A tooling assembly and method of aligning a plurality of components for a repair process in an additive manufacturing machine includes positioning the plurality of components such that a repair surface of each of the plurality of components contacts an alignment plate, e.g., under the force of gravity or using biasing members. The method further includes surrounding the alignment plate with containment walls to define a reservoir around the plurality of components and dispensing a fill material, such as wax or a potting material, into the reservoir which is configured for fixing a relative position of the plurality of components when the fill material is solidified.

A precipitation-strengthened cast product welding repair method is a method of repairing a damaged portion of a precipitation-strengthened cast product. The method includes: forming a first weld layer on a surface of the damaged portion by micro tungsten inert gas (TIG) welding using a solid-solution-strengthened welding material having higher toughness than the cast product; and forming a second weld layer on the first weld layer by building up the second weld layer by laser welding using a dual multi-phase nanostructure intermetallic compound as a welding material and being higher in heat supply rate than the micro TIG welding.

A metallic product is produced by an additive manufacturing method. A device for practicing has a controller with a stored instruction set for implementing the manufacturing of the metallic product. The metallic product is manufactured in a piece- wise or layer-wise manner on a target platform by a print head that is in two-way communication with the controller. The print head operates on a momentum transfer technique in which pulsed energy from an impulse source is used to launch pieces of metal toward the target platform, the pieces of metal bonding at the target platform to manufacture the metallic product.

A metallic product is produced by an additive manufacturing method. A device for practicing has a controller with a stored instruction set for implementing the manufacturing of the metallic product. The metallic product is manufactured in a piece- wise or layer-wise manner on a target platform by a print head that is in two-way communication with the controller. The print head operates on a momentum transfer technique in which pulsed energy from an impulse source is used to launch pieces of metal toward the target platform, the pieces of metal bonding at the target platform to manufacture the metallic product.

A method for restoring a blade or vane platform of a gas turbine assembly configured for a power plant by: providing a blade or a vane having a platform with an edge deterioration zone; removing the deterioration zone by electro discharging machining technology; and rebuilding a removed zone by additive manufacturing technology. The removing can be performed to create a recessed plane along a platform edge, the recessed plane being connected to a platform plane by an enter inclined plane and an exit inclined plane arranged opposed along the platform edge.

A method for manufacturing a compressor impeller or rotor including a hub that carries blades, involving a step of manufacturing a hub which includes all or some of the blades, and a step of additive manufacture by adding localised material using a method such as the LMD process to form or finish each blade.

Methods of forming a desired geometry at a location on a superalloy part are disclosed. The method may include directing particles of a powder mixture including a low melt temperature superalloy powder and a high melt temperature superalloy powder to the location on the superalloy part at a velocity sufficient to cause the superalloy powders to deform and to form a mechanical bond but not metallurgical bond to the superalloy part. The directing of particles continues until the desired geometry is formed. Heat is applied to the powder mixture on the repair location. The heat causes the low melt temperature superalloy powder to melt, creating the metallurgical bonding at the location. Another method uses the same directing to form a preform for repairing the location on the part. The low melt temperature superalloy powder melts at <1287° C.), and the high melt temperature superalloy powder melts at >1287° C.

A surface cooler configured to be operably coupled to an aircraft fan casing includes a body having a first surface configured to confront the aircraft fan casing and a second surface opposite the first surface, multiple fluid passages located within the body, and a set of fins located on at least the second surface of the body.

The invention relates to a device for maintaining and/or repairing a construction machine, with a mobile maintenance station that can be placed at the jobsite where the construction machine is being used, comprising a 3D printer for printing replacement parts for the construction machine on the basis of component data and/or a mobile display device for displaying repair information on the construction machine on the basis of component data, wherein a data supply station that is at a separate location from the maintenance station is provided, can be connected to the maintenance station by way of a communication link and is configured for providing the maintenance station with 3D printing data for printing the replacement part, and the maintenance station is configured for printing the replacement part layer by layer on the basis of the 3D printing data received from the data supply station.

Embodiments of the present invention provides an approach for repairing defects in a structure, located in difficult to reach area, by using a self-guiding and self-melting robotic thread. The approach can use an external guidance system to find the target location of the structure and deploy a robotic thread to the defective area. Portion of the robotic thread contains a filler material can have similar materials to the structure. After the system has determined the size, length and volume of the repair, the system calculates the required length of the robotic thread and guides the thread to the defective area. Once the robotic thread is in place, the filler material begins to melt via heat. The filler material, in a melted and pliable state, can flow into the defect area. Once cooled, the filler material can now support the structure.