Abstract: An example method of attaching an airfoil for an integrally bladed rotor includes placing a support collar in an installed position around at least a leading edge and trailing edge of an airfoil stub to be repaired in an integrally bladed rotor. The support collar and the airfoil stub together have a midline that is positioned between opposing, laterally outer surfaces of the airfoil stub when the support collar is in the installed position. The method performs linear friction welding to add a replacement airfoil to the airfoil stub.

Abstract: A method of repairing an integrally bladed rotor includes the steps of placing a support collar around at least a leading and trailing edge portions of the blade stub, and performing linear friction welding to add a replacement airfoil to the blade stub. The linear friction welding is generally along a direction between the leading and trailing edges. In addition, the support collar leading and trailing edge portions are connected together.

Abstract: A method is provided for repairing a damaged rotor blade on an integrally bladed rotor by removing a damaged portion of a damaged blade leaving a blade stub extending outwardly from the disk and performing a linear friction welding operation to attach a replacement blade segment to the blade stub. The rotor may be disposed operation using a linear friction welding apparatus. The method includes disposing a support collar about the blade stub and securing the support collar to the linear friction welding apparatus prior to a commencement of the bonding operation. A lower surface of the support collar is contoured to mate with a portion of an outer circumference surface of the rotor disk.

Abstract: A method of repairing a rotor blade, for example on an integrally bladed rotor, includes preparing a surface on a damaged area of the blade. The blade has first and second airfoil surfaces adjoining the prepared surface that are spaced apart a distance. An edge of a patch abuts the prepared surface to provide a weld interface defining a welding plane. First and second cover sheets respectively overlap the first and second airfoil surfaces. The first and second cover sheets adjoin the edge and the first and second airfoil surfaces. The blade, patch and first and second cover sheets are welded along the welding plane providing a welded joint at the weld interface. The first and second cover sheets are substantially unsecured to the first and second airfoil surfaces subsequent to the welding operation.