Abstract: A method for fabricating a component for a gas turbine engine includes providing a blisk forging fabricated from a first material, inertia welding a second material to the blisk forging to create a bi-alloy blisk forging, and machining the bi-alloy blisk forging to pre-determined dimensions.

Abstract: A workpiece structure having a hole therein is repaired by preparing a stack having a first confinement sheet, a first donor sheet, a workpiece structure having a hole therein, a plug of a plug material in the hole, optionally a second donor sheet, and a second confinement sheet. The first confinement sheet, the first donor sheet, the second donor sheet, and the second confinement sheet each overlie the hole. The first confinement sheet and the second confinement sheet each melt at a temperature greater than do the first donor sheet, the plug, and the second donor sheet. The stack is locally heated at the hole using an electrical current source to a temperature sufficiently high to locally melt the first donor sheet, the plug, the second donor sheet, and the workpiece structure. The stack is thereafter cooled to solidify all melted material and form a weldment.

Abstract: A process for repairing a compressor rear frame of a gas turbine engine. The process entails removing a seal flange from the inner casing wall of the frame to define an annular face on the casing wall, and fabricating a replacement flange to have an annular face with a radial width greater than the radial width of the annular face of the casing wall. The faces of the flange and wall are mated to form a joint, a penetration-enhancing flux is deposited adjacent the joint, and a single-pass gas tungsten arc welding operation is performed to form a root weldment that extends completely through the joint. The flux is then removed and a gas tungsten arc welding operation is performed to deposit a filler on the root weldment and form a second weldment that completely overlays but does not penetrate through the root weldment.

Abstract: A method for replacing a portion of a gas turbine engine rotor blade, the rotor blade having a contour defined by a blade first sidewall and a blade second sidewall includes cutting through the rotor blade such that a cut line extends from a leading edge of the blade to a trailing edge of the blade, and between the first sidewall and the second sidewall, removing the portion of the rotor blade that is radially outward of the cut line, and coupling a replacement blade portion to remaining blade portion such that the newly formed rotor blade is formed with a pre-determined aerodynamic contour.

Abstract: A fusion welding method is provided for fusion welding at juxtaposed interface surfaces a first member, for example made of a first metal based on at least one of Ru, Rh, Pd, and Pt, with a second member made of a second metal, for example a high temperature alloy based on at least one of Fe, Co, and Ni, including at least one identified element, for example Al, that can form a continuous layer of a brittle intermetallic compound with the first metal that is free of such element. With the interface surfaces disposed in contact, energy is generated at the interface surfaces in a combination of an amount and for a first time selected to be sufficient to heat the interface surfaces to a fusion welding temperature. However, the first time is less than a second time that enables formation at the fusion welding temperature of the continuous layer of the brittle intermetallic compound at the interface surfaces.