Abstract: An airfoil component for attaching to a cropped airfoil is provided. The cropped airfoil comprises a cropped airfoil attachment section and a cropped first side opposite a cropped second side, which each extend axially between a cropped first edge and a cropped second edge to define a cropped chord length. The airfoil component comprises a body having a component first side opposite a component second side. The body defines an attachment section for attaching the airfoil component to the cropped airfoil at the cropped airfoil attachment section. The attachment section extends axially between a component first edge and a component second edge to define a component chord length, and the attachment section is oversized with respect to the cropped airfoil attachment section such that the component chord length is longer than the cropped chord length. Systems and methods also are provided.

Abstract: An airfoil component for attaching to a cropped airfoil is provided. The cropped airfoil comprises a cropped airfoil attachment section and a cropped first side opposite a cropped second side, which each extend axially between a cropped first edge and a cropped second edge to define a cropped chord length. The airfoil component comprises a body having a component first side opposite a component second side. The body defines an attachment section for attaching the airfoil component to the cropped airfoil at the cropped airfoil attachment section. The attachment section extends axially between a component first edge and a component second edge to define a component chord length, and the attachment section is oversized with respect to the cropped airfoil attachment section such that the component chord length is longer than the cropped chord length. Systems and methods also are provided.

Abstract: An airfoil component for attaching to a cropped airfoil is provided. The cropped airfoil comprises a cropped airfoil attachment section and a cropped first side opposite a cropped second side, which each extend axially between a cropped first edge and a cropped second edge to define a cropped chord length. The airfoil component comprises a body having a component first side opposite a component second side. The body defines an attachment section for attaching the airfoil component to the cropped airfoil at the cropped airfoil attachment section. The attachment section extends axially between a component first edge and a component second edge to define a component chord length, and the attachment section is oversized with respect to the cropped airfoil attachment section such that the component chord length is longer than the cropped chord length. Systems and methods also are provided.

Abstract: A method of repairing a blisk having a hub with circumferentially spaced blades. The method can include removing a portion of a blade and replacing the portion with a replacement piece. The method can further include welding the replacement portion to the blade. The method can further include at least one of inspecting the weld after the completion of the weld and prior to heat treatment, dimensionally inspecting the replacement piece after machining, peening the blade, and surface finishing the replacement piece.

Abstract: A method for repairing a degraded bolt hole in a casing flange by reaming and removing at least some corrosion on an inside and around the hole to form a reamed hole, mounting the flange to float relative to upper and lower electrodes of a welding machine, radially and axially clamping an area of the flange surrounding the reamed hole, placing upper and lower filler slugs in the reamed hole, placing the electrodes against upper and lower filler slugs and applying a welding current through the electrodes while applying pressure to the filler slugs with the electrodes and resistively heating and melting the filler slugs to form a weldment, and pulsing the welding current on and off. Pulsing may be performed with progressively increasing amounts of current. In situ tempering under the pressure of the electrodes may be performed on a substantially liquid pool formed by the welding current.

Abstract: A method for bonding airfoil sections includes aligning upper and stub airfoil sections having upper airfoil pressure and suction sides and stub airfoil pressure and suction sides respectively, pressing together upper and stub airfoil cross sections at upper and stub airfoil distal ends of the upper and stub airfoil sections respectively, and then resistance welding, preferably solid state resistance welding, the upper and stub airfoil sections together along the upper and stub airfoil cross sections by passing electrical current across the upper and stub airfoil cross sections. The upper and stub airfoil sections may be clamped between pressure and suction side upper airfoil electrodes and between the stub airfoil pressure and suction sides respectively. The method may be performed while the stub airfoil section is attached to an airfoil carrier such as a rotor disk rim, a gas turbine engine drum, or a gas turbine engine blade platform.

Abstract: A method for repairing a degraded bolt hole in a casing flange by reaming and removing at least some corrosion on an inside and around the hole to form a reamed hole, mounting the flange to float relative to upper and lower electrodes of a welding machine, radially and axially clamping an area of the flange surrounding the reamed hole, placing upper and lower filler slugs in the reamed hole, placing the electrodes against upper and lower filler slugs and applying a welding current through the electrodes while applying pressure to the filler slugs with the electrodes and resistively heating and melting the filler slugs to form a weldment, and pulsing the welding current on and off. Pulsing may be performed with progressively increasing amounts of current. In situ tempering under the pressure of the electrodes may be performed on a substantially liquid pool formed by the welding current.

Abstract: A method for bonding airfoil sections includes aligning upper and stub airfoil sections having upper airfoil pressure and suction sides and stub airfoil pressure and suction sides respectively, pressing together upper and stub airfoil cross sections at upper and stub airfoil distal ends of the upper and stub airfoil sections respectively, and then resistance welding, preferably solid state resistance welding, the upper and stub airfoil sections together along the upper and stub airfoil cross sections by passing electrical current across the upper and stub airfoil cross sections. The upper and stub airfoil sections may be clamped between pressure and suction side upper airfoil electrodes and between the stub airfoil pressure and suction sides respectively. The method may be performed while the stub airfoil section is attached to an airfoil carrier such as a rotor disk rim, a gas turbine engine drum, or a gas turbine engine blade platform.