An upstream rail of a turbine engine turbine casing, which includes a casing body extending along a longitudinal axis, includes a base including a radial face, extending substantially radially from the casing body, a plate including an upper face, extending substantially along the longitudinal axis, a connection portion between the base and the plate, including a concave face connecting the radial and upper faces, the concave and radial faces extending on either side of an edge. The upstream rail is repaired through a method including covering a surface with a solder, the surface including the upper and concave faces such that the solder extends until the edge, and machining the covered surface, in a single action, in a direction toward the radial face, so as to reshape the surface, wherein the machining of the covered surface is performed on a portion of the radial face.

A method for repairing an upstream rail of a turbine engine turbine casing, the casing including a casing body extending along a longitudinal axis, the upstream rail including: a base including a radial surface, extending substantially radially from the casing body; a plate including an upper surface, extending substantially along the longitudinal axis; and a connection portion between the base and the plate, including a concave surface connecting the radial surface and the upper surface, the concave surface and the radial surface extending on either side of an edge, the method including: covering a surface with a solder, the surface including the upper surface and the concave surface, such that the solder extends substantially until the edge; and a step of machining the covered surface, in a single action, in the direction of the radial surface, and at least until the edge, so as to reshape the surface.

A system includes a gas turbine component having a recessed portion with a recessed surface in a hard-to-weld (HTW) material. The system includes a plate disposed over the recessed portion. The plate has an easy-to-weld (ETW) material. The plate has an outer surface and an inner surface, and the inner surface faces the recessed portion. The system includes a braze material disposed within the recessed portion between the recessed surface and the inner surface of the plate. The braze material is configured to bond the recessed surface of the recessed portion with the inner surface of the plate when the braze material is heated to a brazing temperature. The system includes a filler material disposed on the outer surface of the plate disposed over the recessed portion. Application of the filler material to the outer surface of the plate is configured to heat the braze material to the brazing temperature.

A system and method detect weld defects in real time. Cameras capture images of a weld pool as well as ripple shape and fillet geometry. A processor receives the images and communicates with a database that stores correlated potential weld defects with images of a mock weld molten pool and images of a mock weld ripple shape and fillet geometry. The processor computes an aggregate probability that a weld position corresponding to the images captured by the cameras contains a defect based on the potential defects correlated in the database.

A system and method for cooling a turbine blade tip shroud is provided. The turbine blade comprises a blade attachment, a platform extending radially outward from the attachment, an airfoil extending radially outward from the platform, and a tip shroud extending radially outward from the airfoil. The tip shroud has one or more knife edges extending radially outward from an outer surface of the tip shroud. One or more cooling passages extend through the airfoil and to the tip shroud. The turbine blade also includes one or more tip plates secured at or near the outer surface of the tip shroud thereby forming a plenum between the outer surface and the one or more tip plates. The one or more tip plates also include a plurality of cooling holes for flowing cooling air through the plenum to cool the tip shroud.

A method of welding a superalloy component includes the following sequential steps. A welding step for welding a cavity using a filler metal in an inert atmosphere, where the cavity is located in the component. A covering step for covering the filler metal and a portion of the component with a weld filler layer in the inert atmosphere. The weld filler layer has a greater ductility than material comprising the component and/or material comprising the filler metal. A second covering step for covering the weld filler layer with a braze material, and subsequently performing a brazing operation. A heat treating step heat treats the component.

A method of remanufacturing a turbine component is provided. This method includes removing a donor portion from a damaged component; removing a to-be-replaced portion from a serviceable component generally equivalent to the donor portion leaving a remainder; and welding the donor portion to the remainder. A BOAS for a gas turbine engine is also provided that includes a serviceable BOAS with a donor portion from a damaged BOAS welded thereto.

A method of refurbishing worn diaphragm rails for turbo machines. This method comprises machining the worn part of the diaphragm rails such that a clean and geometrically exact machined surface is achieved. Welding one or more layers on these machined surfaces builds up a cladding that overtops the nominal dimensions of new diaphragm. The method further comprises machining the cladding such that it has the nominal dimensions of a new diaphragm.

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.

An alloy includes a matrix that includes an amount of high-melting-temperature superalloy between about 30% and 95% by weight and an amount of low-melting-temperature superalloy between about 0% and 70% by weight. The alloy also includes an amount of a ceramic reinforcement material between about 2% and 50% by volume, dispersed in the matrix.