An air turbine starter that includes a housing. The housing can circumscribe a turbine coupled that is coupled to a gear train in a gear box via a drive shaft. A primary air flow path is defined between a primary inlet and a primary outlet. Air in the primary air flow path can flow into a secondary air flow path or rotate the turbine, that converts energy from the air flow to rotational mechanical energy. Air in the secondary air flow path can pass through at least a first cavity and first passage before rejoining the primary air flow or joining ambient air.

A method for optimizing energy conversion installation service measures, wherein the energy conversion installation has at least the following machines: at least one gas turbine; at least one generator; and optionally at least one steam turbine; wherein repairs are carried out on the at least one machine, in particular a defective component or defective components of the at least one machine either is/are or will be replaced by a new, identical component or new, identical components and/or repaired; and wherein, while carrying out these repairs, further measures for extending the service life of machines or the components thereof and/or further measures for optimizing machines or the components thereof are carried out.

A method of repair of a part is provided and includes removing a section that is damaged from the part, casting a replacement section for the part, the replacement section having a geometry similar to that of the section in an undamaged condition and bonding the replacement section to the part using field assisted sintering technology (FAST).

An airfoil component for attaching to a cropped airfoil is provided. The cropped airfoil comprises a cropped airfoil attachment section and a cropped first side opposite a cropped second side, which each extend axially between a cropped first edge and a cropped second edge to define a cropped chord length. The airfoil component comprises a body having a component first side opposite a component second side. The body defines an attachment section for attaching the airfoil component to the cropped airfoil at the cropped airfoil attachment section. The attachment section extends axially between a component first edge and a component second edge to define a component chord length, and the attachment section is oversized with respect to the cropped airfoil attachment section such that the component chord length is longer than the cropped chord length. Systems and methods also are provided.

Thermal insulation blankets and methods of using the same to repair articles, such as components of turbine engines are disclosed. The thermal insulation blankets are a multilayer composite material that includes: a first flexible fiberglass fabric layer having two sides that are coated with a coating that covers the fiberglass fibers; an intermediate second fiberglass insulation blanket layer made of continuous glass fibers; and a third layer of flexible heat reflective material. The method involves wrapping a component, such as a component of a turbine engine, with one or more thermal insulation blankets in order to retain heat within the confines of a prescribed area for installing or removing parts with a precision fitment. The blankets allow enough heat to induce even thermal expansion of the components.

A sprayable thermal barrier coating powder mixture for a gas turbine engine includes: a dry composition having a low surface area ceramic powder having a median particle size distribution greater than 5 microns and less than 50 microns, and a high surface area ceramic powder having a median particle size distribution smaller than 5 microns, wherein the low surface area ceramic powder makes up at least 50% by weight of the dry composition of the sprayable thermal barrier coating powder mixture.

Repaired rotors are provided. The rotors are repaired by using an indenter apparatus for plastically straining original portions of the rotor and adjacent repair welds. The weld nugget, adjacent heat affected zones, and the adjacent parent-metal portions or new metal portions, are indented at a weld nugget 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 original parent-metal of the rotor. Repaired integrally bladed rotors for gas turbine engines, such as aircraft engines, are provided. Blades for gas turbine engines, including integrally bladed rotors, may be advantageously provided, having been manufactured or repaired as described.

A process of treating a component includes mechanically removing surface debris from a base coating of the component, identifying at least one surface feature in the base coating, and applying an overlay coating layer over the surface feature of the base coating without stripping off the base coating. A process of treating a gas turbine component includes mechanically removing surface debris from a base coating of the gas turbine component, identifying at least one surface feature in the base coating of corrosion pits, dents, spalls, and combinations thereof, and applying an overlay coating layer over the surface feature of the base coating without stripping off the base coating. A treated gas turbine component includes a gas turbine component substrate and a base coating on the gas turbine component substrate having at least one healed surface feature. The healed surface feature includes an overlay coating layer on the base coating.

Methods for repairing a component having a damaged region are provided. The method can include removing the damaged portion from the component to form an intermediate component, wherein the damaged portion has an original geometry; and applying using additive manufacturing a repaired portion onto the intermediate component to form a repaired component. The repaired portion can have a repaired geometry that includes at least one film hole absent in the original geometry, with the film holes being fluidly connected to a cooling supply of the repaired component.

A method of developing a suggested blend repair to an airfoil includes the steps of: (a) storing history with regard to a particular airfoil in a particular engine; (b) taking information with regard to new damage to the particular airfoil; (c) reaching an initial blend recommendation based upon step (b); (d) assessing whether the initial blend recommendation of step (c) would be appropriate to repair the new damage based upon a consideration of steps (a)-(c); and (e) reporting a final blend recommendation. An airfoil repair recommendation system is also disclosed.