The present invention is directed to in situ methods for maintaining turbine assemblies. One such method includes: disposing a maintenance apparatus on the rotor; positioning the maintenance apparatus proximate to the damaged region by rotating the rotor; and repairing the damaged region by operating a repair tool disposed on the apparatus. Another method includes: disposing a maintenance apparatus on the stator; positioning the damaged region proximate to the maintenance apparatus by rotating the rotor; and repairing the damaged region by operating a repair tool disposed on the apparatus.

Provided is a method for machining a component by removing material, in particular by removing chips, within a groove provided in the component, in which method: spatially resolved measurement data, which include information about faults, in particular cracks in the component, are provided, and machining of the component by removing material, in particular by removing chips, is performed by means of at least one machining tool mounted for movement in a motorized manner, in particular for translation and/or pivoting in a motorized manner, and is controlled in accordance with the provided measurement data preferably in an automated manner with respect to the positions on the component at which the at least one machining tool is brought into engagement with the component in order to remove material in the region of faults that are present.

A dual walled component includes a spar comprising a plurality of pedestals; a coversheet attached to a first set of pedestals from the plurality of pedestals; and a repaired coversheet portion attached to a second set of pedestals from the plurality of pedestals and to the coversheet, where the repaired coversheet portion includes a braze material.

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.

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 is directed to in situ methods for maintaining turbine assemblies. One such method includes: disposing a maintenance apparatus on the rotor; positioning the maintenance apparatus proximate to the damaged region by rotating the rotor; and repairing the damaged region by operating a repair tool disposed on the apparatus. Another method includes: disposing a maintenance apparatus on the stator; positioning the damaged region proximate to the maintenance apparatus by rotating the rotor; and repairing the damaged region by operating a repair tool disposed on the apparatus.

A method of remanufacturing a turbine blade having a platform includes placing a puck against a surface of the platform. The method may include electrical discharge machining an interface between the puck and the platform and brazing the puck to the platform. A total radial thickness of a finally remanufactured platform of the remanufactured turbine blade is greater than an initial radial thickness of the platform before remanufacturing the turbine blade.

A method of repairing a cast article defect, in accordance with various embodiments, is disclosed herein. The method may comprise: machining an aperture at a defect location of a cast article; coating a plug side surface of a plug with a braze material; coating at least one of a top surface or a bottom surface of the plug with an excess braze material; inserting the plug into the aperture from the inner surface of the cast article towards the outer surface of the cast article and leaving at least one void between a the braze material and a side surface of the aperture; and heating the cast article and the plug.

A dual walled component includes a spar comprising a plurality of pedestals; a coversheet attached to a first set of pedestals from the plurality of pedestals; and a repaired coversheet portion attached to a second set of pedestals from the plurality of pedestals and to the coversheet, where the repaired coversheet portion includes a braze material.

An upstream rail of a turbine engine turbine casing, which includes a casing body extending along a longitudinal axis, includes a base including a radial face, extending substantially radially from the casing body, a plate including an upper face, extending substantially along the longitudinal axis, a connection portion between the base and the plate, including a concave face connecting the radial and upper faces, the concave and radial faces extending on either side of an edge. The upstream rail is repaired through a method including covering a surface with a solder, the surface including the upper and concave faces such that the solder extends until the edge, and machining the covered surface, in a single action, in a direction toward the radial face, so as to reshape the surface, wherein the machining of the covered surface is performed on a portion of the radial face.