A component including a body, and an additively manufactured (AM) metal coupon including a first section and a stress-relief section, is disclosed. The stress-relief section includes a porous region having a porosity between 2% to 50% open space volume to total volume of the stress-relief section. The stress-relief section has at least one of thermal conductivity, tensile strength, ductility, or fatigue strength less than first section. A braze material couples the AM metal coupon to a coupon opening in the body. The stress-relief section creates a low-stress zone in the metal coupon that can be located near or adjacent to a high-stress zone. The stress-relief section reduces residual stress in the metal coupon, which reduces the related challenges of coupling the metal coupon to the body of the component, especially where superalloy materials are used.

A method of reducing depletion of elements from an airfoil includes disposing a bond coating on the airfoil, where the airfoil comprises cooling channels. The airfoil includes a material that has an initial composition. A cooling hole is machined in the airfoil to contact the cooling channels such that a fluid travelling in the cooling channel may be discharged via the cooling hole. The machining of the cooling hole results in a formation of a depleted region around the cooling hole. The depleted region is depleted of a portion of the initial composition of the airfoil. A top coat is disposed on the bond coat. The airfoil is subjected to a heat treatment at a temperature effective to promote diffusion of elements from a non-depleted region to the depleted region around the cooling hole.

A repair method is a repair method of a rotor including a rotor body extending in an axial direction about an axis and a plurality of impellers arranged in the axial direction and fixed to the rotor body, the repair method including: a step of performing welding on a repair area of the rotor body to fill a damaged portion with a welded portion; a step of performing heat treatment only on the repair area in the rotor after the welding is performed; and a step of scraping a part of the welded portion after the heat treatment is performed, to form a processing surface smoothly connected to an outer surface.

A method for repairing a turbine part having a cooling hole or crack, by inserting at least one superalloy wire or pin into the cooling hole or placing a superalloy wire into the crack, providing a braze filler alloy and diffusion brazing the turbine part, forming a new cooling hole that is offset from the cooling hole that was present on the turbine part, such that part of the at least one superalloy wire or pin forms a part of the at least one wall of the newly formed cooling hole, or such that no part of the at least one superalloy wire or pin or braze material is removed, or wherein the repaired crack has a repaired surface along the surface of the turbine part, which is formed from a portion of the at least one superalloy wire.

A method of treating a cast metal matrix, the method comprising steps of depositing a self-fluxing first layer of material on an outer surface-connected void of the cast metal matrix, depositing a second layer of material on the cast metal matrix thereby closing off the outer surface-connected void so that the outer surface-connected void is an effective internal void, and hot isostatic pressing the cast metal matrix so that the self-fluxing first layer facilitates healing the effective internal void and complete metallurgical bonding of the surfaces of the outer surface-connected void.

An adaptive blending system and method are disclosed. A blending operation is performed on defects of a turbine engine component based on an initial blending profile. The adaptive blending system ad method dynamically observes and detects strain data of the defects during the blending operation. The detected strain data of the defects are sent to a processor for analysis in a substantially real-time basis to obtain strain levels of the defects. The processor generates a strain level of a defect based on the detected strain data, and generates an adjusted blending profile for use in the blending operation.

An adaptive blending system and method are disclosed. A blending operation is performed on defects of a turbine engine component based on an initial blending profile. The adaptive blending system ad method dynamically observes and detects strain data of the defects during the blending operation. The detected strain data of the defects are sent to a processor for analysis in a substantially real-time basis to obtain strain levels of the defects. The processor generates a strain level of a defect based on the detected strain data, and generates an adjusted blending profile for use in the blending operation.

A method and apparatus for applying a controlled thickness patch of repair material to a damaged surface adjacent a filleted surface disposed between a case surface and a strut is disclosed. A spacer is positioned on the case surface adjacent the filleted surface, with an outermost surface of the spacer dimensioned to intersect the filleted surface at a predetermined drop height from the case surface. Repair material is applied to the damaged surface by screeding with a straight edge. The straight edge is positioned with a first end against the outermost surface of the spacer and the filleted surface at the drop height, and a second end positioned against the strut or a guide mask disposed thereon so as to form a controlled thickness patch of repair material to the strut and filleted surface when the repair material is screeded.