Abstract: In a method of making a leading edge component for an airfoil device, a first elongate sheet is provided and has a shape substantially conforming to a surface on one of a suction side or a pressure side of an airfoil. A second elongate sheet is provided and has a shape substantially conforming to a surface on the other of the suction side or the pressure side of the airfoil. The elongate sheets can be welded together at least along respective elongate edges thereof, in such a way as to form a leading edge base structure comprising a weld extending the length of the elongate sheets. Material deposits can be provided onto an outer surface of the leading edge base structure in such a way as to substantially cover the weld, whereby the leading edge component is formed.

Abstract: In a method of making a leading edge component for an airfoil device a first elongate sheet is provided and has a shape substantially conforming to a surface on one of a suction side or a pressure side of an airfoil. A second elongate sheet is provided and has a shape substantially conforming to a surface on the other of the suction side or the pressure side of the airfoil. The elongate sheet can be welded together at least along respective elongate edges thereof, in such a way as to form a leading edge base structure comprising a weld extending the length of the elongate sheets. Material deposits can be provided onto an outer surface of the leading edge base structure in such a way as to substantially cover the weld, whereby the leading edge component is formed.

Abstract: A laser spray nozzle assembly includes a nozzle body with first and second spaced apart end portions. A beam passageway extends between the end portions and permits a laser beam to pass therethrough. A housing surrounds the second end portion. The housing is spaced from the second end portion and forms an annular passage. The housing has an opening coaxial with the beam passageway for permitting the laser beam to pass therethrough. A cladding powder supply system is operably associated with the passage for supplying cladding powder thereto so that the powder exits the opening coaxial with the beam.