A method of manufacturing the aerofoil, and an aerofoil. The method includes: casting a first body portion having a passage passing there-through; casting a second body portion; and joining the first body portion and the second body portion to form the aerofoil. The passage extends from an opening at a first end at or near a leading edge to an opening at a second end at or near a trailing edge. The passage is formed during the casting process by a core; and the core is supported at the first and second ends through the respective openings of the passage.

Systems and methods for additively manufacturing or repairing a component from a base material. The system may include an inoculation source to direct inoculation materials and a laser metal deposition (LMD) system to direct laser energy during laser processing of additive materials deposited in a melt pool on the base material. The LMD system includes a laser energy source configured to direct laser energy towards the base material and inoculation materials to form the melt pool thereon and to process the deposited additive materials and inoculation materials to form layers on the base material upon solidification.

A process of fabricating a shield, a process of preparing a component, and an erosion shield are disclosed. The process of fabricating the shield includes forming a near-net shape shield. The near-net shape shield includes a nickel-based layer and an erosion-resistant alloy layer. The nickel-based layer is configured to facilitate secure attachment of the near-net shaped to a component. The process of preparing the component includes securing a near-net shape shield to a substrate of a component.

An airfoil surface includes a first titanium portion, a second titanium portion, an aluminum alloy braze disposed there between, and a titanium coating covering the aluminum alloy braze, at least part of the first titanium portion and at least part of the second titanium portion.

A method includes applying a material coating to a surface of a machine component, wherein the material coating is formed from a combination of a hardfacing material, aluminum-containing particles, and a braze material. The method also includes thermally treating the material coating at a temperature to generate an oxide layer comprising aluminum from the aluminum-containing particles, wherein the oxide layer is configured to reduce oxidation of the hardfacing material, and the braze material is configured to facilitate binding between the material coating and the surface of the machine component.

A method of repairing a superalloy component includes subjecting the superalloy component, including a repair area, to a phase agglomeration cycle, which includes stepped heating and controlled cooling of the component. The method further includes applying weld material to the repair area to create a weld surface; and covering the weld surface with brazing material. The component is then subjected to a braze cycle to produce a brazed component. The brazed component is cleaned, and the cleaned component is subjected to a restorative heat treatment to restore the microcrystalline structure and mechanical properties of the component.

A method for applying an abrasive comprises: applying, to a substrate, the integral combination of: a self-braze material; and an abrasive embedded in the self-braze material; and securing the combination to the substrate.

The present invention relates to a method for producing and/or repairing wear-stressed recesses or openings on components (22) of a turbomachine, especially of elements of a flow passage boundary, and also to corresponding components, wherein the method comprises: producing an at least two-layer molded repair part (15), one layer (2) of which is formed by an Ni-solder and a further layer (3) of which is formed from a mixture of an Ni-solder (4) and hard material particles (5) of hard alloys on a base of cobalt or nickel and which at least partially has an outer shape which is complementary to the inner shape of the recess (20) or opening which is to be repaired, inserting the molded repair part (15) into the recess (20) or opening and at least partially heat-treating the component (22) for soldering the molded repair part (15) onto the component.

Systems and methods for moving a substrate to a vision system using a robot; using the vision system to determine where a braze material is to be applied to the substrate; moving the substrate to a braze dispenser using the robot; applying a braze material to the substrate using the braze dispenser based on the determination from the vision system; and using the vison system to determine whether to apply additional braze to the substrate, including for the substrate of a component for gas turbine engine, such as configured for use in an aircraft.

A technique for repairing a dual walled component comprising a spar comprising a plurality of pedestals and a coversheet attached to the plurality of pedestals may include removing a damaged portion of the coversheet from the dual walled component to expose a plurality of exposed pedestals and define a repair location and an adjacent coversheet portion. The technique also may include filling space between the plurality of exposed pedestals with a stop material. The stop material may define a surface substantially aligned with a pedestal-contacting surface of the adjacent coversheet portion. In some examples, the method additionally includes positioning a braze material on the surface of the stop material and attaching the braze material to the plurality of exposed pedestals and adjacent coversheet portion to form a repaired coversheet portion.