Methods for repairing a component having a damaged region are provided. The method can include removing the damaged portion from the component to form an intermediate component, wherein the damaged portion has an original geometry; and applying using additive manufacturing a repaired portion onto the intermediate component to form a repaired component. The repaired portion can have a repaired geometry that includes at least one film hole absent in the original geometry, with the film holes being fluidly connected to a cooling supply of the repaired component.

Methods for repairing a trailing edge of an airfoil are provided. The method can include removing a portion of the trailing edge of the airfoil to form an intermediate component, and then applying using additive manufacturing a replacement portion on the intermediate component to form a repaired airfoil. The replacement portion defines at least one trailing edge ejection slot.

Methods for repairing an airfoil having a damaged region are provided. The method can include removing the damaged portion from the airfoil to form an intermediate component. The damaged portion generally includes an original film hole having an original cross-sectional geometry. Using additive manufacturing, a replacement portion is then applied on the intermediate component to form a repaired component with the replacement portion including a rebuilt film hole having a rebuilt cross-sectional geometry that is different than the original cross-sectional geometry.

A method for repairing an upstream rail of a turbine engine turbine casing, the casing including a casing body extending along a longitudinal axis, the upstream rail including: a base including a radial surface, extending substantially radially from the casing body; a plate including an upper surface, extending substantially along the longitudinal axis; and a connection portion between the base and the plate, including a concave surface connecting the radial surface and the upper surface, the concave surface and the radial surface extending on either side of an edge, the method including: covering a surface with a solder, the surface including the upper surface and the concave surface, such that the solder extends substantially until the edge; and a step of machining the covered surface, in a single action, in the direction of the radial surface, and at least until the edge, so as to reshape the surface.

A multi component braze filler alloy is described having a melting temperature less than about 1235 deg. C. and greater than about 1150 deg. C. This alloy can be processed by hot isostatic pressing (HIP) at a temperature above about 1065 deg. C. and is particularly suited for the repair of gas turbine blades and vanes, especially those made from Alloy 247. The relatively low Ti content in the present braze alloy tends to form less MC carbides at the joint interface, particularly in comparison with other braze alloys high in Zr and/or Hf. Processes for employing this braze filler alloy in processing of nickel-base superalloys, especially Alloy 247, are presented.

An active braze alloy composition is described, including nickel; or a combination of nickel and cobalt; about 2% by weight to about 30% by weight germanium; and about 1% by weight to about 5% by weight boron and about 0.5% by weight to about 5% by weight of at least active element. The composition is free of silicon. Braze alloy joints formed of the braze alloy composition, and located in various devices, structures, and machines, are also described. A related method for repairing a crack or other cavity within a metal component, using the braze composition, is further described.

A repair method for repairing an assembly including a main body and an old reinforcement, the assembly including an initial hole passing through the old reinforcement and at least a portion of the main body, the method including removing the old reinforcement; positioning a plug in the initial hole in the main body; fastening a new reinforcement on the main body, the new reinforcement covering the plug; and forming a new hole passing through the new reinforcement and at least a portion of the main body.

Example systems may include an energy source, a material delivery device, and a computing device. The computing device, based on a target height of a layer deposited on a component by directed energy deposition, may control an energy source directed at a component and may control a material delivery device. Controlling the energy source may include advancing an energy beam along a first path to form an advancing molten pool on the component. Controlling the material delivery device may include delivering a material to the advancing molten pool. The material may combine with the advancing molten pool to form a first raised track having an actual height. The layer may include the first raised track. A deposited region of the component may include the layer. The actual height may affect a resultant microstructure within the deposited region.

A structural element for repairing a damaged component comprising a shaped cavity configured to receive the damaged component and a repair material, the shaped cavity comprising a material having a first melting point and the repair material comprising a material having a second melting point that is lower than the first melting point. The shaped cavity may comprise a preform for the damaged component. The preform may comprise a mold configured to reconstruct the shape of the damaged component. The repair material may comprise a first material and a second material, the second material having a melting point that is lower than the first material. The repair material may comprise a Nickel-Boron composition. The repair material may have a melting point that is approximately 40 degrees Fahrenheit lower than the melting point of the damaged component.

The present disclosure is directed to a system and method for repairing an abradable material coated on a casing of a gas turbine engine. The system includes an articulating guide configured to fit into an access port of the gas turbine engine. Further, the articulating guide has a proximal end and a distal end. The system also includes a repair tool configured at a distal end of the articulating guide. The repair tool includes a body having a proximal end and a shaped distal end, with the shaped distal end extending away from the body. Thus, the shaped distal body is configured to trench out an area of the abradable material comprising a defect. The system also includes a filler material for filling the trenched out area.