Abstract: The present invention includes an apparatus and method by which the three-dimensional form or configuration of a distorted workpiece, such as a turbine component, is reverse engineered, and then this reverse engineering capability is combined with welding equipment, preferably a laser powder fusion welder, all integrally carried within a single machine, whereby a tool path unique to each workpiece is created and the welding machine accurately replaces lost material on the workpiece. The present invention consists of a series of operations or steps, preferably carried out by a single machine.

Abstract: A method and apparatus for cutting a profile in a workpiece, such as a turbine disk, without cracking the parent material which includes providing a grinding wheel having a ceramic grinding surface formed with an optimized grain material and grain spacing to produce large chips that are easily removed from the workpiece, applying the grinding wheel to the workpiece at a predetermined material removal rate, and increasing the material removal rate when the burning point is recognized at the surface of the workpiece by the grinding action of the grinding wheel, and delivering coolant/lubricant to the workpiece during the grinding operation.

Abstract: The present invention includes an apparatus and method by which the three-dimensional form or configuration of a distorted workpiece, such as a turbine component, is reverse engineered, and then this reverse engineering capability is combined with welding equipment, preferably a laser powder fusion welder, all integrally carried within a single machine, whereby a tool path unique to each workpiece is created and the welding machine accurately replaces lost material on the workpiece. The present invention consists of a series of operations or steps, preferably carried out by a single machine.