Abstract: Methods are provided for repairing a damaged section of an air-cooled turbine blade, the blade having a first wall, a second wall, a trailing edge, and a plurality of cooling holes, the plenum formed between the first and second walls and having a predetermined shape, and the plurality of cooling holes formed on the trailing edge in flow communication with the plenum and having predetermined shapes. In one embodiment, and by way of example only, the method includes the steps of injecting a filler material into the blade plenum and the plurality of blade cooling holes, the filler material capable of solidifying into the predetermined shapes of the blade plenum and blade cooling holes. Then, the damaged section of the blade is laser welded and machined to original dimensions. Next, the filler material is removed.

Abstract: Methods are provided for repairing a degraded section of a turbine blade, the turbine blade comprising a base material. In one embodiment, and by way of example only, the method includes the step of electro-spark depositing a first material on the turbine blade degraded section to form an intermediate layer thereon, the first material comprising a material that is substantially similar to the base material. Next, a second material is laser welded onto the intermediate layer to form a repaired section. This invention combines the low-heat input of electro-spark deposition with the high welding quality and high deposition rate of laser powder fusion welding.

Abstract: A mobile support system for a hand-held laser welding wand includes a movable cart, a laser source, a fluid source, and a filler medium supply source. The laser source is mounted on the movable cart and is configured to supply laser light for the hand-held laser welding wand. The fluid source is mounted on the movable cart and is configured to supply cooling fluid for the hand-held laser welding wand. The filler medium supply source is mounted on the movable cart and is configured to supply a filler medium for use by the hand-held laser welding wand. The mobile support system is transportable to areas remote from a work shop environment, and provides stand-alone support for the hand-held laser welding wand.

Abstract: A hand-held laser welding wand includes internal flow passages through which filler media, gas, and coolant may flow. The wand is dimensioned to be grasped with a single hand, and includes an optics assembly disposed therein. The wand is configured such that the optics assembly, or portions thereof, may be readily serviced without having to breach coolant seals or remove a plurality of threaded screws.

Abstract: A mobile support system for a hand-held laser welding wand includes a movable cart, a laser source, a fluid source, and a filler medium supply source. The laser source is mounted on the movable cart and is configured to supply laser light for the hand-held laser welding wand. The fluid source is mounted on the movable cart and is configured to supply cooling fluid for the hand-held laser welding wand. The filler medium supply source is mounted on the movable cart and is configured to supply a filler medium for use by the hand-held laser welding wand. The mobile support system is transportable to areas remote from a work shop environment, and provides stand-alone support for the hand-held laser welding wand.

Abstract: Methods are provided for repairing cracks in a damaged section of a gas turbine engine component with an in-situ brazing process. In an embodiment, by way of example only, the method includes applying a braze paste to the damaged section of the component, the braze paste comprising a braze material and an organic binder. The method also includes subjecting the damaged section of the component to a first temperature that is below a brazing temperature of the braze material to thereby substantially decompose and evaporate the organic binder, and heating the braze material using laser energy to a second temperature that is substantially equal to or above the brazing temperature to form the brazed joint on the component.

Abstract: A hand-held laser welding wand includes a main body that is dimensioned to be grasped by a hand and a nozzle assembly. The nozzle assembly includes a laser extension tip and a feeder material extension tip in a configuration that provides the hand-held laser welding wand with the capability of conducting laser welding operations in relatively deep crevices or other hard to reach places.

Abstract: A hand-held laser-welding wand includes a gas lens assembly that develops an inert gas atmosphere around a weld pool. The lens assembly additionally reflects laser light and thermal radiation that is reflected off a work piece surface away from the hand of a user of the hand-held laser welding wand.

Abstract: A method for providing a pre-welding heat treatment to a workpiece surface is described wherein the method includes the steps of: generating through a laser generator a laser beam characterized by a power and focal point; positioning the laser generator such that the focal point of the laser beam is above the workpiece surface so as to generate a defocused laser beam; directing the defocused laser beam toward the workpiece surface so as to project a laser beam spot on the workpiece surface; scanning the laser beam spot over the workpiece surface thereby heating the workpiece surface so as to provide a pre-welding heat treatment; repositioning the laser generator such that the focal point of the laser beam is changed; and laser welding the workpiece with substantially the same power as in the generating step. The method is further adapted for use with a hand held Nd:YAG laser torch, and the workpiece may be a superalloy gas turbine engine component.

Abstract: A hand-held laser welding wand includes one or more removable filler media delivery extension tips. The wand is dimensioned to be grasped with a single hand, thus filler media of various types and forms may be supplied to the weld area on a workpiece using various types of delivery systems and methods, including fully automated, semi-automated, or manually. The filler media may be wholly or partially delivered via the filler media delivery passages. One or more of the extension tips may be inserted into the filler media delivery passages to efficiently, precisely, and robustly supply filler media of various types and forms to the workpiece weld area.

Abstract: A hand-held laser welding wand includes internal flow passages through which filler media, gas, and coolant may flow. The wand is dimensioned to be grasped with a single hand, thus filler media of various types and forms, gas, and coolant may be supplied to the hand-held laser welding wand via external systems and delivery devices without substantially impairing operation of the wand.

Abstract: A control console that is used in conjunction with a hand-held laser welding wand is adapted to couple to an electrically controllable filler media supply source, and to an electrically controllable laser source. The control console includes a control switch that is electrically coupled to the filler media supply source and the laser source and is configured to such that an operator can independently and simultaneously control the filler media supply source to either supply or not supply filler media, and the laser source to either emit or not emit laser light therefrom. The control switch is preferably further configured to control the optical power level of the laser source.