Abstract: A method, apparatus, and system for correcting unbalance of a turbocharger component relative to an axis of rotation of the turbocharger component. The method includes determining one or more unbalance characteristics for the turbocharger component, determining parameters for a first correction operation to be performed in a first correction plane, and moving the turbocharger component to align a first correction area of the turbocharger component with respect to a first water jet cutter and performing the first correction operation using the first water jet cutter. The method may include determining parameters for a second correction operation to be performed in a second correction plane and moving the turbocharger component to align a second correction area of the turbocharger component with respect to a second water jet cutter and performing the second correction operation using the second water jet cutter.

Abstract: A method of servicing, or repairing a crack in, a dovetail portion of a dynamoelectric machine's rotor coil slot wall. The coil slot wall includes a radial entry surface connected to an inwardly tapered surface. The inwardly tapered surface is connected to an intermediate radial surface. A machining step machines a first groove in the radial entry surface and inwardly tapered surface. The first groove extends linearly to the intermediate radial surface. The first groove is configured so that a smooth and linear surface is created along a length of the first groove. A second machining step machines a second groove in the intermediate radial surface in an orientation substantially perpendicular to the first groove. A portion of the second groove contacts a portion of the first groove. At least one of the first groove and the second groove are configured to remove damaged material from the coil slot wall.

Abstract: A method for repairing a blade wherein the blade comprises a metallic substrate shaped to define an airfoil having a tip. A coating is on the tip. The method comprises: machining to at least partially remove the coating; plating a nickel-based base layer; and plating an abrasive layer comprising a nickel-based matrix and an abrasive.

Abstract: The present invention discloses a novel and improved method for repairing a shrouded blade and a reconditioned shrouded blade. More specifically, a way of measuring a set of previously-operated blades to determine their post-operation geometric characteristics is provided where an offset due to deformation of the hardface surfaces of the shroud is determined. The hardface surfaces of the shroud are rough-machined and blade-compatible material is added to the hardface surfaces. A first side hardface surface of the shroud is then machined to a desired dimension offset relative to an originally manufactured blade after which a second side hardface surface is machined such that the distance between the hardface surfaces satisfies the cross-shroud dimension, which is similar to that of an originally manufactured blade.

Abstract: A number of variations may include a product that may include a substrate that may include an aluminum-nickel alloy and at least one surface and a coating that may include a metallic material deposited over the at least one surface via laser cladding.

Abstract: A method is provided of replacing a damaged blade of an integrally bladed rotor assembly including a disc and a plurality of blades extending outwardly from a rim of the disc. The method includes the steps of: removing the damaged blade to leave a blade repair stub projecting from the rim; locating sacrificial supports at the underside of the rim beneath the repair stub, the supports projecting axially beyond the trailing and leading edges of the rim; depositing metal around the trailing and leading edges of the repair stub, the deposited metal, supported by the sacrificial supports, projecting axially beyond the trailing and leading edges of the rim; attaching a replacement blade to the repair stub by linear friction welding; and removing excess deposited metal, upset metal from the linear friction welding, and the sacrificial supports.

Abstract: A shaker screen including a composite frame, a removable grid attached to the composite frame, and at least one filtering element attached to the removable grid is disclosed. A method including forming a composite frame, forming a removable grid, attaching at least one filtering element to the removable grid, and attaching the removable grid to the composite frame is disclosed. Additionally, a method for rebuilding a shaker screen, the method including removing a first screen assembly from a composite frame, the screen assembly having a removable grid and at least one filtering element, and attaching a second screen assembly to the composite frame is disclosed.

Abstract: A fuel nozzle guide for a combustor of a turbine engine includes an annular base with a hub section, the hub section at least partially formed of a Cold Metal Transfer (CMT) weld and a method and system therefor.

Abstract: A repairing method includes heating a base material by a heater, and irradiating a laser beam to a repair region of the base material by using a laser oscillator unit, after the base material is heated. In the method, generation of a crack and a break can be suppressed, and the repair region can be repaired more appropriately.

Abstract: In a method of repairing a component substrate (18), especially a substrate (18) composed of a superalloy such as a nickel based superalloy, a portion of the substrate (18) at a distressed region (26) to be repaired is removed forming a repair opening (28) through the substrate (18). The repair opening (28) is adjacent to an internal cavity (20) of the component (10). The cavity (20) is filled with a filler material (30) such as a powdered metal alloy having a composition corresponding to that of the substrate (18). Heat is then applied to the filler material (30) and across the repair opening (28) to melt the filler material, which is allowed to cool to form a repair deposit (36, 40, 50) fused to the substrate (18) and across the opening (28). Any un-consumed filler material (30) is subsequently removed from the cavity (20).

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 method of manufacturing a furcated composite post (1) comprising at least two strips (7, 8) that are joined together along their length in a furcated manner. The method comprises the steps of feeding one or more of the strips (7, 8) at a set rate to working rolls of a roll mill for profile rolling to a desired cross section/profile, feeding the strips (7, 8) at the same set rate to positioning rolls for holding the strips (7, 8) in a correct orientation for joining, and joining the strips together, preferably by welding the strips (7, 8) along their length.

Abstract: An example method of repairing an airfoil includes the steps of securing additional material to a worn airfoil and limiting movement of the additional material with a guide. The method alters some of the additional material to form a desired airfoil contour. Another example method of forming a portion of an airfoil includes the steps of securing additional material to an airfoil, limiting movement of the additional material with a guide, and altering some of the additional material to form a desired airfoil contour.

Abstract: Embodiments of the invention relate to superabrasive compacts including multiple superabrasive cutting portions and methods of repairing a rotary drill bit that employs at least one of such superabrasive compacts.

Abstract: The invention relates to a procedure for repair of high pressure turbine blades of an aircraft engine, with the steps:—separating a damaged section of the high pressure turbine blade; and—generating a section to replace the separated section on or upon the high pressure turbine blade by means of laser beam generation from the powder bed, as well as a high pressure turbine blade.

Abstract: A method for repairing a component may include machining a depression into the component. A size and a shape of the depression may be configured to remove a damaged portion of the component; and wherein the depression forms a repair volume. The method also may include depositing a plurality of continuous additive weld layers, each continuous additive weld layer of the plurality of continuous additive weld layers having a beginning point and an ending point. The beginning point and the ending point of a first continuous additive weld layer of the plurality of additive weld layers may be formed at or beyond an outer boundary of the repair volume. The beginning points and the ending points of the remainder of the plurality of continuous additive weld layers may be formed at or beyond the outer boundary of the repair volume.

Abstract: The present invention provides a method of producing a common rail having a common rail body and a holder which include chemical components of 0.01-0.3 mass % of C, 0.01-0.5 mass % of Si, 0.01-3.0 mass % of Mn, 0.0003-0.01 mass % of B, 0.001-0.01 mass % of N, over 0.01-0.5 mass % of Al, 0.01-0.05 mass % of Ti, P limited to 0.03 mass % or less, S limited to 0.01 mass % or less, O limited to 0.01 mass % or less, a total content of As, Sn, Sb, Pb, and Zn limited to 0.015 mass % or less, the balance including Fe and inevitable impurities, in which the TLB value is 0.001% or more, the method including: inserting an insert metal; performing liquid phase diffusion bonding; performing laser-peening; and removing a surface layer.

Abstract: The invention relates to a method for replacing tubes in a hydrocarbon-vapor reforming unit, that comprises before launching any new production campaign: measuring the expansion of the tube diameters; taking X-ray photographs of the tubes; realizing replicas of the surfaces of the tubes; wherein a tube is replaced when it fulfills at least one of the following conditions; the diameter expansion is higher than 3%; the X-ray photograph includes at least one crack; the replica shows a sufficient thermal ageing and/or creep deformation.

Abstract: A method of repairing a substrate that may prevent a metal layer from being corroded. A substrate including a metal layer and an insulating layer on the metal layer is first provided. Then, a laser beam having a wavelength range having a high transmittance with respect to the insulating layer is irradiated to selectively remove a portion of the metal layer. Also, a first laser beam is irradiated to remove a portion of the metal layer and a portion of the insulating layer, and then a second laser beam is irradiated onto side surfaces of the exposed insulating layer to melt the insulating layer, thereby forming a corrosion preventing layer covering the metal layer.

Abstract: A turbine rotor blade repair method which reduces the occurrence of cracks due to welding is provided. A turbine rotor blade repair method for repairing damage of a fin at a tip of a turbine rotor blade includes overlaying a damaged portion of the fin with metal by welding (step S2); peening on a boundary region between the fin and the overlaying metal (step S4); and after the peening, performing solution treatment to repair the damage of the fin of the turbine rotor blade (step S6).

Abstract: A remanufacturing and salvaging strategy for fuel injector tips such as high flow fuel injector tips includes blocking a first set of spray orifices in the fuel injector tip, including at least partially filling the first set of spray orifices with a material, for example by laser welding. New spray orifices are formed in virgin material of the fuel injector tip, offset from the former spray orifices, also for example via a laser. A remanufactured fuel injector tip includes blocked former spray orifices as well as new spray orifices configured to permit spraying of fuel from the fuel injector tip.

Abstract: A pocket restitution assembly comprises a pocket formed in a surface that includes a central axis, an anchor seated in the pocket and aligned with the central axis, a tool attachment comprising an end for connection to the anchor, and a hollow bit slidably and rotatably sitting on the tool attachment. The hollow bit may fit within the pocket. Weld material may be deposited within the pocket to form an interior of the pocket. The weld material may be shaped by the hollow bit to accept a cutting element.

Abstract: A restored metallic extrusion processing element comprises a tubular metal core around which is consolidated a powdered metal extrusion component that includes metallurgically bonded interior shell and exterior working portions. The interior shell portion covers the core and is characterized by a first multiple-crystalline microstructure, and the exterior working portion is characterized by a second multiple crystalline microstructure of densified powdered metal particles. The exterior working portion has an outside surface including outer working surface features that extend along the length of the extrusion processing element. A bond interface of metallurgical type defines a crystalline microstructure boundary between the first and second multiple-crystalline microstructures.

Abstract: An electronic component repair method for removing an electronic component soldered on a substrate, the method includes: mounting a heat transfer plate on the electronic component to be removed, the heat transfer plate being formed by bonding a plurality of heat transfer members via a heat insulating member, heating the heat transfer plate mounted on the electronic component by a heating unit, the heating unit heating individually each of the heat transfer members by different heat amount; and removing the electronic component from the substrate after the heating.

Abstract: A rail repair method enables repair of rails and rail-like structures. A rail defect is initially identified and removed as contained within a volumetric material portion so as to form a contoured void while maintaining continuity of the rail opposite the void. A pre-formed insert is then placed into the void thereby effecting a rail-to-insert interface. Current is driven through the interface as force directs the insert against the rail. Resistance heat and pressure weld the insert to the rail. The flash welding aspects remove oxides and other impurities from the interface, and the forge welding aspects create a robust solid state weld. Excess material, whether flash, rail, or insert-based, is removed during the finishing processes to provide a virtually seamless rail repair. The solid state weld repair methodology may be used to repair any number of targeted metallic rail-like structures.

Abstract: Disclosed are a bending roller apparatus and methods for use thereof for repairing a control arm of automotive suspension. An example apparatus includes a base having a saddle supporting a matrix to which the control arm is removably affixed. The matrix provides longitudinal and lateral movements and rotation of the control arm in a horizontal plane. The apparatus includes a matrix position calibration means for calibrating longitudinal, lateral and rotary positions of the matrix. The apparatus includes a bending roller positioning means for calibrating vertical and longitudinal positions of a bending roller to bring the bending roller in a contact with the upward-extending flange. The apparatus further includes bending roller means for bending the upward-extending flange inwards by rolling the bending roller along the circumference of the flange while applying a downward force on the flange thereby bending it inwards and sealing off the ball stud in the receptacle.

Abstract: A method of repairing a stator assembly of a gas turbine engine includes removing a worn surface of the stator assembly to provide a revealed area, and securing additional material to the stator assembly utilizing gas metal arc welding.

Abstract: A method of repairing a damaged coated vane from a turbine module without removing the vane from the module is taught. The method includes locally removing the coating in the vicinity of the damage as well as any underlying damage in the superalloy substrate. A diffusible coating precursor is then applied to the damage site. A heat treating fixture is then mounted on the vane and repair site is heated to up to 2000° F. in an inert environment to interdiffuse the coating precursor and the substrate. After the diffusion anneal, the vane is cleaned and the module is returned to service.

Abstract: A system and method for refurbishing forged components. The system includes an identification subsystem for identifying a forged component for refurbishment, a removal subsystem for removing portions of the forged component, and a rebuilding subsystem for rebuilding the forged component, the rebuilding subsystem including an assembly for adding a non-molten material to the forged component.

Abstract: A method of repairing a seal wire groove is disclosed, the groove forming an annular structure having an outer surface and an inner surface and defining an original profile when new, comprising the steps of: removing a less-than-annular portion of the original profile of the groove to remove damaged portions of at least one of the inner and outer surfaces thereby forming a void; adding new material to the void; and shaping the new material to form a new profile of the groove.

Abstract: A method for restoring a worn rail section includes cleaning a worn surface of a rail section to expose a clean metal surface, heating the rail section to a first temperature before welding, welding new metal on the clean metal surface of the rail section after heating the rail section to the first temperature, heating the rail section to a second temperature after the welding to heat-treat a heat-affected area caused by the welding, and shaping the rail section, wherein the welding is performed by a gas metal arc welding (GMAW) process.

Abstract: The method according to the invention for reprocessing the worn surface of grinding rollers (2) of a material bed roller mill comprises the following method steps: a. providing a mobile processing station (6) which is arranged in a container (8) and comprises at least one machine tool (9) and a drive (10) for rotating the grinding roller, b. removing the complete roller unit (A) containing the grinding roller to be reprocessed from the material bed roller mill, c. positioning the complete roller unit in front on the mobile processing station and coupling the drive to the shaft (1) of the grinding roller, d. producing a new cylindrical surface (2h) using the machine tool, and e. producing a new wear protection comprising new profiled bodies (2c) and/or build-up welding.

Abstract: A method of repairing a metallic artefact (40) with an open defect in or on a metallic surface or substrate of the metallic artefact includes cold forging the open defect to close the open defect and thereafter laser cladding the cold forged defect with a plurality of laser clad beads (44) applied to the metallic surface or substrate to cover the cold forged defect with a cladded metal layer. Advantageously, in-situ repair of fluid-filled vessels, pipes or the like is made possible by the repair method, in some instances eliminates the need to shut equipment down thereby reducing downtime and the cost associated with lost production.

Abstract: A method of manufacturing an article by diffusion bonding, the method comprising the steps of assembling first and second component parts having a joint therebetween; sealing the joint against infiltration by solid particulate material, without causing phase change of the component parts; and applying heat and isostatic pressure via a solid particulate material to form a consolidated joint by diffusion bonding.

Abstract: A method for machining a sealing seat of a shut-off valve in a power generating or industrial plant. An upper valve part and the internal housing fittings are removed from the housing of the shut-off valve to thereby expose a housing opening. A clamping device with a counter-bearing is introduced through the housing opening into the connection pipe and fastened to its inner wall. A machine tool with a bearing is introduced through the housing opening and mounted with its bearing on the counter-bearing. A machining step is carried out with the machine tool on the sealing seat. Then the machine tool is detached and removed through the housing opening. The clamping device is detached from the connection pipe and removed through the housing opening. Then, the upper valve part and the internal fittings are reattached to the housing.

Abstract: A compliant plate seal arrangement manufacturing method is provided. A compliant plate seal manufacturing method includes assembling a plurality of t-shims and a plurality of spacer shims into a straight weld fixture, thereby forming a shim pack having a front and rear end and sides, welding the sides of the shim pack to a top plate, removing a portion of the weld fixture, removing the plurality of spacer shims, shaping the shim pack into a target diameter, and applying a radial flow plate to the leaf pack.

Abstract: A method for forming a dense coating on a limited region of a subject body is disclosed. The method is composed of the steps of: applying one selected from the group of a compressed body of a powder of a metal and a sintered compressed body of a powder of a metal to a working electrode; executing discharge deposition to deposit a first coating from the working electrode on the subject body by applying the subject body as a workpiece of the discharge deposition; executing discharge deposition to deposit a second coating from the working electrode on the first coating by applying the subject body as a workpiece of the discharge deposition; and heating the subject body in one selected from the group of a vacuum, an air and an oxidizing atmosphere so as to densify the second coating or oxidizing the second coating at least in part to generate a solid lubricant substance.

Abstract: A gas turbine engine hot gas component repair method for defects that do not extend through the thickness of the component is provided. First defects are removed by machining a cavity in the surface of a component. Coupons, fittable within the cavities are manufactured, are for example coated with brazing medium on an inner surface and then joined to the component by joining means such as laser metal forming. The joint holds the coupon during later heat treatment, thereby eliminating a need for holding aids. Before heat treatment, a further brazing medium can be applied to the surface of the coupon overlapping onto the component. A single heat treatment, brazing the coupon to the component and, brazing the brazing medium to the outer surface of the coupon can, then be used to complete the repair.

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 and an apparatus for mobile repair of a stationary rotor seals of a turbo machine is provided. The method includes the following steps, 3D-scanning of the stationary seal, generation of 3D-model of the stationary seal, removing of the damaged spots of the seal using laser cutting, and generating a new seal at the repair spot by use of a second process head, which generates the seal by laser powder cladding. The apparatus includes a 3D-scanner, a cutting tool, and a first process head and a second process head.

Abstract: A method for restoring a crack formed within a turbo charger engine transition section, the method including preparing a crack in the transition section to receive a material within the crack, applying the material within the crack, and retaining structural integrity of the transition section proximate the crack while at least one of preparing the crack and applying the material.

Abstract: A remanufacturing and salvaging strategy for fuel injector tips such as high flow fuel injector tips includes blocking a first set of spray orifices in the fuel injector tip, including at least partially filling the first set of spray orifices with a material, for example by laser welding. New spray orifices are formed in virgin material of the fuel injector tip, offset from the former spray orifices, also for example via a laser. A remanufactured fuel injector tip includes blocked former spray orifices as well as new spray orifices configured to permit spraying of fuel from the fuel injector tip.

Abstract: A method for repairing a crack in an electromechanical rotor (10), including forming a plurality of slots (12) on a periphery of a core portion (11) of an electromechanical rotor (10) along an axial direction thereof; inserting coils into the slots (12), respectively; forming a plurality of wedges for maintaining the coils in the slots (12), respectively; and forming a cut hole (20) at the core portion (11) from an outer surface of the core portion (11) so as to remove at least a deeper area of a crack created at the core portion (11) at a contacting surface between the corresponding wedge and the corresponding slot (12).

Abstract: A method for providing weld inlays and onlays to primary nozzles of a nuclear reactor comprising: providing a first welding device in a first primary nozzle of the nuclear reactor; providing a second welding device in a second primary nozzle of the nuclear reactor; providing a third welding device in a third primary nozzle of the nuclear reactor; and operating the first, second and third welding devices at the same time. Other methods are also provided.

Abstract: A method for repairing a turbine engine component comprises the steps of providing a turbine engine component formed from a nickel-based superalloy, removing any defects from the turbine engine component, the removing step comprising subjecting the turbine engine component to a solutioning heat treatment using a heating rate in the range of from 29 degrees Fahrenheit/minute to approximately 40 degrees Fahrenheit/minute as the component passes through a temperature in the range of from 1100 degrees Fahrenheit to 1600 degrees Fahrenheit, and welding the turbine engine component to effect the repair. A deliberately slow post-solution treatment cooling rate is used to substantially prevent weld cracks.

Abstract: An electrical discharge assembly for processing a workpiece having a cooling passage with first and second portions includes a first electrode having a first shape for machining the first portion of the cooling passage and a second electrode having a second shape for machining the second portion of the cooling passage. In a method for repairing cooling passages in a workpiece, a first electrode having a first shape is positioned in a cooling passage. The first electrode is electrically powered to machine a first portion of the cooling passage. A second electrode having a second shape is positioned in the cooling passage. The second electrode is electrically powered to machine a second portion of the cooling passage.

Abstract: A repairable labyrinth seal of a gas turbine engine comprises at least one fin having a base with a thickness and a tip portion extending therefrom. A shoulder distinguishes the base from the tip portion. The shoulder defines a machining site suitable for receiving a welded replacement piece for shaping a new tapered tip portion following removal of a worn tapered tip portion.

Abstract: A blade is repaired by utilizing a super abrasive machining quill and/or wheel to form the contour and restore the height of the blade. By utilizing super abrasive machining, the contour and height can be quickly returned to desired dimensions by removing unwanted added material.

Abstract: In a method for removing a crack in an electromechanical rotor, a through-hole penetrating from a side of one of slots adjacent to each other via a rotor core portion to a side of the other slot is formed to include a crack in the rotor core portion occurring to a contact surface with a wedge, in an electromechanical rotor including a plurality of slots formed in an axial direction in an outer peripheral surface of the rotor core portion, a coil housed in the slot, a wedge inserted in an upper portion of the slot to be arranged in the axial direction and holding the coil in the slot, and the crack is removed.

Abstract: A method for repairing a damaged probe from a probe card comprising the steps of removing the damaged probe from the probe card, separating one a plurality of replacement probes from a substrate and installing the one probe separated from the plurality of replacement probes where the damaged probe was removed.