A lock and pin for the structural and fluid tight repair of cracks not amenable to high temperature repairs or synthetic material patches. Fluid tight pins and locks seal the crack while one or more locks prevent the crack from growing. These repairs need to endure the remaining life cycle of the machinery part while withstanding all the strain, pressure, heat and expansion and contraction of the part before the crack(s) were formed. Often these cracks evolved due to engineering design flaws that will require even greater strength from these areas than when new.

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 method of repairing or, in certain cases, strengthening a metallic substrate at a damage site is provided and includes removing material from the substrate around the damage site to form a recess, and cold spraying particulate material into the recess to form a bead of deposited material.

A method of repairing or, in certain cases, strengthening a metallic substrate at a damage site is provided and includes removing material from the substrate around the damage site to form a recess, and cold spraying particulate material into the recess to form a bead of deposited material.

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.

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.

Methods for repairing an airfoil having a damaged region are provided. The method can include removing the damaged portion from the airfoil to form an intermediate component. The damaged portion generally includes an original film hole having an original cross-sectional geometry. Using additive manufacturing, a replacement portion is then applied on the intermediate component to form a repaired component with the replacement portion including a rebuilt film hole having a rebuilt cross-sectional geometry that is different than the original cross-sectional geometry.

A method of attaching a tube having a tube wall defining a tube channel therein to a workpiece having a workpiece wall. A workpiece opening defined by a workpiece opening wall surface is formed in the workpiece wall. A tube engagement surface is formed on the tube wall for engagement with the workpiece opening wall surface. A workpiece heated portion in the workpiece, and a tube heated portion in the tube, are heated in a non-oxidizing atmosphere by energized heating elements to a hot working temperature. The tube is subjected to an engagement motion, moving the tube engagement surface relative to the workpiece opening wall surface. While the heated portions are at the hot working temperature, and while the tube is subject to the engagement motion, the tube engagement surface is pressed against the workpiece opening wall surface, for plastic deformation of the heated portions, to create a metallic bond.

A method of attaching a tube having a tube wall defining a tube channel therein to a workpiece having a workpiece wall. A workpiece opening defined by a workpiece opening wall surface is formed in the workpiece wall. A tube engagement surface is formed on the tube wall for engagement with the workpiece opening wall surface. A workpiece heated portion in the workpiece, and a tube heated portion in the tube, are heated in a non-oxidizing atmosphere by energized heating elements to a hot working temperature. The tube is subjected to an engagement motion, moving the tube engagement surface relative to the workpiece opening wall surface. While the heated portions are at the hot working temperature, and while the tube is subject to the engagement motion, the tube engagement surface is pressed against the workpiece opening wall surface, for plastic deformation of the heated portions, to create a metallic bond.

A method of removing a crack in a metallic material during a metal making process. The method including: determining the presence of a crack and its crack depth during the metal making process by a crack detecting unit utilizing inductive measurement, sending a crack detection signal and crack depth to a crack removal unit arranged on known distance from the crack detecting unit, the crack removal unit including an ejector configured to eject a carving means, and to vary the intensity of the ejected carving means, removing the detected crack by activating the ejector based on the crack detection signal with an intensity of the ejected carving means based at least on the crack depth.