A method for forming a secondary component from an original component having an original shape includes separating the original component into a parent component and a replaced portion, and forming a replacement coupon using an additive manufacturing system. The replacement coupon is shaped to substantially match the original shape of the replaced portion. The method further includes coupling the replacement coupon to the parent component to form the secondary component. The method also includes at least one of (i) removing the replacement coupon from a build plate of the additive manufacturing system prior to application of any heat treatment to the as-built replacement coupon, wherein the replacement coupon maintains a near-net original shape of the replaced portion after removal, and (ii) entering the secondary component into normal duty with no hot isostatic press treatment of the replacement coupon having been performed.

Provided are workpiece-assemblies, and systems and methods for aligning a plurality of workpieces with a build plane. A system may include an alignment plate, one or more elevating blocks, and a workpiece-assembly. A workpiece-assembly may include a build plate that has a plurality of workpiece docks, a plurality of workpiece shoes that have a slot configured to receive a portion of one or more workpieces respectively inserted or insertable into the plurality of workpiece docks, a plurality of biasing members respectively situated or situatable between the build plate and the plurality of workpiece shoes so as to exert a biasing force upon the workpiece shoes, and one or more clamping mechanisms coupled or couplable to the build plate and operable to secure the plurality of workpiece shoes within the respective workpiece docks.

A method of furnace-less brazing of a substrate is provided. The method includes providing a substrate having a brazing region thereon; disposing braze precursor material containing a nickel powder, an aluminum powder, and a platinum group metal powder on the brazing region; and initiating an exothermic reaction of the braze precursor material such that the exothermic reaction produces a braze material that reaches a braze temperature above the liquidus temperature for the braze material. A braze precursor material is also provided.

A tooling assembly for mounting a plurality of components, such as compressor blades, in a powder bed additive manufacturing machine to facilitate a repair process is provided. The tooling assembly includes component fixtures configured for receiving each of the compressor blades, a mounting plate for receiving the component fixtures, and a complementary fixture defining a plurality of voids within which the compressor blades are received when the complementary fixture is mounted to the mounting plate such that less powder is required to fill the powder bed.

A method for building structures on existing components includes preparing an auxiliary plate suitable for fastening on the working plate, wherein the auxiliary plate has at least one reference marking, fastening the component on the auxiliary plate, optionally processing the at least one surface to be processed for providing a surface that is substantially parallel to the working plane of the device, measuring the at least one reference marking and the component, wherein the position is recorded, introducing the auxiliary plate with the at least one reference marking and the component into the device and detachably fastening the auxiliary plate on the working plate and processing the component in the device for additive manufacturing by working data on the basis of measuring data. A device and a composite structure for additive manufacturing is used in the method.

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 a 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 less than 1287° C., and the high melt temperature superalloy powder melts at greater than 1287° C.

A method of reworking or repairing a component includes removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity that results in a through hole; sealing the through hole with a backing; and at least partially filling the cavity with a multiple of layers of a multiple of laser powder deposition spots, each of the multiple of laser powder deposition spots formed of a filler alloy, a first layer of the multiple of layers includes a perimeter of the multiple of laser powder deposition spots that overlap a wall of the cavity and the backing.

A method of reworking or repairing a component includes removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity that results in a through hole; sealing the through hole with a backing; and at least partially filling the cavity with a multiple of layers of a multiple of laser powder deposition spots, each of the multiple of laser powder deposition spots formed of a filler alloy, a first layer of the multiple of layers includes a perimeter of the multiple of laser powder deposition spots that overlap a wall of the cavity and the backing.

Systems and methods for repairing compressor blades using hybrid manufacturing techniques. A tool for repairing a compressor blade has a plurality of support bases, and a slot configured for securement of said compressor blade to said mounting tool. The tool has a pair of support bases, each of which is configured for the building of a sacrificial support thereon to stabilize the compressor blade during repair. The tool is coupled to a hybrid manufacturing machinery and the sacrificial supports stabilize the compressor blade during additive and subtractive manufacturing processes.

The invention relates to a device and a method for repairing components by means of additive manufacturing. The deviation of the surface of the component from a predetermined dimensions within a repair region is determined along a specified tool path. In a subsequent filling cycle, a selective application of a filler along the specified tool path is carried out.