Abstract: The present invention is directed to a process for repairing cracks in a turbine engine component. The process comprises the steps of providing a component, preferably formed from a single crystal nickel based material, with at least one crack, applying a repair alloy composition containing a single crystal nickel based alloy, a first nickel based braze alloy and a second nickel based braze alloy to the crack(s), and subjecting the component with the applied repair alloy composition to a thermal cycle to diffuse the repair alloy composition into the crack(s).

Abstract: Novel materials and methods for repairing/reclassifying superalloy components are described herein. These materials are non-traditional blends of materials having a much higher base material content than traditional repair/reclassification materials. In embodiments used to repair/reclassify nickel-based components, these materials may comprise about 5-18.9 weight percent of a low melting point alloy and about 81.1-95 weight percent of a base material. In embodiments used to repair/reclassify cobalt-based components, these materials may comprise about 15-30 weight percent of a low melting point alloy and about 70-85 weight percent of a base material. These materials can be used to repair surface defects and/or build up worn or eroded areas of a component to meet precise dimensional and metallurgical requirements. These materials create robust repaired components having a dense, isothermally solidified structure having minimal borides and a high re-melt temperature.