Abstract: Methods and apparatus for welding a component to fill a groove therein. The method entails simultaneously projecting an electric arc and at least first and second laser beams into the groove. The electric arc melts and deposits a filler material in the groove while the first and second laser beams are projected onto opposite first and second walls, respectively, of the groove. The axis of each of the first and second laser beams is oriented at an acute angle relative to the respective wall thereof.

Abstract: A welding process, welding system and welded article are disclosed. The welding process includes directing energy from one or more fusion beams to join a first element to a second element and to join the first element to a third element. The directing of the energy is at a first lateral angle and a second lateral angle with respect to the first element. The welding system includes an energy emitting device, a first fusion beam and a second fusion beam. The first fusion beam and the second fusion beam are oriented to extend diagonally through an article. The laser welded article includes the first element joined to the second element, and the first element joined to the third element. A fillet weld is formed in a first inaccessible portion between the first element and the second element and a second inaccessible portion between the first element and the third element.

Abstract: A cladding system and method for applying a cladding to a power generation system component including a first weld bead, a second weld and a filler bead. The first weld is deposited on the surface with a first energy source and solidified to form a first weld bead. The second weld is deposited on the surface adjacent to the first weld bead with the first energy source, wherein depositing the second weld creates a surface depression between the first weld bead and second weld. The filler bead is simultaneously deposited in the surface depression with a second energy source while depositing the second weld bead. The second weld and the filler bead are solidified to form the cladding bead.

Abstract: A ternary magnetic braze alloy and method for applying the braze alloy in areas having limited access. The magnetic braze alloy is a nickel-based braze alloy from the perminvar region of the Ni, Fe, Co phase diagram. The braze alloy includes, by weight percent 8-45% Fe, 0-78% Co, 2.0-4.0% of an element selected from the group consisting of B and Si and combinations thereof, and the balance Ni. The nickel-based braze alloy is characterized by a brazing temperature in the range of 1850-2100° F. The nickel-based braze alloy is magnetic below its Curie temperature.

Abstract: A joining process and a joined article are disclosed. The joining process includes positioning an article having a base material, and friction welding a pre-sintered preform to the base material. The pre-sintered preform forms a feature on the article. The joined article includes a feature joined to a base material by friction welding of a pre-sintered preform.

Abstract: A multilayer component and fabrication process are disclosed. The multilayer component includes a foil surface layer abutting the bond coat layer and a channel-forming material positioned between the foil surface layer and a substrate. The channel-forming material defines at least a portion of a channel. The channel can be at least partially defined by a channel-forming material brazed with a foil surface layer to a substrate of the multilayer component. The process includes applying one or more layers to a foil surface layer and applying a channel-forming material to at least partially define a channel between the foil surface layer and a substrate.

Abstract: A component repair arrangement includes a material depositing electrospark rod configured to deposit a material onto the component. Also included is a first routing hose for flowing a first shielding gas to a location proximate a tip of the material depositing electrospark rod, the first shielding gas removing a plurality of sparks generated proximate the tip.

Abstract: A method of welding a joint includes directing a first output from a high energy density heat source, such as a laser, against a first side of the joint. The method further includes directing a second output from an arc welding heat source, such as a gas metal arc welding torch, against a second side of the joint. The first output produces a keyhole surrounded by a molten metal pool which extends from the first side of the joint toward the second side of the joint. In some embodiments a third output from a second arc welding heat source may also be directed at the first side of the joint. A second molten metal pool produced by the arc welding heat source joins with the first molten metal pool and the third molten metal pool to form a common molten metal pool which solidifies to form the weld.

Abstract: An article comprising a substrate; a bond layer disposed on the substrate, the bond layer comprising one or more bonding segments and at least one reinforcing segment; at least one protective layer disposed on the bond layer; and at least one cooling hole extending through the substrate, the at least one reinforcing segment and the at least one protective layer, wherein the at least one reinforcing segment reduces cracking and/or delamination at the interface between the substrate and the bond layer, and methods of making the same.

Abstract: Hybrid welding apparatuses include a laser that produces a leading laser beam, and, an arc welder that produces a trailing backhand weld arc, wherein the leading laser beam and the trailing backhand weld arc are directed towards a common molten pool, and wherein the trailing backhand weld arc trails the leading laser beam as the leading laser beam progresses in a weld direction.

Abstract: Hybrid coating systems include an electrospark deposition device having an electrode that deposits a coating on a substrate and a laser that produces a laser beam directed towards at least a portion of the coating as the coating is deposited on the substrate.

Abstract: A method of providing an oxidation resistant coating is disclosed. The method includes providing a substrate having a first surface and cooling holes. A portable coating device includes electro-spark deposition (ESD) equipment and an ESD torch connected with the ESD equipment. The ESD torch has an inert gas source and a rotary electrode conductive material. The rotary electrode is positioned within the ESD torch, and is shielded by an inert gas. The rotary electrode applies a compositionally controlled protective coating to the first surface of the substrate. Then the rotary electrode is inserted into the cooling hole and generates an electrospark between rotary ESD electrode and the substrate to form a rounded edge and deposit a coating of electrode material alloy at a cooling hole edge.

Abstract: A double-sided tribrid welding technique and apparatus for root pass welding of narrow groove welds. The welding technique utilizes three welding devices. A welding apparatus on a backside of the weld joint may strike an arc on the backside of the weld joint; a welding apparatus on a narrow groove side of the weld may strike an arc within the narrow groove weld joint, while the remaining welding apparatus is a laser that can help establish a keyhole as a common pool of molten metal at the root without burning through the root. Once the arcs are struck substantially simultaneously and the laser is energized, the welding heads move simultaneously, the arc welders assisting in maintaining pre-heat temperature, while minimizing distortion and cracking. Adjusting arc weld parameters provides deformation on completion of the root pass so as to compensate for distortion due to metal shrinkage in subsequent passes.

Abstract: A method for repairing a component with a leak are disclosed. In an embodiment, a component having at least one fluid flow path with a leak therein is provided. The component may be made of a first material. A second material may be introduced into the fluid flow path, and propelled into the location of the leak in the flow path. Once there, the second material is melted and solidified, forming a plug that occludes the leak.

Abstract: A method comprising introducing a first casting material into a casting mold; applying directional solidification to the first casting material in the casting mold; introducing a second casting material into the casting mold, the second casting material having a different chemical composition than the first casting material; applying directional solidification to the second casting material in the casting mold; and forming a molded article, wherein the molded article comprises a first region

Abstract: An adaptive control hybrid welding system including hybrid welding apparatus, control system connected to hybrid welding apparatus, and seam tracker connected to control system is provided. Hybrid welding apparatus includes a laser and an electric arc welder. Laser and electric arc welder each have adjustable welding parameters. Control system modifies welding parameters of laser and electric arc welder, and spacing between laser beam and arc of welder. Seam tracker is operable to measure seam property of adjacent workpieces prior to welding. Seam tracker is operable to send signals to control system in response to the measured seam property. Control system modifies welding parameters based on signal from seam tracker and adaptive control hybrid welding apparatus joins adjacent workpieces having variable gap sizes of up to 2.5 mm with full penetration welds. Also provided is a method of controlling the adaptive control hybrid welding system.

Abstract: A hybrid welding system including a hybrid welding apparatus and method of welding are provided. The hybrid welding apparatus includes a laser, an electric arc welder with a non-consumable electrode and a wire feeding device. The electric arc welder provides an electric arc without feeding a welding wire. The wire feeding device is arranged and disposed to feed a wire to a treatment area, which is located between the projections of laser beam and the electric arc. The laser and the electric arc welder are arranged and disposed to direct energy toward at least two adjacent components to form a common molten pool. The wire is fed by the wire feeding device into the common molten pool created by the laser and the electric arc.

Abstract: A system is disclosed for reducing an internal diameter of a hole in a metal substrate. The system includes an electrospark device having an electrospark torch and an electrode holder rotatable about an axis. An electrode is removably supported in the electrode holder. The electrospark device configured to apply a coating of a material of which the electrode is formed, to the substrate on an inner wall of the hole when the electrode is rotated within the hole.

Abstract: A dual-wire hybrid welding system includes a hybrid welding apparatus having laser, electric arc welder and second wire feeding device. Electric arc welder includes first wire feeding device for feeding first wire. Second wire feeding device is arranged and disposed to feed a second wire to electric arc welder. Laser and electric arc welder are arranged and disposed to direct energy toward at least two adjacent components along a joint and first wire is a consumable electrode fed into joint to establish molten pool generated by both laser and arc welder with first wire. Second wire is fed to molten pool to form a common molten pool. Common molten pool is operable to provide a full penetration weld with less total heat input to join the at least two adjacent components without cracking the components at a high constant weld speed.

Abstract: A method of welding alloys having a ductility drop temperature range to limit strain-age cracking. The method involves the use of a welding device to weld a weld area of an article while maintaining temperatures throughout the weld area and a heat affected zone adjacent the weld area within a non-crack sensitive temperature range that is above a ductility drop temperature range of the alloy being welded. During welding, the temperatures of the weld area and the heat affected zone are predominantly controlled with heat input from the welding device. Once the welding has been terminated, the weld area and the heat affected zone are cooled from the non-crack sensitive temperature range through the ductility drop temperature range to a temperature below the ductility drop temperature range of the alloy.