Methods for performing in situ balancing of an internal rotating component of a gas turbine engine are provided. The method can include inserting a repair tool through an access port of the gas turbine engine with the repair tool including a tip end positioned within the gas turbine engine and a material supply end positioned outside the gas turbine engine. The tip end of the repair tool is positioned adjacent to a surface of the internal rotating component of the gas turbine engine. A new material is supplied from the material supply end of the repair tool to the tip end of the repair tool; and is expelling from the tip end of the repair tool in a direction of the surface of the rotating component such that the new material is added onto a portion of the rotating part.

In one aspect, a method for performing in situ repairs of internal components of a gas turbine engine may generally include inserting a repair tool through an access port of the gas turbine engine such that the repair tool includes a tip end positioned within the gas turbine engine and a material supply end positioned outside the gas turbine engine. The method may also include positioning the tip end of the repair tool adjacent to a defect of an internal component of the gas turbine engine, wherein the defect defines a fillable volume along a portion of the internal component. In addition, the method may include supplying a filler material to the tip end of the repair tool and expelling the filler material from the tip end of the repair tool such that the fillable volume is at least partially filled with the filler material.

In one aspect, a method for performing in situ repairs of internal components of a gas turbine engine may generally include inserting a repair tool through an access port of the gas turbine engine such that the repair tool includes a tip end positioned within the gas turbine engine and a material supply end positioned outside the gas turbine engine. The method may also include positioning the tip end of the repair tool adjacent to a defect of an internal component of the gas turbine engine, wherein the defect defines a fillable volume along a portion of the internal component. In addition, the method may include supplying a filler material to the tip end of the repair tool and expelling the filler material from the tip end of the repair tool such that the fillable volume is at least partially filled with the filler material.

A gas turbine engine blade (10), including a base portion (12) having a cast wall, and a tip portion (14) attached to the base portion and having a wall (60) formed by an additive manufacturing process. The tip portion wall may be formed to be solid and less than 2 mm in thickness, or it may be corrugated and be greater than 2 mm in thickness. Openings (80) defining the wall corrugations may be semi-circular, rectangular, trapezoidal, or elliptical in cross-sectional shape. The resulting blade has lower tip mass while retaining adequate mechanical properties. The tip portion may be formed to have a directionally solidified grain structure on a base portion having an equiaxed grain structure.

A gas turbine engine blade (10), including a base portion (12) having a cast wall, and a tip portion (14) attached to the base portion and having a wall (60) formed by an additive manufacturing process. The tip portion wall may be formed to be solid and less than 2 mm in thickness, or it may be corrugated and be greater than 2 mm in thickness. Openings (80) defining the wall corrugations may be semi-circular, rectangular, trapezoidal, or elliptical in cross-sectional shape. The resulting blade has lower tip mass while retaining adequate mechanical properties. The tip portion may be formed to have a directionally solidified grain structure on a base portion having an equiaxed grain structure.

The reusable liquid metal castable drill bushing assembly for use in a fixture plate includes a cylindrical sleeve having an inner diameter, a cylindrical drill bushing having an outer diameter, a liquid metal disposed between the outer diameter of the cylindrical drill hushing and the inner diameter of the cylindrical sleeve, a seal disposed on the cylindrical sleeve, the cylindrical drill bushing, and the liquid metal such that the seal retains the liquid metal between the outer diameter of the cylindrical drill bushing and the inner diameter of the cylindrical sleeve.

The reusable liquid metal castable drill bushing assembly for use in a fixture plate includes a cylindrical sleeve having an inner diameter, a cylindrical drill bushing having an outer diameter, a liquid metal disposed between the outer diameter of the cylindrical drill hushing and the inner diameter of the cylindrical sleeve, a seal disposed on the cylindrical sleeve, the cylindrical drill bushing, and the liquid metal such that the seal retains the liquid metal between the outer diameter of the cylindrical drill bushing and the inner diameter of the cylindrical sleeve.

A method for electrically insulating a connector module mounted on a printed circuit board assembly, the method including coating a first portion of a piece of sheet metal with an insulation material, forming the piece of sheet metal into a metal frame, wherein a second portion of the piece of sheet metal not coated with the insulation material is formed into a grounding pin, assembling the connector module, wherein components of the connector module include the metal frame, a housing, and a set of external pins, and mounting the connector module on a printed circuit board to form a printed circuit board assembly, wherein the set of external pins are electrically connected to a corresponding set of vias on the printed circuit board, and the grounding pin is electrically connected to a ground on the printed circuit board.

A method of manufacturing a component includes additively manufacturing a crucible; directionally solidifying a metal material within the crucible; and removing the crucible to reveal the component. A component for a gas turbine engine includes a directionally solidified metal material component, the directionally solidified metal material component having been additively manufactured of a metal material concurrently with a core, the metal material having been remelted and directionally solidified.

A method of manufacturing a component includes additively manufacturing a crucible; directionally solidifying a metal material within the crucible; and removing the crucible to reveal the component. A component for a gas turbine engine includes a directionally solidified metal material component, the directionally solidified metal material component having been additively manufactured of a metal material concurrently with a core, the metal material having been remelted and directionally solidified.