A method of manufacturing a turbine blade includes a brazing treatment for joining a brazing material to a base material of a turbine blade by heating the base material having the brazing material arranged thereon and melting the brazing material, a stabilizing treatment for heating the base material having been subjected to the brazing treatment; and an aging treatment for heating the base material having been subjected to the stabilizing treatment. The brazing treatment and the stabilizing treatment are performed with a sequential heating treatment.

A method of preparing a surface for diffusion bonding comprises contacting a binder material with a discontinuous surface comprising surface regions separated by gaps. The binder material is selectively deposited onto the surface regions and has a sufficient viscosity to form a self-supporting layer without flowing into the gaps. The self-supporting layer of binder material comprises a mass density in a range from about 0.001 g/in.sup.2 to about 0.050 g/in.sup.2. A braze powder is distributed over the self-supporting layer of binder material, and a predetermined amount of the braze powder is attached to the binder material. The discontinuous surface is then heated to remove the binder material and adhere the braze powder to the discontinuous surface. Thus, a prewet surface with a braze deposit thereon is formed.

A system for creating a braze joint within a component. The system includes an environment operable to reach a braze temperature sufficient to melt at least a portion of a braze material. The system also includes a component within the environment, the component including a base having a base surface, a recess depending from the base surface into the base to an inner edge, and a braze material within the recess and forming a cap above the base surface. The braze material fills the recess from the cap to the inner edge. The cap has an exposed braze surface. The system also includes an insulation layer that at least partially covers the exposed braze surface.

The disclosure describes example techniques and assemblies for joining a first component and a second component. The techniques may include positioning the first and second component adjacent to each other to define a joint region between adjacent portions of the first component and the second component. The techniques may also include inserting a solid retainer material into the joint region through an aperture in one of the first component or the second component to form a mechanical interlock between the first component and the second component and sealing the aperture to retain the solid retainer material within the joint region. The solid retainer material includes at least one of a metal, a metal alloy, or a ceramic.

A method for selectively adhering braze powders to a surface comprises applying a binder material to a surface, depositing a braze powder on the binder material, and then directing a laser beam onto the braze powder while the laser beam moves along a predetermined path relative to the surface. The laser beam selectively heats the braze powder and the binder material along the predetermined path such that the binder material is removed and the braze powder is sintered and bonded to the surface. Thus, a braze deposit is formed at one or more predetermined locations on the surface. After forming the braze deposit, excess braze powder and binder material, that is, the braze powder and binder material not selectively heated by the laser, are removed from the surface.

A method for selectively adhering braze powders to a surface comprises applying a braze powder to a surface, and then directing a laser beam onto the braze powder while the laser beam moves along a predetermined path relative to the surface. The laser beam selectively heats the braze powder along the predetermined path such that the braze powder is sintered and bonded to the surface. Thus, a braze deposit is formed at one or more predetermined locations on the surface. After forming the braze deposit, excess braze powder, that is, the braze powder not selectively heated by the laser, is removed from the surface.

A printing method for selectively depositing braze powders on a surface comprises extruding a filament from a nozzle moving relative to a surface, where the filament comprises a flowable carrier mixed with a braze powder. As the nozzle moves, the filament is deposited on the surface in a predetermined pattern defined by the motion of the nozzle relative to the surface; thus, the braze powders are deposited at one or more predetermined locations on the surface.

A rotor assembly for a gas turbine engine is disclosed. The assembly includes: a composite fan blade, the fan blade including a root; a metallic rotor including a slot for receiving the root; the root being at least partially coated with a metal to form a metal-coated portion; the metal-coated portion of the root being at least partially covered with an intermediate material; and the root, metal-coated portion and intermediate material being received in the slot and bonded to the rotor.

A cored filler wire (10) used in a laser metal deposition (LMD) process and method of using the same. The cored filler wire includes an outer shell (12) surrounding an inner filler material (14). The outer shell is formed from a first material, e.g., a nickel based alloy having a low gamma prime content. The inner filler comprises at least a second material, e.g., a nickel based superalloy powder material comprising a gamma prime content higher than the first material. Upon laser processing, via LMD, and subsequent solidification, the resulting build-up layer (18) formed from the processed cored filler wire comprises an identical or near identical chemical composition to that of the underlying base material (5) or component being repaired.

A method of processing a joint, including forming an actively brazed joint in a vacuum furnace, wherein the actively brazed joint is formed from at least two components coupled together by a volume of a joining metal alloy having a solidus temperature and a liquidus temperature, wherein the joining metal alloy is heated to a first temperature that is higher than the liquidus temperature in the vacuum furnace. The method also includes cooling the actively brazed joint to a second temperature lower than the solidus temperature, and maintaining the second temperature within the vacuum furnace for a predefined duration to form at least one region of segregated crystallization within the volume of the joining metal alloy, the at least one region of segregated crystallization is configured to increase the liquidus temperature of a layer of brazed metal, formed from the joining metal alloy, between the at least two components.