Abstract: Methods are provided for structurally repairing a component having a damaged internally threaded opening. The damaged internally threaded opening is machined to a predetermined diameter, thereby forming a machined opening. At least one notch is formed in the machined opening, thereby forming a notched opening. A selected amount of repair material is cold sprayed into the notched opening, including into the at least one notch. A plurality of internal threads is formed from the repair material to form a repaired internally threaded opening in the component. The repaired components are also provided.

Abstract: Methods are provided for structurally repairing a component having a damaged internally threaded opening. The damaged internally threaded opening is machined to a predetermined diameter, thereby forming a machined opening. At least one notch is formed in the machined opening, thereby forming a notched opening. A selected amount of repair material is cold sprayed into the notched opening, including into the at least one notch. A plurality of internal threads is formed from the repair material to form a repaired internally threaded opening in the component. The repaired components are also provided.

Abstract: A method for repairing an aluminum part having a worn portion is provided. In one embodiment, the method includes the steps of: (i) producing a first substantially non-porous coating over the worn portion utilizing a cold spray process wherein a powder mixture is propelled against the worn portion of the aluminum part, and (ii) anodizing the aluminum part to grow an aluminum oxide layer overlaying the first substantially non-porous coating. The powder mixture includes aluminum and an alloy media.

Abstract: Methods are provided for repairing an engine component. In an embodiment, a method includes forming at least one layer of a first braze alloy mixture including about 40% by weight of a first base alloy material and about 60% by weight of a first braze alloy material, over a structural feature of the component. The first braze alloy material includes chromium, cobalt, tungsten, tantalum, aluminum, hafnium, carbon, boron, and a balance of nickel. A second braze alloy mixture is disposed over the at least one layer of the first braze alloy mixture, the second braze alloy mixture including between about 50% and about 60% by weight of a second base alloy material, and between about 40% and about 50% by weight of a second braze alloy material. The component is then subjected to heat treatment, and may be further subjected to machining, coating and final inspection.

Abstract: A method of forming a wear-resistant coating on a surface of a substrate includes the step of depositing a material comprising a rhenium-based composition onto the substrate surface using a handheld laser deposition device. A soluble interlayer may be formed on the surface of the substrate prior to the laser deposition step, and a heat treatment may be performed after the laser deposition step.

Abstract: A method for repairing an aluminum part having a worn portion is provided. In one embodiment, the method includes the steps of: (i) producing a first substantially non-porous coating over the worn portion utilizing a cold spray process wherein a powder mixture is propelled against the worn portion of the aluminum part, and (ii) anodizing the aluminum part to grow an aluminum oxide layer overlaying the first substantially non-porous coating. The powder mixture includes aluminum and an alloy media.

Abstract: Methods are provided for repairing an engine component. In an embodiment, a method includes forming at least one layer of a first braze alloy mixture including about 40% by weight of a first base alloy material and about 60% by weight of a first braze alloy material, over a structural feature of the component. The first braze alloy material includes chromium, cobalt, tungsten, tantalum, aluminum, hafnium, carbon, boron, and a balance of nickel. A second braze alloy mixture is disposed over the at least one layer of the first braze alloy mixture, the second braze alloy mixture including between about 50% and about 60% by weight of a second base alloy material, and between about 40% and about 50% by weight of a second braze alloy material. The component is then subjected to heat treatment, and may be further subjected to machining, coating and final inspection.