Abstract: A method for repairing or replacing a mechanically retained vane is provided. The method comprises the steps of forming an oversized cavity in an outer base, inserting a flared end of a vane in the oversized cavity, and inserting a wedge for mechanically retaining the flared end of the vane in the oversized cavity. The wedge has a first surface with a constant pitch angle to match the outer base cavity and a second surface with a variable pitch angle to match the vane tip dovetail.

Abstract: A thermal management process for enabling the restoration of a surface of a metallic detail in the presence of at least one bonding material, comprising preparing at least one damaged area on a metallic detail; disposing at least one thermal management component upon a bonding material or a surface area proximate to the bonding material to which the metallic detail is joined; masking at least the surface area and the bonding material with a masking agent; and dimensionally restoring a surface of the metallic detail disposed on the article at a processing temperature lower than a temperature which would degrade the bonding material, the substrate, or the bondment interface therebetween.

Abstract: A replacement fan exit guide vane assembly for installation between an inner case and an outer case of a gas turbine engine includes an airfoil structure having an outer end and an inner end, a wedge structure connected to the outer end of the airfoil structure, a base plate positioned between the outer end of the airfoil structure and the outer case, a conformable material, and a slip collar having an opening therethrough and a recess formed along the opening. The airfoil structure extends through the opening, and the recess accepts the wedge structure to create an interference fit between the slip collar and the base plate. The conformable material is disposed along the opening and the recess in the slip collar, and also along the baseplate, in order to provide dampening relative to the airfoil structure and the wedge structure.

Abstract: A method of restoring a section of a component having a honeycomb bonded to a skin includes the steps of separating a first honeycomb from the skin, wherein the honeycomb includes an uneven surface. At least a portion of the uneven surface is removed to form a bonding surface on the skin. A conformable layer is bonded to the uneven surface. Then a replacement honeycomb is then bonded to the conformable layer.

Abstract: A component to be repaired includes a relatively rigid plate. On a surface that may have been subject to fracture, a resin material is first laid down, then a relatively flexible material is positioned outwardly of the resin material to repair the barrier. A part may also be formed initially with the flexible material. In another feature of this application, a method of forming a barrier includes providing a composite material, and applying a relatively flexible material on a surface of the composite material, and concurrently molding the relatively flexible material with the composite material using a composite mold.

Abstract: A method of restoring a section of a component having a honeycomb bonded to a skin includes the steps of separating a first honeycomb from the skin, wherein the honeycomb includes an uneven surface. At least a portion of the uneven surface is removed to form a bonding surface on the skin. A conformable layer is bonded to the uneven surface. Then a replacement honeycomb is then bonded to the conformable layer.

Abstract: A method for repairing or replacing a mechanically retained vane is provided. The method comprises the steps of forming an oversized cavity in a support structure, inserting a flared end of a vane in the oversized cavity, and inserting a wedge for mechanically retaining the flared end of the vane in the oversized cavity.

Abstract: A process for applying erosion resistant coatings includes the steps of applying a fluoroelastomer based solution to at least a portion of at least one perforated surface of an article, at least one perforated surface includes a plurality of perforations, and each of the perforations has a pre-coating diameter of no less than about 0.025 inches and no greater than about 0.075 inches; drying at least one perforated surface coated with the fluoroelastomer based solution; and curing at least one perforated surface coated with the fluoroelastomer based solution to form an erosion resistant coating.

Abstract: A thermal management process for enabling the restoration of a surface of a metallic detail in the presence of at least one bonding material, comprising preparing at least one damaged area on a metallic detail; disposing at least one thermal management component upon a bonding material or a surface area proximate to the bonding material to which the metallic detail is joined; masking at least the surface area and the bonding material with a masking agent; and dimensionally restoring a surface of the metallic detail disposed on the article at a processing temperature lower than a temperature which would degrade the bonding material, the substrate, or the bondment interface therebetween.

Abstract: A replacement fan exit guide vane assembly for installation between an inner case and an outer case of a gas turbine engine includes an airfoil structure having an outer end and an inner end, a wedge structure connected to the outer end of the airfoil structure, a base plate positioned between the outer end of the airfoil structure and the outer case, a conformable material, and a slip collar having an opening therethrough and a recess formed along the opening. The airfoil structure extends through the opening, and the recess accepts the wedge structure to create an interference fit between the slip collar and the base plate. The conformable material is disposed along the opening and the recess in the slip collar, and also along the baseplate, in order to provide dampening relative to the airfoil structure and the wedge structure.

Abstract: A method for repairing or replacing a mechanically retained vane is provided. The method comprises the steps of forming an oversized cavity in an outer base, inserting a flared end of a vane in the oversized cavity, and inserting a wedge for mechanically retaining the flared end of the vane in the oversized cavity. The wedge has a first surface with a constant pitch angle to match the outer base cavity and a second surface with a variable pitch angle to match the vane tip dovetail.

Abstract: A doubler assembly repairs at least one damaged aperture of a composite flange. The doubler assembly includes an insert, an adhesive, and a support. The insert is positioned in the damaged aperture to provide compressive load transfer through the composite flange. The adhesive is positioned directly on at least a portion of the composite flange proximate the damaged aperture. The support is positioned over the adhesive.

Abstract: A method of restoring a section of a composite includes the steps of removing an undesirable section of a composite and securing a repair section in the location of the removed undesirable section. One or more covers are secured on at least a portion the repair section to prevent or resist peeling of the repair section.

Abstract: A method of restoring a section of a composite includes the steps of removing an undesirable section of a perforated composite and depositing a repair material in the location of the removed, undesirable section. The repair material is then cured. Before completing the curing step, one or more opening are formed through the repair material to produce one or more perforations through the repair material upon completing the curing step.

Abstract: A method of restoring a section of a component having a honeycomb bonded to a skin includes the steps of separating a first honeycomb from the skin, wherein the honeycomb includes an uneven surface. At least a portion of the uneven surface is removed to form a bonding surface on the skin. A conformable layer is bonded to the uneven surface. Then a replacement honeycomb is then bonded to the conformable layer.

Abstract: A method for repairing or replacing a mechanically retained vane is provided. The method comprises the steps of forming an oversized cavity in a support structure, inserting a flared end of a vane in the oversized cavity, and inserting a wedge for mechanically retaining the flared end of the vane in the oversized cavity.

Abstract: A doubler assembly repairs at least one damaged aperture of a composite flange. The doubler assembly includes an insert, an adhesive, and a support. The insert is positioned in the damaged aperture to provide compressive load transfer through the composite flange. The adhesive is positioned directly on at least a portion of the composite flange proximate the damaged aperture. The support is positioned over the adhesive.

Abstract: A method and system for repairing a damaged hole includes a deformable rod and a fabric wrapped around a middle portion of the rod. A first portion of the rod is inserted into the damaged hole. The rod is stretched to align the middle portion of the rod and the fabric with an inside circumference of the hole. The rod is then relaxed to compress the fabric against the inside circumference of the hole.