Abstract: The present invention provides an apparatus and method for an adaptive machining and weld repair process useful for repairing airfoils, particularly damage to an airfoil leading edge and tip. The process first machines away damaged portions of the airfoil. Next, the actual profile of the airfoil subsequent to the removal of the damaged material is measured using a Coordinate Measuring Machine. The data is then used to generate a deformation profile. Filler material is then added to the machined area using the data of the deformation profile to produce an airfoil that approximates the ideal shape of a restored airfoil. At this point, the actual profile of the welded airfoil is measured using the Coordinate Measuring Machine. The data is then used to generate a deformation profile and the airfoil is machined using the date of the deformation profile to produce that shape. The adaptive technology minimizes the amount of stock on material that needs to be removed by hand.

Abstract: The present invention provides an apparatus for automated laser welding repairs. The apparatus is adapted for use with components of gas turbine engines such as compressor and turbine airfoils and blisks. The apparatus comprises a dual means of providing filler material. The filler material may be provided through a wire feeder. Optionally, the filler material may be provided through a powder feeder.

Abstract: A method for repairing a titanium alloy surface of a turbine component includes the step of cold gas-dynamic spraying a powder material comprising at least one titanium alloy directly on the titanium alloy surface. The method may further include the steps of hot isostatic pressing the cold gas-dynamic sprayed turbine component, and performing a separate heat treating step after the hot isostatic pressing. Thus, the cold gas-dynamic spray process and post-spray processing can be employed to effectively repair degraded areas on compressor turbine components.

Abstract: The present invention provides an apparatus for use in automated welding repairs, particularly those repairs intended for impellers, blisks, and similar structures. There is provided a welding shield which is shaped to fit securely within valleys of an impeller. An individual shield is sized to match with a particular impeller design. When in place, the shield covers exposed areas of the valley and thus protects that area from welding damage. The shield may include welding resistant materials on exposed surfaces. A plurality of shields can protect as many impeller valleys as needed. The shield fits securely so that it does not dislodge during automated welding operations. If desired shields can be moved and repositioned so as to expose previously protected areas thus allowing welding to take place in the newly exposed areas.