A method of forming an erosion shield for a turbine blade includes depositing a layer of filler material defining an upper surface. The method also includes depositing a layer of erosion-resistant material across the upper surface of the layer of filler material. An interface is defined between the layer of filler material and the layer of erosion-resistant material and has a shape of the upper surface. The method also includes machining the layer of filler material to produce the erosion shield. The erosion shield has the layer of erosion-resistant material, the machined layer of filler material, and the interface defined therebetween. An inner surface of the erosion shield is defined by the machined layer of filler material that is sized and shaped for attaching to a leading edge of the turbine blade. Each of the interface and the inner surface extend a length of the erosion shield.

A method for forming a turbine component is disclosed, including applying a metal composition to a structure by an additive manufacturing technique and lengthening the structure by the additive manufacturing technique. The structure is a transition piece or a combustion liner-transition piece assembly. Lengthening the structure forms a structure extension. A picture frame is formed on an outer surface of the structure extension by the additive manufacturing technique.

A process of welding a weld turbulator on an article includes forming a weld pool on a surface of the article using an arc welder, directing at least one beam of at least one beam welder to at least one fusion edge of the weld pool, and translating the arc welder and the beam welder in a weld direction to shape the weld pool into the weld turbulator extending in the weld direction and having the fusion edge. A turbulator welding system includes an arc welder arranged and disposed to provide an electric arc on a surface of an article to form a weld pool and at least one beam welder arranged and disposed to provide at least one beam to at least one fusion edge of the weld pool. A component includes an article having a surface and a weld turbulator on the surface of the article.

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.

Disclosed is a method of manufacturing an airfoil structure. The airfoil structure includes a plurality of airfoils, a support for supporting the airfoils, and a case for covering the airfoils. Each airfoil includes an airfoil body, and an airflow generator for producing induced airflow by generating plasma. The method includes a process of forming the airflow generator that includes a first electrode forming step of forming a first electrode on the airfoil body, a dielectric layer forming step of forming a dielectric layer on the airfoil body by forming ceramic powder into a film to cover the first electrode through room temperature impact consolidation, and a second electrode forming step of forming a second electrode on a surface of the dielectric layer, such that the second electrode is electrically connected to the first electrode, and an alternating-current voltage is applied to the second electrode.

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.

A method of repairing a blisk having a hub with circumferentially spaced blades. The method can include removing a portion of a blade and replacing the portion with a replacement piece. The method can further include welding the replacement portion to the blade. The method can further include at least one of inspecting the weld after the completion of the weld and prior to heat treatment, dimensionally inspecting the replacement piece after machining, peening the blade, and surface finishing the replacement piece.

Various embodiments include a rotor key member having: a body with a primary axis extending in a direction substantially perpendicular to an axial direction in a steam turbine, the body including: a first pair of opposing sides; a second pair of opposing sides extending between the first pair of opposing sides; a top surface and a bottom surface extending between the second pair of opposing sides; and a fillet, bevel or chamfer edge extending between a first one of the first pair of opposing sides and the bottom surface and extending an entire length of the body along the primary axis; and a slot within the body, the slot extending a portion of a length of the body along the primary axis between the second pair of opposing sides and forming an opening in a second one of the first pair of opposing sides.

A baffle assembly includes a collar with a port and a baffle positioned in the port. The baffle includes two ends, a hollow body, and a weld connecting the baffle to the collar, and the collar continuously surrounds the body of the baffle.

A method of manufacturing a replacement body for a component is provided. The method includes the steps of: a) additively manufacturing a crucible for casting of the replacement body; b) solidifying a metal material within the crucible to form a directionally solidified microstructure within the replacement body; and c) removing the crucible to reveal the directionally solidified replacement body.