A tooling assembly for mounting a plurality of components, such as compressor blades, in a powder bed additive manufacturing machine to facilitate a repair process is provided. The tooling assembly includes component fixtures configured for receiving each of the compressor blades, a mounting plate for receiving the component fixtures, and a magnet assembly operably coupling the component fixtures to the mounting plate in a desired position and orientation to facilitate an improved printing process.

A method of furnace-less brazing of a substrate is provided. The method includes providing a substrate having a braze region thereon; disposing braze precursor material containing a nickel powder, an aluminum powder, and a platinum group metal powder on the braze region; and initiating an exothermic reaction of the braze precursor material such that the exothermic reaction produces a braze material that reaches a braze temperature above the solidus temperature of the braze material. A braze precursor material is also provided.

A method for prefabricating a poor fusion defect by controlling a LMD process, including: obtaining a model, with a shaping zone and a defect prefabricated zone that has a preset defect; and performing a layerwise slicing process on the model. For each deposition layer of the defect prefabricated zone, the preset defect has a maximum dimension a0 in a perpendicular direction; for the shaping zone, performing a shaping process under predetermined shaping process parameters of the LMD process; and for the defect prefabricated zone, controlling shaping process parameters as follows: when a0<D, with respect to the shaping zone, changing a scan pitch between shaping paths and a powder feed rate in the deposition layer, thereby prefabricating the poor fusion defect; and when a0≥D, with respect to the shaping zone.

A method of repairing a piston seal assembly comprises removing worn material from a piston seal groove to generate a worked seal groove, applying a groove buildup member to the worked seal groove, and disposing a seal member proximate the groove buildup member.

A process control system and a method for process control of a solid-state additive manufacturing system capable of performing various additive processes, such as joining, additive manufacturing, coating, repair and others, are disclosed. The process control system is capable of simultaneous measuring, monitoring and controlling multiple process variables, viz. material temperature, actuator down force, tool force (or torque), tool position, tool angular and transverse velocity, spindle torque (angular velocity), filler flow rate, filler composition, track width, inert gas flow rate and others. A feeding system for continuous supply of filler material to the solid-state additive manufacturing system is also disclosed. The filler material can be in a form of a powder, granules, briquettes, beads, flakes, wires, rods, films, scrap pieces, sheets, blocks or their combinations. Methods for generation of different periodic and non-periodic structures and joints using the process-controlled solid-state additive manufacturing system are also disclosed.

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 hybrid diffusion-brazing process and hybrid diffusion-brazed article are disclosed. The hybrid diffusion-brazing process includes providing a component having a temperature-tolerant region and a temperature-sensitive region, brazing a braze material to the temperature-tolerant region during a localized brazing cycle, then heating the component in a furnace during a diffusion cycle. The brazing and the heating diffusion-braze the braze material to the component, and the localized brazing cycle is performed independent of the diffusion cycle in the hybrid diffusion-brazing process. The hybrid diffusion-brazed article includes a component, and a braze material diffusion-brazed to the component with a filler material. The filler material has a melting temperature that is above a tolerance temperature of the component.

A rotor disk for a gas turbine engine includes a disk body having a central bore extending therethrough. The disk body includes a bore body that extends around the central bore, a web that extends radially outward from the bore body having decreased thickness relative to the bore body and a peripheral rim that is located at an outer end of the web. The peripheral rim includes blade mounting structures for engaging complementary mounting structures of rotor blades. The bore body has a bore cavity that extends continuously through the bore body and about an entire periphery of the central bore. The bore cavity has a central axis that forms a circle about the central bore.