Abstract: A method for additively manufacturing a component is provided. The method may include forming a surface on the top layer of the component, scanning the surface of the top layer of the component to determine if a defect is present in the surface, and if detected, correcting the defect within the surface. Scanning the surface of the top layer of the component to determine if a defect is present in the surface may be performed by obtaining data indicative of the surface of the top layer of the component by interrogating the surface of the top layer of the component with a scanning device, and comparing the data with a reference database to determine if an irregularity is present.

Abstract: Methods for remotely joining material a surface area of a component of a gas turbine engine are provided. The method can include inserting an integrated repair interface attached to a cable delivery system within a gas turbine engine; positioning a tip of the integrated repair interface adjacent to a defect defined within a surface of the component; temporarily attaching the tip adjacent to the defect within the surface of the component; and supplying a new material to the area to fill the defect.

Abstract: The present disclosure is directed to a system and method for detecting distortion in a component of a gas turbine engine. In one embodiment, the system includes at least one detectable datum marker configured at least partially within the component. Further, the system includes a non-destructive inspection tool configured to monitor a location of the detectable datum marker over time. Thus, distortion of the component can be detected as a function of movement of the location of the detectable datum.

Abstract: Methods for material build-up on a tip of a blade of a gas turbine engine are provided. The method can include inserting a material supply and an inflatable bladder between the tip and a shroud such that the material supply is exposed to the tip and the inflatable bladder is positioned between the material supply and a shroud, inflating the inflatable bladder to force contact between the material supply and the tip, and causing relative movement between the material supply and the tip. The relative movement, in combination with the radial biased contact between the material supply and the tip, creates heat through friction. As such, the relative movement can frictionally weld new material from the material supply onto the tip of the blade. For example, the heat created can be sufficient to melt the surface of the material supply to transfer material from the material supply to the tip.

Abstract: A process for producing an internal cavity in a CMC article and mandrels used therewith. The process entails incorporating a mandrel made of a fusible material that is melted and drained during a thermal treatment of a CMC preform to form the CMC article. The mandrel material is preferably non-wetting and non-reactive with any constituents of the CMC preform during the thermal treatment. The mandrel is preferably tin or an alloy of tin.

Abstract: A method for forming an in situ temporary barrier within a gas turbine engine is provided. The method can include installing a bladder within the gas turbine engine, wherein the bladder defines a bladder body, and inflating the bladder with an inflating fluid such that the bladder body forms a circumferential seal within the gas turbine engine. The bladder body can be positioned between a row of stator vanes and an annular array of rotating blades to form a circumferential seal therebetween. A second bladder may be positioned circumferentially within the gas turbine engine.

Abstract: Methods and features for repairing CMC components are provided. Methods include positioning a plurality of CMC plies at a damaged area of a CMC component and densifying the component and plies. For example, each ply may be a unidirectional ply positioned at the damaged area such that the plurality of plies is oriented in a plurality of directions. As another example, each ply may define a ply direction and comprise a plurality of ceramic fibers substantially extending along the ply direction, and the ply directions of at least two plies may be differently oriented. A repair patch for a CMC component also is provided that comprises a plurality of CMC plies. Fibers forming a first ply extend substantially along a first ply direction and fibers forming a second ply extend substantially along a second ply direction. The first and second plies of the repair patch are oriented in different directions.

Abstract: A method of joining two components using additive manufacturing is provided. The method includes forming a first component made of a first material; forming an interlocking transition zone from the first material and a second material; and forming a second component made of the second material. The interlocking transition zone includes a plurality of projections alternately extending from the first component and the second component, respectively, to undetachably couple the first component and the second component.

Abstract: Matrix composite component repair processes are disclosed. The matrix composite repair process includes applying a repair material to a matrix composite component, securing the repair material to the matrix composite component with an external securing mechanism and curing the repair material to bond the repair material to the matrix composite component during the securing by the external securing mechanism. The matrix composite component is selected from the group consisting of a ceramic matrix composite, a polymer matrix composite, and a metal matrix composite. In another embodiment, the repair process includes applying a partially-cured repair material to a matrix composite component, and curing the repair material to bond the repair material to the matrix composite component, an external securing mechanism securing the repair material throughout a curing period, In another embodiment, the external securing mechanism is consumed or decomposed during the repair process.

Abstract: Methods for repairing surface of a metal substrate are provided, which can include preparing the surface of the metal substrate for repair; melt attaching a base layer onto the surface of the metal substrate; fusing a plurality of first layers of a first material via additive manufacturing to the base coating; forming an interlocking transition zone via additive manufacturing from the first material and a second material; and fusing a plurality of second layers of the second material via additive manufacturing on the interlocking transition zone. The interlocking transition zone can have a plurality of projections alternately extending from the plurality of first layers and the plurality of second layers, respectively, to undetachably couple the plurality of first layers to the plurality of second layers. A repaired metal substrate is also provided.

Abstract: In one aspect, a method for performing in situ repairs of internal components of a gas turbine engine may generally include inserting a repair tool within an interior of the gas turbine engine such that a tip end of the repair tool is positioned within the gas turbine engine and an exterior end is positioned outside the gas turbine engine. The method may also include positioning the tip end of the repair tool adjacent to a defect of an internal component, wherein the defect defines a fillable volume along a portion of the internal component. In addition, the method may include intermixing two or more constituents of a repair agent within the repair tool at a mixing location defined within the gas turbine engine, and expelling the repair agent from the tip end such that the fillable volume is at least partially filled with the repair agent.

Abstract: An apparatus for manufacturing an axi-symmetric part. The apparatus includes a vessel configured to contain the powder. The vessel is also configured to receive a part such that at least a portion of the part contacts the powder contained within the vessel. A first energy source is configured to generate a first beam of energy. The first beam of energy is configured to melt the powder at a first predetermined location such that the melted powder fuses to the part.

Abstract: Methods for performing in situ balancing of an internal rotating component of a gas turbine engine are provided. The method can include inserting a repair tool through an access port of the gas turbine engine with the repair tool including a tip end positioned within the gas turbine engine and a material supply end positioned outside the gas turbine engine. The tip end of the repair tool is positioned adjacent to a surface of the internal rotating component of the gas turbine engine. A new material is supplied from the material supply end of the repair tool to the tip end of the repair tool; and is expelling from the tip end of the repair tool in a direction of the surface of the rotating component such that the new material is added onto a portion of the rotating part.

Abstract: The present invention relates to a ceramic or metallic component including a first region having a first porosity ranging between 1 and 30%. The component includes a second region having a second porosity that is less than the first porosity. The component includes at least one graded transition between the first and second regions.

Abstract: Methods are provided for securing a tool within a gas turbine engine. The method can include inserting a tool into the engine; inserting a bladder between a portion of the tool and a component in the engine; and inflating the bladder to temporarily secure the tool in its position. For example, two tools (or more) can be inserted into the engine and secured by the bladder.

Abstract: Methods are provided for repairing a surface of a component within a gas turbine engine. A first bladder and a second bladder can be installed (simultaneously or independently) within the gas turbine engine. The first bladder and the second bladder can then be inflated with an inflating fluid to form a first circumferential seal and a second circumferential seal to define an isolated area within the gas turbine engine. All the surfaces within the isolated area can then be coated with a masking layer. At least a portion of the masking layer can then be removed to expose a working area, and a coating can be formed on the working area.

Abstract: A gas turbine blade may have a bond coat applied to its surface. A porous substrate may be applied to the bond layer and one or more protective layers may be applied to the bond layer such that the fiber mesh is embedded between the bond layer and the protective layer to prevent creep.

Abstract: The present disclosure is directed to a system and method for preventing damage to one or more components of the gas turbine engine during a repair procedure. The method includes locating one or more gaps of one or more components of the gas turbine engine in the vicinity of the defect. Further, the method includes filling the one or more gaps with a filler material so as to prevent arcing over the gaps during repair. Thus, the method also includes applying an electrical discharge to the defect.

Abstract: Methods for material build-up on a tip of a blade of a gas turbine engine are provided. The method can include inserting a material supply and an inflatable bladder between the tip and a shroud such that the material supply is exposed to the tip and the inflatable bladder is positioned between the material supply and a shroud, inflating the inflatable bladder to force contact between the material supply and the tip, and causing relative movement between the material supply and the tip. The relative movement, in combination with the radial biased contact between the material supply and the tip, creates heat through friction. As such, the relative movement can frictionally weld new material from the material supply onto the tip of the blade. For example, the heat created can be sufficient to melt the surface of the material supply to transfer material from the material supply to the tip.

Abstract: A method for forming an in situ temporary barrier within a gas turbine engine is provided. The method can include installing a bladder within the gas turbine engine, wherein the bladder defines a bladder body, and inflating the bladder with an inflating fluid such that the bladder body forms a circumferential seal within the gas turbine engine. The bladder body can be positioned between a row of stator vanes and an annular array of rotating blades to form a circumferential seal therebetween. A second bladder may be positioned circumferentially within the gas turbine engine.