Abstract: A system and method for repairing a metal substrate includes an electrospark device and an electrode removably supported in the electrode holder. The electrospark device applies a coating of a material when placed into contact with the metal substrate. A cooling device to lowers the temperature of shielding gas flow below an ambient temperature. A conduit is arranged to direct a flow of the shielding gas to the interface of the electrode and the substrate to cool the area of the substrate receiving the coating.

Abstract: A system and method for repairing a metal substrate includes an electrospark device and an electrode removably supported in the electrode holder. The electrospark device applies a coating of a material when placed into contact with the metal substrate. A cooling device to lowers the temperature of shielding gas flow below an ambient temperature. A conduit is arranged to direct a flow of the shielding gas to the interface of the electrode and the substrate to cool the area of the substrate receiving the coating.

Abstract: Methods of reducing an initial cross-sectional area of a hole in a component to a predetermined cross-sectional area including preparing a composition comprising at least an aluminum alloy with a melting temperature higher than aluminum, applying the composition to an interior surface of the hole, and then heating the component to cause a metal within the component to diffuse from the component into the composition and react with the aluminum alloy in the composition to form a coating on the interior surface of the hole. The heating step is performed to selectively modify the initial cross-sectional area of the hole and thereby directly attain the predetermined cross-sectional area thereof.

Abstract: A turbine component and a process of fabricating a component are disclosed. The process includes excavating a base metal of the component to form a fill region and filling the fill region with a filler metal. The filler metal has a filler metal elongation that is at least 25% greater than a base metal elongation of the base metal. The filler includes, by weight, between about 4% and about 7% iron, between about 14% and about 17% chromium, between about 15% and about 17% molybdenum, between about 3% and about 5% tungsten, up to about 0.02% carbon, up to about 1% manganese, up to about 2.5% cobalt, and a balance of nickel and/or the filler metal elongation is greater than about 35% in/in per two inches.

Abstract: A system and method for repairing a metal substrate includes an electrospark device and an electrode removably supported in the electrode holder. The electrospark device applies a coating of a material when placed into contact with the metal substrate. A cooling device to lowers the temperature of shielding gas flow below an ambient temperature. A conduit is arranged to direct a flow of the shielding gas to the interface of the electrode and the substrate to cool the area of the substrate receiving the coating.

Abstract: Methods of reducing an initial cross-sectional area of a hole in a component to a predetermined cross-sectional area including preparing a composition comprising at least an aluminum alloy with a melting temperature higher than aluminum, applying the composition to an interior surface of the hole, and then heating the component to cause a metal within the component to diffuse from the component into the composition and react with the aluminum alloy in the composition to form a coating on the interior surface of the hole. The heating step is performed to selectively modify the initial cross-sectional area of the hole and thereby directly attain the predetermined cross-sectional area thereof.

Abstract: A turbine component and a process of fabricating a component are disclosed. The process includes excavating a base metal of the component to form a fill region and filling the fill region with a filler metal. The filler metal has a filler metal elongation that is at least 25% greater than a base metal elongation of the base metal. The filler includes, by weight, between about 4% and about 7% iron, between about 14% and about 17% chromium, between about 15% and about 17% molybdenum, between about 3% and about 5% tungsten, up to about 0.02% carbon, up to about 1% manganese, up to about 2.5% cobalt, and a balance of nickel and/or the filler metal elongation is greater than about 35% in/in per two inches.

Abstract: A system and method for repairing a metal substrate includes an electrospark device and an electrode removably supported in the electrode holder. The electrospark device applies a coating of a material when placed into contact with the metal substrate. A cooling device to lowers the temperature of shielding gas flow below an ambient temperature. A conduit is arranged to direct a flow of the shielding gas to the interface of the electrode and the substrate to cool the area of the substrate receiving the coating.