A method of forming a coating system on a surface of a superalloy component having film holes defined therein is provided. The method may include applying NiCoCrAlY on the surface of the superalloy component to form a NiCoCrAlY layer while keeping the film holes open (e.g., wherein the NiCoCrAlY layer has a chromium content that is higher than the superalloy component), then heating the NiCoCrAlY layer to a treatment temperature of about 900? C. to about 1200? C., then forming a platinum-group metal layer on the NiCoCrAlY layer, and then forming an aluminide coating over platinum-group metal layer. The NiCoCrAlY may be applied onto an existing coating system on the surface of the superalloy component, wherein the existing coating system is a Co-based coating system that is substantially free from Ni.

Methods for remotely joining material a surface area of a component of a gas turbine engine are provided. The method can include inserting an integrated repair interface attached to a cable delivery system within a gas turbine engine; positioning a tip of the integrated repair interface adjacent to a defect defined within a surface of the component; temporarily attaching the tip adjacent to the defect within the surface of the component; and supplying a new material to the area to fill the defect.

Components having cracks can be repaired more simply by the localized deposition of braze material onto a region that is to be repaired, and surrounding weld filler material. A method is disclosed for repairing a damaged component. The component has a substrate with cracks, wherein material is to be deposited at least in a region of a build-up region having the cracks. The method includes a braze material deposited at least in the region of the cracks and a weld filler material is deposited in the other regions of the build-up region, wherein the melting point of the braze material is at least 10K lower than that of the material of the substrate and the weld filler material, in which the braze material is always surrounded by a weld filler material in a plane, in particular completely surrounded.

A repair method for a gas turbine blade. The repair method include: a step of removing a thermal barrier coating to expose at least part of a base material of the gas turbine blade; a first etching step of etching the exposed base material; and a first identification step of identifying a base material deterioration layer that is harder than the base material from the etched base material. The repair method further includes a first removal step of removing the identified base material deterioration layer if the base material deterioration layer is identified in the first identification step; and a step of applying a thermal barrier coating to the exposed base material. The thermal barrier applying step is performed after it is determined that there is no base material deterioration layer in the first identification step, or after the base material deterioration layer is removed in the first removal step.

Boron and silicon free braze alloys useful for structural repairs of superalloy gas turbine engine components. The braze alloy composition may contain only elements that are contained in the superalloy material to be repaired, and may have melting temperature ranges as low as 10 C. to facilitate producing a high strength homogenized braze joint during a solution heat treatment of the superalloy substrate material.

Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

A method of mounting a replacement tip section to an exposed end of a rotor blade includes removing an existing tip section from the rotor blade to create the exposed end of the rotor blade, installing the rotor blade having the exposed end onto a holding fixture, assembling the replacement tip section about the exposed end of the rotor blade, positioning a bonding fixture about the replacement tip section, and curing the replacement tip section to the exposed end of the rotor blade.

A process for rejuvenating a turbine disk having a plurality of slots includes the steps of determining a depth of a damaged layer containing M23C6 carbide dissolution; and removing the damaged layer from the slots in accordance with the determined depth.

A turbine component patch delivery system can include a compressed gas source fluidly connected to a delivery line comprising a dispensing end. The turbine component patch delivery system can further include one or more turbine component patch carriers that can be projected out of the dispensing end of the delivery line by the compressed gas source, wherein each of the one or more turbine component patch carriers comprise a turbine component patch material housed within a breakaway shell.