Abstract: A method for repairing a tip portion of a turbine component having a structural defect is provided. The method includes removing a damaged section in turbine component with a structural defect in a tip portion of the turbine component. A pre-sintered preform is provided including a first portion having a first composition and a second portion having a second composition. The pre-sintered preform is configured to mate with an upper surface of a remaining portion of the turbine component. The method also includes applying the pre-sintered preform to the upper surface, wherein the PSP comprises a superalloy material and a braze material. The PSP and the remaining portion of the turbine component are subjected to a brazing process to melt the braze material and fill in the structural defect.

Abstract: A method, including: replacing an original blade shelf (16) of a gas turbine engine blade (10) with a new blade shelf (64) that is located closer to a base (18) of the blade than the original blade shelf; adding mass to the blade until a mass of the blade with the new blade shelf is greater than a mass of the blade with the original blade shelf in order to maintain a same contribution by the blade with the new blade shelf as a contribution by the blade with the original blade shelf to a dynamic balance of a rotor arrangement.

Abstract: A coating arrangement (16), including: a layer (18) of bond coat material (20); and a light-transmissive thermal barrier coating (TBC) mesh (28) having a TBC material (24) and secured in position relative to the layer of bond coat material. The coating arrangement may be positioned over a superalloy substrate material (12) and melted with a laser beam (62) to metallurgically bond the thermal barrier coating onto the substrate.

Abstract: Components, such as turbine blades or vanes, are formed to a desired shape and dimensions by ablation machining a work piece surface. Recast layer material created on the work piece surface during the ablation machining is subsequently removed by fluoride ion cleaning (FIC). Exemplary ablation machining methods include laser machining and electric discharge machining (EDM). The work piece material may include superalloys commonly used for fabrication of turbine blades or vanes, which are susceptible to recast layer formation during EDM or laser machining. Post ablation FIC recast layer removal is easier than known methods, such as mechanical grinding, secondary EDM machining of the layer at lower speeds and/or current intensity, or chemical etching processes. Ablation machining processes can be optimized for speed and efficiency without regard for recast layer avoidance, with knowledge that the recast layer will be subsequently removed by the complimentary FIC process.

Abstract: A coating arrangement (16), including: a layer (18) of bond coat material (20); and a light-transmissive thermal barrier coating (TBC) mesh (28) having a TBC material (24) and secured in position relative to the layer of bond coat material. The coating arrangement may be positioned over a superalloy substrate material (12) and melted with a laser beam (62) to metallurgically bond the thermal barrier coating onto the substrate.

Abstract: A method, including: replacing an original blade shelf (16) of a gas turbine engine blade (10) with a new blade shelf (64) that is located closer to a base (18) of the blade than the original blade shelf; adding mass to the blade until a mass of the blade with the new blade shelf is greater than a mass of the blade with the original blade shelf in order to maintain a same contribution by the blade with the new blade shelf as a contribution by the blade with the original blade shelf to a dynamic balance of a rotor arrangement.

Abstract: A reusable template for simultaneously forming a plurality of cooling passages in a component for use in a turbine engine includes a first surface defining an electrode entry surface, a second surface opposed from the first surface and defining a component mating surface, and a plurality of electrode passages pre-formed in the template and extending from the first surface to the second surface. The second surface of the template has a shape that corresponds to an outer surface of the component such that the template is capable of being snugly positioned against the outer surface of the component. During an electro-discharge machining operation, a plurality of electrodes are simultaneously inserted through the pre-formed electrode passages in the template and into the component while supplying an electric current to the electrodes to remove material from the component so as to form the cooling passages therein.

Abstract: Components, such as turbine blades or vanes, are formed to a desired shape and dimensions by ablation machining a work piece surface. Recast layer material created on the work piece surface during the ablation machining is subsequently removed by fluoride ion cleaning (FIC). Exemplary ablation machining methods include laser machining and electric discharge machining (EDM). The work piece material may include superalloys commonly used for fabrication of turbine blades or vanes, which are susceptible to recast layer formation during EDM or laser machining. Post ablation FIC recast layer removal is easier than known methods, such as mechanical grinding, secondary EDM machining of the layer at lower speeds and/or current intensity, or chemical etching processes. Ablation machining processes can be optimized for speed and efficiency without regard for recast layer avoidance, with knowledge that the recast layer will be subsequently removed by the complimentary FIC process.

Abstract: A flux sheet (20A) and method of using the flux sheet to restore a surface (24) of a metal substrate (26). A laser beam (32) is directed onto the flux sheet to melt it and the surface, then allowed to cool and solidify to produce a restored surface. The flux sheet may be formulated to optically transmit at least 40% of electromagnetic energy from a laser onto the substrate surface. The flux sheet contains a flux composition that may include: a metal oxide, a metal silicate, or both; a metal fluoride; and a metal carbonate. The flux composition may limit the content of certain elements and compounds such as Fe, Li2O, Na2O and K2O. The flux composition may include constituents providing air shielding, contaminant scavenging, viscosity/fluidity enhancement, and optical transmission of laser energy through the flux sheet.

Abstract: A reusable template for simultaneously forming a plurality of cooling passages in a component for use in a turbine engine includes a first surface defining an electrode entry surface, a second surface opposed from the first surface and defining a component mating surface, and a plurality of electrode passages pre-formed in the template and extending from the first surface to the second surface. The second surface of the template has a shape that corresponds to an outer surface of the component such that the template is capable of being snugly positioned against the outer surface of the component. During an electro-discharge machining operation, a plurality of electrodes are simultaneously inserted through the pre-formed electrode passages in the template and into the component while supplying an electric current to the electrodes to remove material from the component so as to form the cooling passages therein.