Abstract: The present invention relates to a method for fabricating an integrally bladed rotor which comprises providing a hub section, preferably formed from a titanium based alloy, and welding an airfoil, also preferably formed from a titanium based alloy, to the hub section. The method further comprises partially aging and cooling the hub section prior to welding and aging the airfoil and the weld joint between the airfoil and the hub section subsequent to welding. The post welding aging step is preferably carried out using a novel encapsulated local airfoil heating device having a plurality of heating elements woven into a jacket made from a high temperature cloth material. The method of the present invention may also be used to repair integrally bladed rotors.

Abstract: The present invention relates to a method for-fabricating an integrally bladed rotor which comprises providing a hub section, preferably formed from a titanium based alloy, and welding an airfoil, also preferably formed from a titanium based alloy, to the hub section. The method further comprises partially aging and cooling the hub section prior to welding and aging the airfoil and the weld joint between the airfoil and the hub section subsequent to welding. The post welding aging step is preferably carried out using a novel encapsulated local airfoil heating device having a plurality of heating elements woven into a jacket made from a high temperature cloth material. The method of the present invention may also be used to repair integrally bladed rotors.

Abstract: The present invention relates to a method for fabricating an integrally bladed rotor which comprises providing a hub section, preferably formed from a titanium based alloy, and welding an airfoil, also preferably formed from a titanium based alloy, to the hub section. The method further comprises partially aging and cooling the hub section prior to welding and aging the airfoil and the weld joint between the airfoil and the hub section subsequent to welding. The post welding aging step is preferably carried out using a novel encapsulated local airfoil heating device having a plurality of heating elements woven into a jacket made from a high temperature cloth material. The method of the present invention may also be used to repair integrally bladed rotors.

Abstract: The present invention relates to a method for fabricating an integrally bladed rotor which comprises providing a hub section, preferably formed from a titanium based alloy, and welding an airfoil, also preferably formed from a titanium based alloy, to the hub section. The method further comprises partially aging and cooling the hub section prior to welding and aging the airfoil and the weld joint between the airfoil and the hub section subsequent to welding. The post welding aging step is preferably carried out using a novel encapsulated local airfoil heating device having a plurality of heating elements woven into a jacket made from a high temperature cloth material. The method of the present invention may also be used to repair integrally bladed rotors.

Abstract: A method for replacing a rotor blade on an integrally bladed rotor having a disk is provided, comprising the steps of: (a) removing a damaged rotor blade, leaving a stub portion of the rotor blade extending out from the disk, the stub portion of the rotor blade having a suction side and a pressure side; (b) providing a die, having a pressure side and a suction side, wherein each side includes a platform trough; (c) fastening the die to the rotor blade stub, with the pressure side of the die positioned on the pressure side of the stub, and the suction side of the die positioned on the suction side of the stub; (d) extruding a portion of the rotor blade stub into the platform troughs, thereby creating a platform; and (e) attaching a rotor blade to the platform.

Abstract: A method is taught for joining a wrought alloy material to a cast alloy, so as to obtain a joint having superior structural integrity. A cast nickel-base superalloy part may be bonded to a wrought nickel-base superalloy part, for example, by positioning a suitable part or blank of said wrought superalloy adjacent to the cast superalloy part, applying a local bonding force to the interface while locally heating the interface to a temperature which causes localized softening, metal flow, and bonding, removing said bonding force, and subjecting the bonded assembly to a local or isothermal heat treatment so as to minimize distortion, optimize properties, and stress relieve the bonded assembly. This method may be used, for example, for the repair or replacement of vane assembly retaining lugs, whereby a replacement lug of a wrought alloy is solid state bonded to the vane assembly in place of the previous retaining lug.

Abstract: A method is taught for the replacement of turbine disk airseal lands, whereby a replacement land ring is solid state bonded to the disk in place of a worn or damaged land.

Abstract: A method is taught for repair of holes in superalloy or titanium materials by using plugs of the same or similar material and heat treatment, whereby a fully recrystallized joint interface is achieved between the plug and the walls of the hole.

Abstract: Techniques for fabricating or repairing integrally bladed rotors are developed. A new or replacement blade is bonded to a projecting stub. The new blade has a collar through which bonding forces are transmitted. After bonding with heat and pressure, final machining and heat treatment operations are performed.