A method of repairing a cast article defect, in accordance with various embodiments, is disclosed herein. The method may comprise: machining an aperture at a defect location of a cast article; coating a plug side surface of a plug with a braze material; coating at least one of a top surface or a bottom surface of the plug with an excess braze material; inserting the plug into the aperture from the inner surface of the cast article towards the outer surface of the cast article and leaving at least one void between a the braze material and a side surface of the aperture; and heating the cast article and the plug.

In some implementations, an apparatus comprises a pipe, a stud that is forge-welded to the pipe, creating a forge-welded stud, a bracket that is operably coupled to the forge-welded stud, and a walkway operably coupled to the bracket.

In some implementations, an apparatus comprises a pipe, a stud that is forge-welded to the pipe, creating a forge-welded stud, a bracket that is operably coupled to the forge-welded stud, and a walkway operably coupled to the bracket.

An assembly and method for repairing sheathing on a tension member of a post-tensioning tendon may include an outer tube having first and second end portions, a tubular long seal positioned inside the outer tube, the tubular long seal being shorter than the outer tube, first and second seals positioned in the first and second end portions of the outer tube, respectively, and first and second nuts retaining the first and second seals in the first and second end portions of the outer tube, respectively. The assembly may define a longitudinal passage adapted to receive the tension member and the presence of the assembly on the tension member seals the portion of the tension member that is within the assembly. An inner tube may be positioned between the outer tube and the tubular long seal and may radially compress the tubular long seal.

An assembly and method for repairing sheathing on a tension member of a post-tensioning tendon may include an outer tube having first and second end portions, a tubular long seal positioned inside the outer tube, the tubular long seal being shorter than the outer tube, first and second seals positioned in the first and second end portions of the outer tube, respectively, and first and second nuts retaining the first and second seals in the first and second end portions of the outer tube, respectively. The assembly may define a longitudinal passage adapted to receive the tension member and the presence of the assembly on the tension member seals the portion of the tension member that is within the assembly. An inner tube may be positioned between the outer tube and the tubular long seal and may radially compress the tubular long seal.

A dual walled component includes a spar comprising a plurality of pedestals; a coversheet attached to a first set of pedestals from the plurality of pedestals; and a repaired coversheet portion attached to a second set of pedestals from the plurality of pedestals and to the coversheet, where the repaired coversheet portion includes a braze material.

A method for repairing a crack in a structure includes mounting a manifold to the structure around the crack. The structure has a nonplanar surface contour that surrounds the crack. The manifold has a base portion, a cover portion, and a plug. The base portion has a grip surface configured to conform to the nonplanar surface contour of the structure. The cover portion is connected to the base portion, and has an injection port and a vent port in fluid communication with a channel aligned to the crack. The injection port transfers a bonding material into and out of the channel. The plug closes and opens the vent port. The method includes filling the channel with the bonding material to direct the bonding material into the crack, and draining the bonding material from the manifold.

A method for repairing a crack in a structure includes mounting a manifold to the structure around the crack. The structure has a nonplanar surface contour that surrounds the crack. The manifold has a base portion, a cover portion, and a plug. The base portion has a grip surface configured to conform to the nonplanar surface contour of the structure. The cover portion is connected to the base portion, and has an injection port and a vent port in fluid communication with a channel aligned to the crack. The injection port transfers a bonding material into and out of the channel. The plug closes and opens the vent port. The method includes filling the channel with the bonding material to direct the bonding material into the crack, and draining the bonding material from the manifold.

An automated welding system includes a mounting platform, a welding tool, an imaging device configured to acquire data associated with an object, and a controller. The controller is configured to receive the acquired data, determine an area to be welded in the acquired data, retrieve stored master model data associated with the object, and compare the acquired data to the stored master model data to identify a master model area in the acquired data. The controller is also configured to mask the master model area in the acquired data, such that the master model area is excluded from the area to be welded, and generate control instructions for controlling at least one of the mounting platform and the welding tool to weld the area to be welded.

Methods for repairing a trailing edge of an airfoil are provided. The method can include removing a portion of the trailing edge of the airfoil to form an intermediate component, and then applying using additive manufacturing a replacement portion on the intermediate component to form a repaired airfoil. The replacement portion defines at least one trailing edge ejection slot.