Abstract: A method of forming a metal product. A metal alloy workpiece substrate is provided have pre-process dimensions. The dimensional differences are determined between the pre-process dimensions of the workpiece substrate and desired post-process dimensions of a post-process metal product formed from the workpiece substrate. A build-up thickness is determined of coating material required to obtain the desired post-process dimensions of the post-process metal product. A high-density coating process is performed to coat the workpiece substrate with a coating material to build-up a thickness of coating material effective to obtain desired finished dimensions after performing a sintering heat treatment process and/or a hot isostatic pressing treatment. The sintering heat treatment is performed on the coated workpiece substrate to densify the coating material.

Abstract: A method for repairing gas turbine engine airfoil parts. The dimensional differences between pre-repaired dimensions of a turbine engine airfoil part and desired post-repair dimensions of the turbine engine airfoil part are determined. A build-up thickness of coating material required to obtain the desired post-repair dimensions of the turbine engine airfoil part is determined. A high-density coating process, such as HVOF, is used to coat the turbine engine airfoil part with a coating material to the determined build-up thickness of coating material effective to obtain the desired post-repair dimensions after performing a sintering heat treatment and a hot isostatic pressing treatment, and, if performed, a re-application of a protective coating. The coating material comprises a metal alloy capable of forming a diffusion bond with the substrate of the turbine engine airfoil part.

Abstract: A method of forming an engine airfoil part. The attributes of a final workpiece product are selected. An appropriate substrate composition is determined depending on the selected attributes. A workpiece substrate is formed to near-finished dimensions. An appropriate coating material composition is determined depending on the selected attributes. The workpiece substrate is prepared for a high-density coating process. The high-density coating process, such as HVOF thermal spray, is performed to coat the workpiece substrate with the coating material. The coating material is built-up to a thickness effective to obtain desired finished dimensions after performing a hot isostatic pressing treatment. The appropriate hot isostatic pressing treatment parameters are determined. The hot isostatic pressing treatment is performed on the coated workpiece substrate to obtain a metal product having the desired finished dimensions and diffusion bonding between the coating material and the workpiece substrate.