Abstract: An example apparatus for replacement of a breached pipe section includes a first cylindrical pipe fitting having a first surface defining a first aperture, a middle pipe member, and a second cylindrical pipe fitting having a second surface defining a second aperture, and first and second aperture caps. A first end of each of the first and second pipe fittings is welded to opposite ends of the middle section, and a second end opposite of each of the first and second pipe fittings is welded through the respective first and second apertures to opposite ends of pipe surrounding the breached pipe section. The first and second aperture caps are welded to the apertures of the first and second pipe fittings to close the respective first and second apertures.

Abstract: A component and a method of processing a component are disclosed. The method includes providing a base metal having a feature, removing the feature to form a processed region, applying a first layer to the processed region, and applying a second layer to the first layer. The base metal, the first layer, and the second layer each have predetermined thermal expansion coefficients, yield strengths, and elongations. The processed component includes the first layer applied to a processed region of the base metal and a second layer applied to the first layer.

Abstract: A wheel resurfacing method and system for resurfacing a worn track wheel to its original profile are provided. The system comprises a support for maintaining the worn railway wheel, a welding device, a controller, and a surface processing device. The worn railway wheel's circumferential surface defining a flange and a tread surface is reconstituted using a welding material. The welding device and the worn railway wheel rotate one relative to the other at a predetermined rate to adaptively aggregate annular welding beads along the circumferential surface to form a curvilinear profile slanted away from the flange. A surface processing device is then actuated to smooth the welded layer to form a substantially uniform surface to reconstitute the worn railway wheel to its original profile.

Abstract: A method of repairing a component comprising: removing a damaged portion of the component to expose a region of the component; providing a patch having a rim exceeding the dimensions of the exposed region; placing the patch on the exposed region of the component such that the exposed region is covered by the patch and the rim is spaced apart from the exposed region; joining the patch to the component around the rim of the patch; and diffusion bonding the patch and the component together. The rim may be spaced apart from the exposed region such that the step of joining the patch to the component does not affect the exposed region. The method may further comprise machining a recess in the damaged region of the component.

Abstract: Methods of to maintaining turbine discs prone to cracks in bucket attachment dovetails are disclosed. In one embodiment, wherein a turbine disc comprises a plurality of bucket attachment dovetail regions, one or more of the bucket attachment dovetail regions comprises a cooling slot, and each cooling slot comprises edges and adjacent surfaces, a method comprises inspecting the one or more of the bucket attachment dovetail regions comprising a cooling slot to confirm that each bucket attachment dovetail region meets predetermined minimum standards. The method further comprises blending the edges of the at least one of the cooling slots. The method further comprises polishing the edges of the at least one of the cooling slots. The method further comprises peening the edges of the at least one of the cooling slots. The method further comprises coating the edges and adjacent surfaces of at least one of the cooling slots.

Abstract: An amorphous braze foil (1) produced by a melt-spin process has an upper side and a lower side. The upper side and the lower side are thinly coated with a film of metallic Ni-based, Co-based, or Ni—Co-based braze powder (2) with a particle size in the nanometer range, wherein both the braze foil (1) and also the braze powder (2) additionally include grain boundary stabilizing elements as alloying elements. In addition, melting point depressants can be present in the braze foil or in the nano braze powder (2) in a commercially common quantity or with a considerably increased proportion. With the braze foil (1) coated in this manner, both the melting temperature of the braze material and also the probability of recrystallization are advantageously reduced when brazing in the adjacent base material (10).

Abstract: In some embodiments, a method removes gold plating on an electronic component. The method includes forming a gold and solder mixture on the electronic component via a first incrementally controlled heating procedure; incrementally cooling the electronic component via a first cooling procedure; wicking part or all of the gold and solder mixture from the electronic component to a metallic screen via a second incrementally controlled heating procedure; and incrementally cooling the electronic component via a second cooling procedure.

Abstract: A damage-repairing method of a transition piece in an embodiment includes; an oxide removing step of removing an oxide on an outer surface 20b of an inner duct 20 of a transition piece 10 having damage; a repair material placing step of placing a brazing repair material 80 on the outer surface 20b of the inner duct 20 so as to cover the damage; and a diffusion brazing step of diffusion heat treating the inner duct 20 to repair the damage formed in the outer surface 20b. The damage-repairing method of the transition piece includes: a pressurized heat treating step of, under high pressure, heat treating the inner duct 20; a surface finishing step of scraping off the brazing repair material 80 projecting from the outer surface 20b; and a non-pressurized heat treating step of solution heat treating and aging heat treating the inner duct 20 under non-pressure.

Abstract: A method of welding alloys having directionally-solidified grain structure. The methods improve the weldability of these alloys by creating a localized region of fine grain structure, wherein the welding occurs in these localized regions. The localized regions are formed by applying strain energy using a variety of different methods, such as by hammer peening, laser peening or sand blasting. Then, a heat treatment step may be used to create recrystallized grains having the fine grain structure. The region of fine grain structure provides better weldability.

Abstract: The invention relates to a stirrer organ (1) in composite construction comprised of a metallic part (4) and a hybrid casting (9), with the hybrid casting (9) being fixed to the metallic part (4) by means of at least one anchoring element which forms at least one back-cutting in the hybrid casting (9). Furthermore, the present invention relates to a method for rehabilitating a damaged metallic stirrer organ which when applied provides a rehabilitated stirrer organ (1) in composite construction. The invention tackles the task of creating a stirrer organ (1) in hybrid construction which features a largest possible metallic part (4) because higher strength can hereby be achieved. This task is inventively solved in that the anchoring element is provided with a perforated plate (5) which is spot-wise fastened to the metallic part (4) and which is arranged at least partly at a small distance to the surface of the metallic part (4) so as to configure the at least one back-cutting.

Abstract: A method for repairing a component of a gas turbine and a solder alloy are disclosed. In an embodiment, the method includes applying the solder alloy to the component in an area of the component having a punctiform damage or a linear imperfection, where the solder alloy is a mixture of a NiCoCrAlY alloy and a Ni-based solder. A molded repair part made of the solder alloy is applied to the component in an area of the component having a planar defect. The component is heat treated to solder the molded repair part on the component and to solder the solder alloy applied to the component in the area of the component having the punctiform damage or the linear imperfection. The component is cooled after the heat treating and, following the cooling, the component is further heat treated.

Abstract: A wheel resurfacing method and system for resurfacing a worn track wheel to its original profile are disclosed. The system comprises a support for maintaining the worn railway wheel, a welding device, a controller, and a surface processing device. The worn railway wheel's circumferential surface defining a flange and a tread surface is reconstituted using a welding material. The welding device and the worn railway wheel rotate one relative to the other at a predetermined rate to adaptively aggregate annular welding beads along the circumferential surface to form a curvilinear profile slanted away from the flange. A surface processing device is then applied to the welded layer to form a substantially uniform surface to reconstitute the worn railway wheel to its original profile.

Abstract: Polymer compositions containing a polymer matrix, a graphene that is covalently bonded to the polymer matrix and metal particles are described herein. A combined concentration of the metal particles and the graphene in the polymer matrix exceeds an electrical percolation threshold. In general, the graphene has a carbon:oxygen ratio of at least about 20:1 so as to impart a high electrical conductivity thereto. The polymer compositions can be used as a lead-free solder material, in which case they can allow multiple rework operations to take place at a connection. Methods for making and using such electrically conductive polymer compositions are also described.

Abstract: Methods for reworking a solder containing one or more joined members are described herein. Such methods can include applying a disintegrating agent to a solder containing a solder material, disintegrating the solder material to form a disintegrated solder material, and removing the disintegrated solder material from the solder. Such methods can also include applying a disintegrating agent containing bismuth to a solder containing a solder material, and heating the solder to liquefy the disintegrating agent. Such methods can also include applying a disintegrating agent containing a bismuth alloy to a solder having a solder material that contains metal nanoparticles, and heating the solder to liquefy the bismuth alloy.

Abstract: A method of repairing an aperture and adjacent defect in a part which is started by removing one or more defects adjacent an aperture in a base material. The material is removed to create a weld seam that extends past an area of high stress concentration on the aperture. An insert of material containing a profile that corresponds to the profile of the base material removed adjacent the aperture and a combination top and runoff plate that encompasses the insert of material are provided. A backing plate is inserted underneath the combination top and runoff plate and insert such that there remains an air space between the backing plate and the combination plate which prevents the combination plate from becoming fused to the backing plate during a welding process. The insert is welded to the base material, and the backing plate is removed. Excess material is removed from the insert to obtain an aperture containing a profile essentially the same as the profile of the aperture prior to initiating the repair.

Abstract: In one aspect, a repair method for repairing components comprising a base material with a directed microstructure is provided. The repair is performed in such a way that the repaired location correspondingly has a directed microstructure like the surrounding base material. A solder is applied in the region of a location to be repaired and is soldered to the component via heat exposure, a temperature gradient, i.e., for instance a temperature variation from a higher temperature to a lower temperature, is thereby produced in the region of the location to be repaired.

Abstract: A braze formulation includes a novel promoter and a metal filler. The promoter includes a blend of potassium tetrafluoroaluminate and potassium tetrafluoroborate. The braze may be used for repairing cracks in a substrate. The braze has a low melt point, removes oxides from within cracks and has improved penetration into cracks for repair.

Abstract: Embodiments of a method for forming an MCrAlY coating on a gas turbine engine component are provided, as are embodiments of a method for repairing a structurally-damaged region of a gas turbine engine component utilizing an MCrAlY material. In one embodiment, the method includes the step of preparing an MCrAlY slurry containing an MCrAlY powder, a low melting point powder, a binder, and a dilutant. After application over the gas turbine engine component, the MCrAlY slurry is heated to a predetermined temperature that exceeds the melting point of the low melting point powder to form an MCrAlY coating on the gas turbine engine component. The MCrAlY powder may have any one of a number of different compositions.

Abstract: A method for restoring blade dovetails to their original shape comprising the steps of removing damaged material from a blade dovetail at a damage site, physically depositing a metal at the damage site in an amount sufficient to replace the removed damaged material, and machining the blade dovetail to the original shape.

Abstract: A method for repairing wider gaps in a substrate of a component by brazing at a brazing temperature is provided. Filler material and solder are prevented from separating in that, in a two-stage process, first the filler material and then the solder are applied to the wider gap. The powder does not melt at the brazing temperature and the filler metal does melt at the brazing temperature.

Abstract: A process for filling openings, including blind holes, through-holes, and cavities, in high temperature components. The process entails forming a powder mixture by mixing particles of at least a base alloy and a second alloy that contains a sufficient amount of a melting point depressant to have a lower melting temperature than the base alloy. The powder mixture is combined with a binder and compacted to form a compacted preform, which is then heated to remove the binder and form a rigid sintered preform. The sintered preform is produced, or optionally is further shaped, to have a cross-sectional shape and dimensions to achieve a clearance of up to 200 micrometers with the opening, after which the preform is placed in the opening and diffusion bonded within the opening to form a brazement comprising the particles of the base alloy dispersed in a matrix formed by the second alloy.

Abstract: A system and method for repairing turbine vane attachment systems in a turbine engine. In at least one embodiment, the invention may be directed to a system and method for repairing wear on a diaphragm hook fit configured to attach diaphragm airfoils, such as stationary turbine vanes, to a combustion turbine case. The restoration system may be formed from a carriage assembly having an assortment of material processing implements usable to build up material in the worn locations of the turbine vane attachment system to reestablish a diaphragm hook fit within the specified tolerances. The restoration system may be configured so that the restoration process may occur without removing a rotor assembly, which can reduce the repair time by about two weeks. Thus, use of the restoration system can result in a significant time and cost savings.

Abstract: A roll (1) for supporting and conveying hot material, including a roll element that has a roll jacket (2) made of a basic material and a wear coat which is applied to the basic material by means of a surface welding process (4) using a welding additive which surrounds the surface of the roll jacket. In order to increase the service life of the wear coat, improve the resistance to wear, and reduce the cost for producing the welded-on surface. The basic material of the roll jacket (2) is steel and contains up to 0.45 percent of C. The welded-on surface (4) is designed as a single-layer weld, and the wear coat contains 12.5 to 14.0 percent of Cr at least in an external zone that surrounds the surface of the roll jacket. Also disclosed are a method for producing the roll (1), a method for repairing a used roll (1), a welding additive and a welding rod for producing the welded-on surface.

Abstract: A method of processing an article includes mechanically working an article having a metallic layer disposed on a titanium substrate and establishing a residual stress region that extends through the metallic layer and at least partially into the titanium substrate.

Abstract: One or more embodiments relate to a production method of multilayer pieces comprising holes having inclined axes and the pieces being resistant to high temperatures and having a bond sub-layer and a thermal barrier coating layer (TBC) comprising depositing the bond sub-layer on the substrate of the piece, depositing the TBC layer, depositing by plasma spraying of a variable or defined composition gradient layer between the TBC layer and the bond sub-layer after the depositing step of the bond sub-layer and drilling the holes via laser beam. A method for repairing a defective piece via the method is described.

Abstract: Systems and methods for providing localized heat treatment of gas turbine components are provided. In this regard, an exemplary method includes: identifying an area of a gas turbine component to which localized heat treatment is to be performed; positioning a resistance heating element, sized and shaped to transfer heat to the area, adjacent the area; electrically coupling a current-limiting power controller to the resistance heating element; and locally heating the area using the resistance heating element, with power being provided to the resistance heating element via the current-limiting power controller.

Abstract: A method and an apparatus for repairing gas-turbine blisks uses an endoscope 15 provided with processing optics featuring a flexible light guide arrangement 16. A laser source 9 is connected to a flexible optical fiber arrangement 10, with a filler material feeder 7 for supplying welding flux via a flexible line 8, with a water supply 11 connected to a flexible line 12, and with an inert gas supply 13 connected to a flexible line 16 for supplying inert gas, with the flexible lines 8, 12, 14, the flexible light guide arrangement 16 and the flexible optical fiber arrangement 10 being combined to form a flexible long repair implement 17 at least at its distal end areas.

Abstract: Disclosed is an austenitic welding material which contains C: 0.01 wt % or less, Si: 0.5 wt % or less, Mn: 0.5 wt % or less, P: 0.005 wt % or less, S: 0.005 wt % or less, Ni: 15 to 40 wt %, Cr: 20 to 30 wt %, N: 0.01 wt % or less, 0: 0.01 wt % or less, and the balance of Fe and inevitable impurities, wherein the content of B contained as one of the inevitable impurities in the welding material is 3 wt ppm or less, and the total content of C, P, S, N and O in the welding material is 0.02 wt % or less.

Abstract: Methods for reworking a solder containing one or more joined members are described herein. Such methods can include applying a disintegrating agent to a solder containing a solder material, disintegrating the solder material to form a disintegrated solder material, and removing the disintegrated solder material from the solder. Such methods can also include applying a disintegrating agent containing bismuth to a solder containing a solder material, and heating the solder to liquefy the disintegrating agent. Such methods can also include applying a disintegrating agent containing a bismuth alloy to a solder having a solder material that contains metal nanoparticles, and heating the solder to liquefy the bismuth alloy.

Abstract: The subject of the invention is a method for repairing sealing surfaces of seal segments, arranged on the inner circumference of a turbine casing section, of a rotor/stator seal of a gas turbine. With the method according to the invention, first of all material is removed from the sealing surfaces of the seal segments with the exception of the base material of the seal segments, a metallic reinforcing coating with a material thickness of at least 1 mm is applied, and then a ceramic coating with a material thickness of 0.3 to 2 mm is applied to it.

Abstract: A method of fabricating and using a braze preform, the method comprising cold pressing a powdered brazing material in a die, thereby forming a braze preform in the die. The braze preform can then be diffusion brazed to a damaged component to repair the component.

Abstract: A component is repaired by removing a damaged region to form a cavity, in which layered repair inserts are installed. The profile of the cavity, and of the exposed surface of each repair insert is measured to serve as the basis for the contact surface of each subsequent repair insert. The repair inserts are fused to the wall of the cavity and to each other in a process in which heated locations of each repair insert are successively heated to minimise heat transfer within the repair inserts and in the underlying substrate material. The repair inserts may be made in a powder bed process from an alloy powder having the same composition as the material of the substrate.

Abstract: A method for repairing wider gaps in a substrate of a component by brazing at a brazing temperature is provided. Filler material and solder are prevented from separating in that, in a two-stage process, first the filler material and then the solder are applied to the wider gap. The powder does not melt at the brazing temperature and the filler metal does melt at the brazing temperature.

Abstract: A powder metallurgical article and process are disclosed. The article is a repaired or enlarged powder metallurgical article. The repaired or enlarged powder metallurgical article includes a formed article including a first alloy and a material including a second alloy. The material is welded to the formed article to form the repaired or enlarged powder metallurgical article. The repaired or enlarged powder metallurgical article includes a substantially uniform grain structure.

Abstract: A method for forming or remanufacturing a component to have an internal space. A refractory metal blocking element is formed, in situ, with at least a portion to be within the internal space. A material is added by at least one of welding, laser cladding, and diffusion brazing, the blocking element at least partially blocking entry of the material to the internal space. The blocking element is removed.

Abstract: The invention relates to a method for repairing components comprising a base material with an oriented microstructure, wherein the repair point comprises a correspondingly oriented microstructure as the surrounding base material. According to the inventive method, solder is applied in the region of a point which is to be repaired and is soldered to the component by means of a heating effect produced by a device. A temperature gradient, i.e., approximately a temperature characteristic, is produced during the heating effect, said temperature characteristic ranging from a high to a low temperature in the region of the point which is to be repaired.

Abstract: Nickel-based superalloys, turbine blades, and methods of improving or repairing turbine engine components are included. A nickel-based superalloy includes, by weight, about 5% to about 12% cobalt, about 3% to about 10% chromium, about 5.5% to about 6.3% aluminum, about 5% to about 10% tantalum, about 3% to about 10% rhenium, about 2% to about 5% of one or more of elements selected from a group consisting of platinum, ruthenium, palladium, and iridium, about 0.1% to about 1.0% hafnium, about 0.01% to about 0.4% yttrium, about 0.01% to about 0.15% silicon, and a balance of nickel.

Abstract: A method for manually reattaching solder balls onto a plurality of contact areas arranged in a pattern on a device to be reballed is provided. First, a single use preform with a plurality of solder balls arranged in a pattern corresponding to the pattern of contact areas on the device is provided. The solder balls are held in respective apertures in the preform by an adhesive layer on the preform that defines a closed end of the apertures and are partially exposed on one side of the preform. A solder paste or paste flux is applied to, at least, the contact areas of the device. The device is manually aligned with the exposed solder balls of the preform and the device and the exposed balls of the preform are manually brought into contact. The aligned device and preform are heated to reflow the solder balls onto the land areas of the device. The preform including the adhesive layer is then removed from the device with the solder balls being retained on the device.

Abstract: A method of repairing an abradable, nickel single crystal material having an abraded surface area by applying a diffusion layer to the abraded surface area comprising a nickel-based alloy having a quantity of an additional element selected from silicon and boron; and also applying an abradable layer to the material comprising a cobalt-based alloy to restore the abraded surface area.

Abstract: A process for repairing one or more worn inlet ports on an interior or exterior surface of an extruder die wherein each inlet port provides an opening into an extrusion channel. The worn inlet port has a funnel shape and a diameter greater than that of the extrusion channel. The worn inlet port is repaired by placing a fused silicon oxide insert into one or more extrusion channels so that an external surface of the insert engages the interior surface of the extrusion channel, thereby forming a pocket around the insert between the circumference or perimeter of the worn inlet port and the external surface of the insert. The pocket is filled with molten metal, and the insert prevents the molten metal from entering the extrusion channel. When the molten metal hardens the inserts are removed. New inlet ports are thereby formed having the same diameter as the extrusion channels.

Abstract: Platinum-modified nickel-based superalloys and turbine engine components are provided. The platinum-modified nickel-based superalloy includes, by weight, aluminum, in a range of about 7.8 percent to about 8.2 percent, tantalum, in a range of about 5.0 percent to about 6.0 percent, rhenium, in a range of about 1.6 percent to about 2.0 percent, platinum, in a range of about 0.8 percent to about 1.4 percent, hafnium, in a range of about 0.20 percent to about 0.40 percent, silicon, in a range of about 0.30 percent to about 0.60 percent, about 0.02 percent carbon, about 0.01 percent boron, and a balance of nickel. The platinum-modified a nickel-based superalloy may also include, by weight, chromium in a range of about 4.0 percent to about 5.0 percent.

Abstract: Providing a metal mold repair method and a metal mold repair paste agent which are capable of repairing cracks with simple work. A repair paste agent containing components that become an alloy is directly applied to a surface of a metal mold having a crack so as to cover the crack part, subsequently a surface of the repair paste agent is coated with an oxidation inhibitor and the repair paste agent is made to penetrate the inside of the crack by heating and becomes an alloy, thereby filling up the crack.

Abstract: In a method of attaching a solder ball, a first material is coated on a solder ball. A second material is coated on a pad of a substrate where the solder ball is to be attached to exothermically react with the first material. The solder ball makes contact with the pad such that the first material and the second material exothermically react with each other to release heat to adhere the solder ball to the pad using the heat.

Abstract: A nickel-base composition is disclosed that includes: about 15 to about 20 wt % Co; about 10 to about 19 wt % Cr; about 2.5 to about 3.4 wt % Al; less than about 0.5 wt % Ta; less than about 1.0 wt % Mo; less than about 0.06 wt % Zr; less than about 0.04 wt % B; about 1.1 to about 1.5 wt % Nb; about 3.0 to about 3.9 wt % Ti; about 3 to about 5 wt. % W; about 0.03 to about 0.07 wt. % C; and balance Ni; wherein aluminum, titanium, niobium, and tantalum are present within the alloy in a combined amount of 9 to 14 atomic percent.

Abstract: The invention relates to a process for repairing at least one connecting area between a partition plate (8) and a tube plate (5) of a water chamber (7) of a heat exchanger (1), in which process the area of weld requiring repair is identified, at least one rail (11) is inserted into the water chamber, the said rail (11) is attached below the tube plate (5), a robot arm (20) is inserted, the robot arm is hoisted within the water chamber, the robot arm is remotely controlled, the connecting area requiring repair is machined and a check is made to ensure that cracks have been eliminated from the repaired area.

Abstract: An improved method of heat treating superalloys prior to welding includes subjecting only the portion of the component to be repaired to a localized heat treatment, leaving the remainder of the component untreated. The localized heat treatment permits the use of higher hold temperatures that are near, at, or above the Ni3(Al,Ti) solution temperature of the alloy. Such heat treatment prevents strain age cracking and also prevents recrystallization in areas that are not heat treated. Such localized heat treatment can be applied before and/or after welding, for material rejuvenation, pre-brazing, and post-brazing.

Abstract: A method of repairing an aperture and adjacent defect wherein one or more defects proximate an aperture are removed from the base material proximate the aperture in an arc shape. An insert containing a profile that corresponds to the arc shaped section of the base material removed is welded to the base material. The weld is accomplished with a single curved path. Next, the insert is removed to create a repaired aperture and a surrounding section that has essentially the same dimensions as the aperture and surrounding section prior to the repair.

Abstract: A method of repairing an aperture and adjacent defect in a part which is started by removing one or more defects adjacent an aperture in a base material. The material is removed to create a weld seam that extends past an area of high stress concentration on the aperture. An insert of material containing a profile that corresponds to the profile of the base material removed adjacent the aperture and a combination top and runoff plate that encompasses the insert of material are provided. A backing plate is inserted underneath the combination top and runoff plate and insert such that there remains an air space between the backing plate and the combination plate which prevents the combination plate from becoming fused to the backing plate during a welding process. The insert is welded to the base material, and the backing plate is removed. Excess material is removed from the insert to obtain an aperture containing a profile essentially the same as the profile of the aperture prior to initiating the repair.

Abstract: A method for joining metal parts of a turbine engine component, the method comprising positioning a nanoparticle foil between faying surfaces of the metal parts, and diffusion bonding the metal with the nanoparticle foil, where the nanoparticle foil has a film thickness of about 100 micrometers or less, and comprises an alloy having an average particle size of about 500 nanometers or less.

Abstract: A method for the repair of a component by a solder is disclosed. The method is performed under specifically selected vacuum conditions in order to prevent oxidation and vaporization.