In one aspect, a method for performing in situ repairs of internal components of a gas turbine engine may generally include inserting a repair tool through an access port of the gas turbine engine such that the repair tool includes a tip end positioned within the gas turbine engine and a material supply end positioned outside the gas turbine engine. The method may also include positioning the tip end of the repair tool adjacent to a defect of an internal component of the gas turbine engine, wherein the defect defines a fillable volume along a portion of the internal component. In addition, the method may include supplying a filler material to the tip end of the repair tool and expelling the filler material from the tip end of the repair tool such that the fillable volume is at least partially filled with the filler material.

A multi-component braze filler alloy comprising at least 70% by weight MarM509A superalloy with the remainder MarM509B superalloy is diffusion brazed to a CM247 alloy base substrate, such as a gas turbine blade or vane. It is shown that generally higher braze temperatures lead to improved results including the possibility of re-welding such a brazed component, resulting in a re-repaired brazed component capable of continued commercial service.

A method of manufacturing a replacement body for a component is provided. The method includes the steps of: a) additively manufacturing a crucible for casting of the replacement body; b) solidifying a metal material within the crucible to form a directionally solidified microstructure within the replacement body; and c) removing the crucible to reveal the directionally solidified replacement body.

An article treatment method includes positioning an article having a base material. A weld filler material is applied to the base material by welding to form a treated article. The weld filler material includes at least one temperature depressant element at a concentration sufficient to form potential eutectic-containing zones in the welded article. The potential eutectic-containing zones contain the at least one temperature depressant element. The welded article is heated to a temperature sufficiently high and for a time sufficiently long to form at least partially liquefied eutectic-containing zones. The at least partially liquefied eutectic zones are capable of flow into cracks formed during the welding.

A method for improving the surface of an aluminum alloy article includes manufacturing the aluminum alloy article using an additive manufacturing technique, wherein the article as-manufactured includes one or more of cracks, roughness, or porosity at a surface of the article; coating the surface of the aluminum alloy article with a diffusion element, the diffusion element being capable of diffusing at least 0.2 mils into the article; heating the aluminum alloy article coated with the diffusion element to cause the diffusion element to diffuse the at least 0.2 mils into the article, thereby forming a diffusion layer of at least 0.2 mils in thickness comprising both aluminum alloy and diffusion element; and removing the diffusion layer from the aluminum alloy article, whereby upon the removing, a resulting improved surface of the article comprises fewer or smaller cracks, reduced roughness, or reduced porosity.

The present invention relates to a component of a turbomachine with a repair layer and a method for repairing wear-damaged components (1, 10) of a turbomachine, in particular of elements of a flow duct boundary, having the following method steps:

preparing the area to be repaired, in order to provide a smooth and clean surface (4),

applying an Ni-based braze (7) with a proportion of hard material particles (8) to the surface (4) to form a repair layer (15), wherein the hard material particles comprise hard alloys based on cobalt or nickel,

heat treating the component to braze the repair layer onto the component under vacuum conditions.

A multi-component braze filler alloy comprising 60-70% by weight CM247 superalloy and BRB braze alloy is diffusion brazed to a CM247 alloy base substrate, such as a gas turbine blade or vane. The substrate/braze interface may be subsequently weld-repaired without de-melting and migrating the braze alloy from the interface. The weld zone and surrounding area are solidification crack resistant. After the alloy composition is brazed to the base substrate the component may be returned to service. Thereafter the component remains repairable by welding or re-brazing, if needed to correct future in-service defects.

A method of removing a ceramic thermal barrier coating system (18). Laser energy (20) is applied to the thermal barrier coating system in the presence of a flux material (22) in order to form a melt (26). Upon removal of the energy, the melt solidifies to from a layer of slag (28) which is more loosely adhered to the underlying metallic substrate (12) than the original thermal barrier coating system. The slag is then broken and released from the substrate with a mechanical process such as grit blasting (30). Sufficient energy may be applied to melt an entire depth of the coating system along with a thin layer (34) of the substrate, thereby forming a refreshed surface (36) on the substrate upon resolidification.

A method for holding a sintering filler material during a brazing/sintering operation for repairing a damaged area of a component wherein the component is in either a bonding face down position, bonding face vertical position or bonding face up position. The method includes providing a wire mesh and attaching the wire mesh to the component in a location corresponding to the damaged area. Further, the method includes forming a gap between the wire mesh and the component. Moreover, the sintering filler material may be inside the wire mesh or both inside and outside the wire mesh in order to secure the sintering filler material to the damaged area.

A method of repairing defect in cast iron workpiece, including: machining the workpiece in the area of the defect to remove the defective material and form a chamber opening at a surface of the workpiece; anchoring a receptacle to the workpiece above the chamber (2), the receptacle is provided with an orifice in communication with the chamber; adding molten iron (4) into the receptacle so that it at least part of it flows into the chamber; adding slagging agent (5) into the receptacle; heating the slagging agent and the molten iron with an electrode (6); adding nodulizing agent into the molten iron so as to segregate graphite; and allowing the molten iron and the workpiece to cool down slowly. The above-described technique also has applicability for connecting two cast iron workpieces (11,12) together.