Abstract: Hollow fan blades for turbo fan gas turbine engines are formed of two separate detail halves. Each detail half has a plurality of cavities and ribs machined out to reduce weight. The floor and opposite interior walls of each cavity are machined simultaneously. The configuration minimizes the number of cutter plunge cuts for the internal cavities, and maximizes cutter size, in order to minimize the time required to machine them. These detail halves are subsequently bonded and given an airfoil shape in the forming operation.

Abstract: The invention relates to a method of manufacturing a hollow blade for turbine engine comprising a foot and a rotor blade, the method comprising a production stage of two external parts (14) as well as an assembling stage via diffusion bonding of these two external parts so as to obtain a blade preform.

Abstract: A hollow blade is shaped by superplastic inflation of a blank made up of welded-together sheets. A die comprising two hollow shapes clamping the outline of the blank is placed inside an autoclave-forming enclosure in order to subject the blank to superplastic inflation, and the two hollow shapes are united by U-shaped clamps made of a material having a coefficient of thermal expansion that is smaller than that of the material constituting said shapes.

Abstract: An aerofoil made from a sheet metal blank which is bent in the shape of an aerofoil such that it has a leading edge, a trailing edge, a pressure side and a suction side, and the blank is joined at the trailing edge. The regions of the sheet metal blank that form the leading edge, trailing edge and pressure side of the aerofoil comprise a plurality of perforations. The suction side region of the sheet metal blank is imperforate.

Abstract: An airfoil (44) formed of a plurality of pre-fired structural CMC panels (46, 48, 50, 52). Each panel is formed to have an open shape having opposed ends (54) that are free to move during the drying, curing and/or firing of the CMC material in order to minimize interlaminar stresses caused by anisotropic sintering shrinkage. The panels are at least partially pre-shrunk prior to being joined together to form the desired structure, such as an airfoil (42) for a gas turbine engine. The panels may be joined together using a backing member (30), using flanged ends (54) and a clamp (56), and/or with a bond material (36), for example.

Abstract: A method for manufacturing an assembly including a stack of at least two primary parts, the primary parts being joined together around their periphery with the exception of a place forming a passage so as to define between the two of them a cavity, and the primary parts having, facing the cavity, at least one face that is covered, in a pattern, with a stop-off product containing a binder that can be thermally degraded, and a sealed reservoir having an open end, the end being joined in a sealed manner to the passage in the stack so as to allow communication between the internal space of the reservoir and the cavity, the reservoir being placed under a partial vacuum, this being produced so as to be non-deformable at the temperature and at the pressure at which the diffusion bonding of the said stack takes place.

Abstract: A hollow fan blade for the fan of an aircraft engine includes a blade base section (2) and a blade tip section (5) which are assembled at opposing faying surfaces (6, 6?) by a joining process. Starting from the respective faying surface, cavities (7, 9) are produced in the two blade portions (2, 5) which are dimensioned in accordance with the loads occurring in the respective blade areas. The joining weld (4) is in a low-loaded area. The blade base section and the blade tip section can be constructed of solid material with formed-in cavities. The blade tip section can also be a sheet-metal structure.

Abstract: A method for repairing defects in a gas turbine component that comprises a substrate and an existing coating on the substrate. The article includes cooling holes having a predetermined air flow requirement and an outer shaped portion and an inner metering portion. The method comprises removing the existing coating and recoating the surface of the article with a nonoriginal coating. After the nonoriginal coating is applied onto the component, the cooling holes that meet a predetermined inspection criteria are reworked to remove the excess nonoriginal coating deposited in the outer shaped portion of the cooling holes. The reworking is done by receiving an electrode, having only a shaped portion with a preselected shape, in the outer shaped portion of the cooling holes thus restoring the cooling holes to the predetermined air flow requirement.

Abstract: A method for fabricating a rotor blade includes casting the turbine rotor blade to include a shank, and a platform having an upper surface and a lower surface, and coupling a first component to the rotor blade such that a first substantially hollow plenum is defined between the first component, the shank, and the platform lower surface.

Abstract: A method of manufacturing a composite structure uses a layer of an insulating material (22) as a mold for forming a substrate of a ceramic matrix composite (CMC) material (24). The insulating material may be formed in the shape of a cylinder (10) with the CMC material wound on an outer surface (14) of the cylinder to form a gas turbine combustor liner (20). Alternatively, the insulating material may be formed in the shape of an airfoil section (32) with the CMC material formed on an inside surface (36) of the insulating material. The airfoil section may be formed of a plurality of halves (42, 44) to facilitate the lay-up of the CMC material onto an easily accessible surface, with the halves then joined together to form the complete composite airfoil. In another embodiment, a box structure (102) defining a hot gas flow passage (98) is manufactured by forming insulating material in the shape of opposed airfoil halves (104) joined at respective opposed ends by platform members (109).

Abstract: A method of forming a blade comprising the steps of forging a part comprising a suction side, a pressure side, and a dividing portion of material greater than a portion of material to be sacrificed between the suction side and the pressure side, splitting the part through the dividing portion of material to form a suction side inner surface and a pressure side inner surface, and joining the suction side inner surface and the pressure side inner surface to form the blade.

Abstract: A hollow fan blade for turbo fan gas turbine engines is formed of two separate detail halves. Each detail half has a plurality of cavities and ribs machined out to reduce weight. These detail halves are subsequently bonded and given an airfoil shape in the forming operation. The present invention provides a hollow fan blade with internal cavity and rib geometry with improved durability that permits the bonding and forming to be performed without the need for gas pressurization. The ability to form the hollow fan blade of the present invention without gas pressurization is a result of the cavity and rib geometry and the orientation of the ribs. The ribs are tapered and transition into a compound radius of the floor that simulates the classical arch design element. The orientation of the ribs is generally in a parallel plane with the load vector that results from forming loads during the pre-form and final form operations.

Abstract: A fan blade (26) comprises a leading edge (44), a trailing edge (46), a concave wall portion (50) extending from the leading edge (44) to the trailing edge (46) and a convex wall portion (52) extending from the leading edge (44) to the trailing edge (46). A flexible wall (56) is arranged within the fan blade (26) to partially define a plurality of chambers (60) with an internal surface (54) of the convex wall portion (52). The flexible wall (56) is arranged substantially parallel to the internal surface (54) of the convex wall portion (52) and a plurality of walls (64) connect the internal surface (54) of the concave wall portion (50) and the flexible wall (56). The chambers (60) contain a fluid. The chambers (60) are interconnected by apertures (62) such that in operation deflection of the flexible wall (56) by vibrations of the fan blade (36) produce a flow of fluid between the chambers (60) through apertures (62), which is restricted by the apertures (62) to damp vibrations of the fan blade (26).

Abstract: A turbomachine blade includes a metal alloy airfoil having a cavity closed off by a cover on a hollowed side, the cover providing aerodynamic continuity of the hollowed side and being bonded via an edge thereof to the rest of the airfoil by a weld bead. The weld bead emerges on the hollowed side and penetrates into the airfoil to a depth P at least equal to the thickness EC of the edge of the cover so as to provide continuity of material between the edge of the cover and the rest of the airfoil over a depth at least equal to the thickness EC of the edge of the cover. A process for manufacturing such a blade is also disclosed.

Abstract: Hollow fan blades for turbo fan gas turbine engines are formed of two separate detail halves. Each detail half has a plurality of cavities and ribs machined out to reduce weight. These detail halves are subsequently bonded and given an airfoil shape in the forming operation. In one embodiment, contiguous cavities are formed around freestanding ends of the ribs to reduce the number of cavities required. The freestanding end of each rib is flared such that it has a larger width than the rest of the rib. The cavity extends continuously around the free, flared end of the rib.

Abstract: A method for applying diffusion aluminide coating on a selective area of a turbine engine component and the coating produced by that method is disclosed. A quartz infrared lamp heats only substantially the localized area of the component to be coated, rather than the complete part. Either halide activated or non-activated tape is applied on the area to be coated and is held in place during coating using a high temperature dimensionally stable tape holder manufactured from graphite or ceramic. The quartz infrared lamp is used to heat only the desired area to a coating temperature of about 1800° F. to about 2000° F. under an inert atmosphere for about 3 to about 8 hours to achieve the desired aluminide coating thickness. No powder masking of the machined surface area is required. Due to the localized heating, aluminum vapor generated from the tape will only deposit aluminide coating on the taped area.

Abstract: A method of diffusion bonding three metal work pieces to form a fan blade, where each workpiece has a flat surface and an excess portion larger than a predetermined size needed to produce a finished fan blade; longitudinally extending slots are provided to interconnect the flat surfaces of the excess portions of the work pieces; the work pieces are assembled into a stack with the flat surfaces in mating abutment and the stack is evacuated from one end of the stack through the slots; heat and pressure are applied across the thickness of the work pieces to diffusion bond the work pieces together to form an integral structure; the excess portions with the slots are then removed.

Abstract: A method for bonding metal components includes the steps of providing metal components to be bonded together at contacting surfaces, the contacting surfaces having an oxide layer; washing the components with an alkali solution to provide alkali-washed components; washing the alkali-washed components with water to provide water-washed components; and bonding the components together at the surfaces.

Abstract: A gas turbine engine (10) fan outlet guide vane (34) is manufactured by diffusion bonding titanium alloy sheet metal workpieces (52, 54) together to form an in integral structure (66). A titanium alloy is weld deposited at predetermined positions (70, 72) and in a predetermined shape to build up bosses (42, 44) at the radially outer end (40) of the hollow integral structure (68). The integral structure (66) is inflated at high temperature to form a hollow integral structure (68) of predetermined aerofoil shape. Apertures (46, 48) are drilled through the bosses (42, 44) to enable the radially outer end (40) of the fan outlet guide vane (34) to be attached to a fan casing (32) of the gas turbine engine (10).

Abstract: A method for installing an expandable stiffener includes providing an assembly including a first sidewall and a second sidewall connected at a leading and trailing edge such that a cavity is defined therebetween, forming an opening extending through the first sidewall and the second sidewall, inserting a first expandable sleeve through the assembly opening such that the sleeve extends between the first and second strut sidewalls, and coupling the sleeve to the first and second sidewalls.

Abstract: A method of manufacturing a gas turbine engine fan blade (10) comprises forming three metal workpieces (50,52,54). A metal slab (30) is upset forged at both ends (32,34) to produce a metal block (40) with increased thickness (42,44) extending from opposite surfaces (36,38). The metal block (40) is cut in an inclined path to form two of the metal workpieces (50,52). The metal workpieces (50,52,54) are assembled into a stack (56) so that the flat surfaces (38,42,46,48) are in mating abutment. Heat and pressure is applied across the thickness of the metal workpieces (50,52,54) to diffusion bond the metal workpieces (53,52,54) together to form an integral structure (100). The integral structure (100) is hot creep formed and superplastically formed to produce the required aerofoil shape and the thickened end is machined to form the blade root (26). The method enables thinner metallic workpieces with better microstructure to be used and increases the yield of metallic workpieces.

Abstract: A process for the rapid production of hollow components of flow machines, in particular turbine blades, for manufacturing development. In the process, the turbine blade to be produced is divided into two or more portions such that none of the portions has a cavity. The two or more portions are individually cast by means of a Rapid Prototype process, and are then joined together to form the hollow component. The process makes possible the simple and cost-effective production of turbine blades for manufacturing development, in particular for the development of the cooling systems.

Abstract: A hollow element such as a turbine blade is manufactured by cutting a metallic member into first and second pieces so that each has a cut side and an opposite uncut side. The cut sides are machined to form interior features of the element. The uncut sides are machined to form exterior features of the element. The pieces are assembled with the cut sides facing each other and the assembly is diffusion bonded.

Abstract: A gas turbine engine fan blade (26) comprises a root portion (40) and an aerofoil portion (42). The aerofoil portion (42) has a leading edge (44), a trailing edge (46), a concave metal wall portion (50) extending from the leading edge (44) to the trailing edge (46) and a convex metal wall portion (52) extending from the leading edge (44) to the trailing edge (46). The aerofoil portion (42) has a hollow interior (54) and the interior (54) of the aerofoil portion (42) is at least partially filled with a vibration damping material (56). The vibration damping material (56) comprises a material having viscoelasticity for example one formed by mixing an amine terminated polymer and bisphenol a-epichlorohydrin epoxy resin.

Abstract: A process of removing deposits from through-holes in a component, such as metallic bond coat and ceramic materials from cooling holes in an air-cooled gas turbine engine. The process is particularly effective in removing a TBC material deposited in a cooling hole of a component as a result of depositing a coating of the TBC material on a surface of the component, in which the deposit is removed from the cooling hole without damaging the cooling hole or the TBC coating surrounding the cooling hole on the coated surface of the component. A preferred feature is that the cooling hole, including the entrance to the hole at a surface of the component opposite the coated surface and the coating surrounding the exit of the hole at the coated surface, exhibits improved surface characteristics that increase the discharge coefficient of the cooling hole, as evidenced by an increase in the effective area of the cooling hole.

Abstract: A method is for producing a turbine blade, in particular, a gas turbine blade, comprising a head, a foot, and a blade section, in addition to an internal canalization system, including individual channels through which coolant gas can pass along a flow path within the turbine blade. The turbine blade also includes a throttle device which influences the passage of the coolant gas without impairing the flow of the coolant gas in the intake area. The throttle device is located in the rear section of the flow path, and is positioned upstream of the exit openings.

Abstract: The present invention relates to a process for producing a turbine blade or vane (13; 14), which has at least one chamber (22; 23, 24, 25) and an inlet (30; 31) for applying a cooling medium to the chamber (22; 23, 24, 25), at least one inlet (30) running at an angle with respect to a longitudinal axis (37) of the turbine blade or vane (13; 14). According to the invention, to form the inlet (30) a core (35) with a projection (33) is used, which projection is arranged at a distance from a mold (40). Therefore, after removal from the mold the inlet (30) of the turbine blade or vane (13; 14) is closed, and is opened up by machining. The invention also relates to a turbine blade or vane, in particular for a gas turbine (10), which has at least one chamber (22; 23, 24, 25) and at least one inlet (30; 31) for applying a cooling medium to the chamber (22; 23, 24, 25).

Abstract: A tip material for a turbine blade or for repairing a damaged tip of a turbine blade having a metallic coating, the material used for the tip is equivalent in composition to the metallic coating material used for the turbine blade. Also disclosed is a method of manufacturing or repairing a tip of a turbine blade having a metallic coating by reforming the blade tip with a material equivalent in composition to the metallic coating material used for the turbine blade by bonding the material to the damaged tip.

Abstract: A method for applying diffusion aluminide coating on a selective area of a turbine engine component and the coating produced by that method is disclosed. A quartz infrared lamp heats only substantially the localized area of the component to be coated, rather than the complete part. Either halide activated or non-activated tape is applied on the area to be coated and is held in place during coating using a high temperature dimensionally stable tape holder manufactured from graphite or ceramic. The quartz infrared lamp is used to heat only the desired area to a coating temperature of about 1800° F. to about 2000° F. under an inert atmosphere for about 3 to about 8 hours to achieve the desired aluminide coating thickness. No powder masking of the machined surface area is required. Due to the localized heating, aluminum vapor generated from the tape will only deposit aluminide coating on the taped area.

Abstract: A method for bonding metal components includes the steps of providing metal components to be bonded together at contacting surfaces, the contacting surfaces having an oxide layer; washing the components with an alkali solution to provide alkali-washed components; washing the alkali-washed components with water to provide water-washed components; and bonding the components together at the surfaces.

Abstract: A method is disclosed for reconditioning blades for turbo-machinery that have a material deficiency resulting from wear and tear, damage, or dimensions that are smaller than specified, in which material is removed, at least from parts of the blade, and is replaced with new material. The actual geometry of the blade is measured at certain specific points and is stored. The desired geometry, or the desired profile in its desired position, is determined via data processing technology. The desired geometry is compared with the actual geometry, and in cases of significant deviations in position, is adjusted to coincide with the actual geometry. The adjusted desired geometry is mathematically reduced by a defined amount of coating to be removed. The calculated net geometry is actually produced via the removal of material, at least over part of the blade, and new material is applied to the finished net geometry, until the desired profile is achieved.

Abstract: A component for use in a flow path of a gas turbine engine. The component includes a body having an exterior surface mountable in the gas turbine engine so the exterior surface is exposed to gases flowing through the flow path of the engine. The body has a cooling hole extending through the body to the exterior surface for transporting cooling air from a cooling air source outside the flow path of the engine to the exterior surface of the body for providing a layer of cooling air adjacent the exterior surface of the body to cool the surface and create a thermal barrier between the exterior surface and the gases flowing through the flow path of the gas turbine engine. The cooling hole is defined by an elongate annular surface extending through the body of the component and terminating at the exterior surface of the body. The hole has a length, a maximum width less than about 0.

Abstract: A method of repairing a gas turbine engine compressor blade airfoils includes machining away airfoil material along leading and trailing edges and a radially outer tip of the airfoil to form leading edge, trailing edge, and tip cut-backs. Then beads of welding material are welded onto the leading edge, trailing edge, and tip cut-backs. Then some of the weld material is machined away from the weld bead to obtain desired finished dimensions of the leading and trailing edges and radially outer tip. Blade material along only radially outermost portions of the leading and trailing edges extending from the tip towards a base of the airfoil is machined away. A rounded corner is formed between the leading edge and trailing edge cut-backs and unmachined portions of the airfoil between the outermost portions of the leading and trailing edges and the base of the airfoil.

Abstract: The trailing edge of a turbine bucket is cut back from a root portion of the bucket to a location 50-75% of the span of the bucket. The cutback portion is tapered, forming an obtuse angle between it and the remaining original portion of the trailing edge outwardly of the cutback portion. A new conical section is thus created of a slightly larger conical and, hence, transverse configuration. The crack is removed upon removal of the material forming the cutback. With the edges of the recreated conical section surrounded, the cutback portion assumes a scalloped configuration with the exit openings of the cooling holes as seen from opposite sides of the bucket.

Abstract: This centrifugal blower fan wheel has extruded-aluminum airfoil blades. The preferred blades have two hollow regions, separated by an angled mid-load support beam, inside the blade. The nose section of the blade (at the leading edge) and the tail section of the blade (at the trailing edge) have open semi-circular grooves which face the adjacent hollow sections and are designed to accept thread cutting or thread forming screws for attachment of the blade to a ring-shroud and back-plate.

Abstract: An airfoil for a gas turbine engine including an inflection that facilitates enhancing film cooling of the airfoil, without adversely affecting aerodynamic efficiency of airfoil is described. The airfoil includes a generally concave first sidewall and a generally convex second sidewall joined at a leading edge and at a trailing edge of the airfoil. A plurality of cooling openings extend between an internal cooling chamber and an external surface of the first sidewall.

Abstract: A steam turbine blade made of Ti-base alloy comprising an &agr;+&bgr; type phase in which a difference of a tensile strength is small between a blade portion and a dovetail portion, a tensile strength at a room temperature of the dovetail portion is equal to or more than 100 kg/mm2 and a suitable toughness is commonly provided together with a strength, as a steam turbine blade having a length of 43 inch or more, a method of manufacturing the same, a steam turbine power generating plant and a low pressure steam turbine.

Abstract: This centrifugal blower fan wheel has extruded-aluminum airfoil blades. The preferred blades have two hollow regions, separated by an angled mid-load support beam, inside the blade. The nose section of the blade (at the leading edge) and the tail section of the blade (at the trailing edge) have open semi-circular grooves which face the adjacent hollow sections and are designed to accept thread cutting or thread forming screws for attachment of the blade to a ring-shroud and back-plate.

Abstract: A gas turbine engine (10) fan outlet guide vane (34) is manufactured by diffusion bonding titanium alloy sheet metal workpieces (52,54) together to form an in integral structure (66). A titanium alloy is weld deposited at predetermined positions (70,72) and in a predetermined shape to build up bosses (42,44) at the radially outer end (40) of the hollow integral structure (68). The integral structure (66) is inflated at high temperature to form a hollow integral structure (68) of predetermined aerofoil shape. Apertures (46,48) are drilled through the bosses (42,44) to enable the radially outer end (40) of the fan outlet guide vane (34) to be attached to a fan casing (32) of the gas turbine engine (10).

Abstract: In a method of producing a turbine blade in hollow section, an especially low defect or scrap rate is to be ensured. To this end, a first core element is connected via a number of approximately cylindrical spacers to a further core element and/or to a casting mold, the cavities left in the casting mold by the core elements being filled by blade material, and the openings remaining in the turbine blade after the removal of the core elements and the spacers and produced by the spacers being closed by stopper elements.

Abstract: A hollow liner (14) for fitting in the interior of a aerofoil vane (10) is crimped prior to fitting within the vane (10). Following fitting, the liner (14) is expanded so as to fit snugly within the vane (10). The technique permits the insertion of liners (14) into vanes (10) that are so configured as to preclude the insertion of conventional liners.

Abstract: A runner for a hydraulic turbine or pump includes a hub and a plurality of blades extending from the hub at spaced intervals therearound. Each blade includes an inner edge secured to the hub and a distal outer edge, a leading edge and an opposed trailing edge, and a curved suction surface and an opposed curved pressure surface. At least one of the blades is fabricated from a curved pressure-side member and a curved suction-side member secured together. The pressure-side member includes at least a substantial portion of the curved pressure surface and an opposed first inner surface. The suction-side member includes at least a substantial portion of the curved suction surface and an opposed second inner surface. The first and second inner surfaces face each other, and at least a portion of the first inner surface is spaced from at least a portion of the second inner surface to form a cavity within the blade. A method of making the hollow blade is also disclosed.

Abstract: A welded hollow nozzle partition formed from sheet metal and having a concave side and a convex side, includes an interior plate welded to an inner surface of the partition. The interior plate serves to strengthen the outer walls of the partition to withstand wall buckling and ballooning under certain operating conditions.

Abstract: A method of manufacturing an article (10) from two metal workpieces (30,32), the first and second metal workpieces (30,32) define the outer profile of the article (10). The second workpiece (32) is thicker than the first workpiece (30). The first workpiece (30) has two flat surfaces (34,36) and the second workpiece has one flat surface (38) and one machined (42) surface (40). Stop of is applied to surface (34) to prevent diffusion bonding at preselected areas. The workpieces (30,32) are assembled into a stack (58) so that the flat surfaces (34,38) are in abutment. Heat and pressure are applied to diffusion bond the workpieces (30,32) together to form an integral structure (60). The integral structure (60) is placed in a die such that the first workpiece (30) faces a convex surface of the die. The integral structure (60) is heated to cause the integral structure (60) to be hot creep formed on the convex surface of the die.

Abstract: A method for repairing a turbine blade (10) wherein the tip (16) of the blade is removed (41,43) and a replacement cap is attached by welding (49). The cap may consist of a plate (48) attached by welding and a squealer (54) formed by depositing weld material (52), as illustrated in FIG. 3. The plate and/or squealer may be formed from a material different from the material of the airfoil portion (42) of the blade in order to optimize the performance of the blade.

Abstract: This invention relates to a process for the manufacture of a blade/vane of a turbomachine, in particular a gas-turbine engine, said blade/vane consisting of a metallic enveloping structure and a supporting structure made of composite material provided inside of the enveloping structure and suitably joined to the enveloping structure. A metal-felt weave is welded or soldered/brazed to the sheet making up the enveloping structure, whereupon this sheet-weave-assembly is shaped by hydroforming or an internal high-pressure forming process to provide the enveloping structure of the blade/vane. Finally, the composite material making up the supporting structure is introduced into the cavity of the enveloping structure.

Abstract: A method of manufacturing a gas turbine engine fan blade (10) comprises forming three metal workpieces (30, 32, 34). The metal workpieces (30, 32, 34) are assembled into a stack (36) so that the flat surfaces (38, 42, 46, 48) are in mating abutment. Heat and pressure is applied across the thickness of the metal workpieces (30, 32, 34) to diffusion bond the metal workpieces (30, 32, 34) together to form an integral structure (80). The integral structure (80) is upset forged at one end (58) to produce an increase in thickness (82) for forming the blade root (26). The upset forged integral structure (80) is then hot creep formed and superplastically formed to produce the required aerofoil shape and the thickened end (82) is machined to form the blade root (26). The method enables thinner metallic workpieces with better microstructure to be used and increases the yield of metallic workpieces.

Abstract: A hybrid gas turbine engine airfoil is made by forming a metal airfoil with a pocket in one side thereof. The pocket is covered by a caul. An elastomeric fluid is injected into the pocket and cured therein for bonding thereto. The caul is removed from the airfoil to expose the cured elastomer conforming to the aerodynamic profile thereof.

Abstract: A leading edge structure of an aircraft airfoil comprises an outer skin, a front wall extended in the spanwise direction of the leading edge structure in a front section of the space defined by the outer skin so as to form an anti-icing duct together with a front part of the outer skin, and a plurality of ribs disposed in the space defined by the outer skin so as to form hot air passages. A laminar structure is formed by superposing upper and lower sheets of a superplastic titanium alloy, inserting a pair of core sheets of a superplastic titanium alloy between the upper and the lower sheet, and forming release agent layers in predetermined regions between the sheets.

Abstract: A process of the kind used for producing or repairing a turbine or compressor or fan blade by laser consolidation wherein a laser beam is moved relative to a metal surface and a stream of metal is supplied to the surface via a supply tube, so that said laser beam melts a thin layer of the metal substrate and also melts the metal being delivered to the substrate and thus forms a band of fused metal on said surface, the process being repeated until a desired blade is built up or repaired. The invention is characterized in that the laser beam is orientated at an acute angle to the surface. The supply tube may deliver the metal substantially along a path normal to the surface, with the laser beam being one of a plurality of laser beams each orientated at an acute angle to the surface and spaced around the supply means.