includes conducting a first thermal analysis (74) of a baseline configuration of a baseline disk that does not have corrosion to determine a first steady state temperature distribution (44). A corrosion damaged disk (12) is then machined (76) to a depth suitable for repairing the corrosion to form a machined disk. A second thermal analysis (78) of the machined disk is conducted to determine a second steady state temperature distribution of the machined disk. A first predicted safe cyclic life (PSCL) (80) is then calculated for disk axisymmetric features (1-10) of the machined disk. A second PSCL (82) is also calculated for disk firtree features (70) of the machined disk. Further, the method (72) is qualified (84) to ensure that the quality of the machined disk is consistent with a new disk.

The method comprises the steps of: a) cutting the shaft of the rotor at a section plane perpendicular to the axis of rotation of the shaft so as to separate the end portion of the shaft on which the bladed discs to be replaced are mounted from the remaining portion of the shaft; b) providing, for each bladed disc to be replaced, a corresponding new bladed disc with a respective hub having a solid cross-section; c) providing a new end portion of the shaft with a solid cross-section; and d) clamping the new bladed discs between the remaining portion of the shaft and the new end portion of the shaft, securing them to the remaining portion of the shaft by anchor bolts.