Abstract: A method for repairing a blade for use in a gas turbine engine, the method comprising removing a distal tip of an airfoil included in the blade to remove damaged portions of the airfoil and to expose previously internal cooling passages. The method further comprising positioning a tip cap in the place of the removed distal tip to cover the internal cooling passages, and welding the tip cap to the airfoil by applying a directed energy beam onto the tip cap and the airfoil at a joint between the tip cap and the airfoil.