Abstract: The present application provides a method of repairing a turbine blade. The method may include the steps of removing an existing tip cap from the turbine blade in whole or in part, machining the turbine blade to form a machined groove, positioning an insert in the machined groove, welding the insert to the turbine blade, and brazing the turbine blade.

Abstract: Platform cooling arrangements in a turbine rotor blade include a feedhole that extends from the suction side slash face to the interior cooling passage, and, one or more branch holes that each extends from the feedhole to the suction side slash face such that coolant flows from the interior cooling passage, through the feedhole to the one or more branch holes and exits the platform along the suction side slash face.

Abstract: A method of selectively applying an overlay coating to a coated article and a selectively treated coated article are provided. The method includes the steps of providing the coated article having a treatment region that includes a bond coat and a thermal barrier coating and selectively applying an overlay coating to the treatment region without stripping the treatment region from the coated article. The bond coat of the coated article which has been exposed to an operational temperature includes a first volume fraction of a ?-phase microstructure that is less than a second volume fraction of a ?-phase microstructure of a comparable bond coat of a comparable article which has not been exposed to the operational temperature. A coated article including an overlay coating selectively applied over a treatment region is also disclosed.

Abstract: A system for adaptively machining a shroud of a blade used in a turbomachine is provided. The system may include a computer system including a module(s) configured to: extract geometric location data from a 3D model of the shroud after use in the turbomachine, the 3D model created by digitizing using a digitizing device. The geometric location data includes geometric location data of a hard face plane of the shroud exposed to wear during turbomachine operation and of a non-worn surface adjacent to the hard face plane substantially unexposed to wear during turbomachine operation. Comparing the geometric location data of the non-worn surface from the three-dimensional model to a manufacturing model of the blade determines a change in position of the non-worn surface from use of the blade in the turbomachine. The change in position is used to modify a machining instruction used by a machining device to repair the hard face plane.

Abstract: The present application provides a method of repairing a turbine blade. The method may include the steps of removing an existing tip cap from the turbine blade in whole or in part, machining the turbine blade to form a machined groove, positioning an insert in the machined groove, welding the insert to the turbine blade, and brazing the turbine blade.

Abstract: A process for forming a thermal barrier coating system on a substrate is disclosed including preparing a slurry including a donor powder, an activator powder, and a binder. The donor powder includes a metallic aluminum alloy having a melting temperature higher than aluminum, and the binder includes at least one organic polymer gel. The process further includes applying the slurry to the substrate, heating the slurry to form an aluminide bond coating including an additive aluminide layer and an aluminide interdiffusion zone disposed between the substrate and the additive aluminide layer, and applying a thermal barrier coating to the aluminide bond coating. The thermal barrier coating may be a dense vertically-cracked thermal barrier coating, and the substrate may be a gas turbine component. Thermal barrier coating systems formed by the process are also disclosed.

Abstract: A modification process and modified article are disclosed. The modification process includes locating an area in an article, removing the area by machining to form a machined region, inserting a modification material into the machined region, securing the modification material to the article, machining the modification material flush with a geometry of the article, and applying a coating over at least a portion of the article. Another modification process includes locating an area under a suction side leading edge tip shroud fillet of an airfoil, removing the area by machining to form a hole, inserting a modification material having improved material properties as compared to an original base material into the hole, securing the modification material in place, machining the modification material and the airfoil to form a new fillet contour, and applying a coating over at least a portion of the airfoil. Also disclosed is the modified article.

Abstract: A system for adaptively machining a shroud of a blade used in a turbomachine is provided. The system may include a computer system including a module(s) configured to: extract geometric location data from a 3D model of the shroud after use in the turbomachine, the 3D model created by digitizing using a digitizing device. The geometric location data includes geometric location data of a hard face plane of the shroud exposed to wear during turbomachine operation and of a non-worn surface adjacent to the hard face plane substantially unexposed to wear during turbomachine operation. Comparing the geometric location data of the non-worn surface from the three-dimensional model to a manufacturing model of the blade determines a change in position of the non-worn surface from use of the blade in the turbomachine. The change in position is used to modify a machining instruction used by a machining device to repair the hard face plane.

Abstract: According to one aspect, a fixture for an airfoil shroud having a first end edge, a second end edge, a leading edge, a trailing edge, a radially outer side and a radially inner side with respect to a rotor axis of a bucket having the airfoil shroud is provided. The fixture includes a base plate, a first member extending from the base plate configured to locate and abut the first end edge, a second member extending from the base plate configured to locate and abut a side of a seal rail, a third member extending from the base plate configured to locate and abut the radially outer side of the airfoil shroud and a template recess formed in the base plate proximate the first end edge to define a geometry of a relief cut in the trailing edge of the airfoil shroud.

Abstract: A system and method for virtually inspecting contact gaps of a blade stage of a turbomachine is disclosed. The system may include a digitizing device for obtaining a three-dimensional model of a shroud of each blade of the blade stage. A computer system may include at least one module configured to perform the following steps: extracting a geometric location data of a hard place plane of each shroud from the three-dimensional model; generating a three-dimensional virtual rendering of the shrouds of the blade stage based on the geometric location data and the known dimensions of the blade stage, the three-dimensional virtual rendering including a rendering of contact gaps between adjacent shrouds; and inspecting the blade stage using the three-dimensional virtual rendering.

Abstract: A method is provided for modifying an airfoil shroud located at a tip of a blade of an airfoil, the airfoil shroud having a first end edge, a second end edge, a leading edge, and a trailing edge. The method includes locating a reference location in the first end edge of the airfoil shroud, the reference location including a portion of a seal rail extending circumferentially from a radially outer surface of the airfoil shroud, and a fillet extending from the radially outer surface and positioned directly adjacent to the seal rail. The method further includes forming a relief cut in the seal rail and fillet without performing a weld process on the airfoil shroud to remove the reference location, and installing the airfoil shroud in a turbomachine directly following forming the relief cut, wherein modifying the airfoil shroud is complete following forming the relief cut.

Abstract: Methods for modifying bucket platforms of turbine buckets include removing a portion of the bucket platform to form a void, wherein the void comprises a predetermined geometry, and adding a filler material in a plurality of layers to fill the void.

Abstract: A bucket tip shroud measurement fixture includes a frame extending from a first end to a second end through an intermediate portion having a first surface and an opposing second surface, a first tip shroud fixing member extending from the second surface of the frame at the first end, and a second tip shroud fixing member extending from the second surface of the frame at the second end. The first and second tip shroud fixing members are configured and disposed to retain and establish an orientation of a bucket tip shroud relative the frame. A plurality of reference points are provided on the frame. The plurality of reference points are configured and disposed to receive a coordinate measuring machine (CMM) probe.

Abstract: Platform cooling arrangements in a turbine rotor blade include a feedhole that extends from the suction side slash face to the interior cooling passage, and, one or more branch holes that each extends from the feedhole to the suction side slash face such that coolant flows from the interior cooling passage, through the feedhole to the one or more branch holes and exits the platform along the suction side slash face.

Abstract: A bucket tip shroud measurement fixture includes a frame extending from a first end to a second end through an intermediate portion having a first surface and an opposing second surface, a first tip shroud fixing member extending from the second surface of the frame at the first end, and a second tip shroud fixing member extending from the second surface of the frame at the second end. The first and second tip shroud fixing members are configured and disposed to retain and establish an orientation of a bucket tip shroud relative the frame. A plurality of reference points are provided on the frame. The plurality of reference points are configured and disposed to receive a coordinate measuring machine (CMM) probe.

Abstract: A method and system for sealing a gap between a bucket dovetail and a rotor is provided. The dovetail seal includes a first end portion extending from a first extent of the first end portion a predetermined distance along a length of the dovetail seal, a second end portion extending from a first extent of the second end portion a predetermined distance along a length of the dovetail seal towards the first end portion, and a body extending between the first and second end portions. The body includes a U-shaped bend complementary to a sealing groove in a dovetail of a turbine blade. The first end portion includes a converging flared cross-section from the first extent of the first end portion toward the second end portion and the second end portion includes a converging flared cross-section from the first extent of the second end portion toward the first end portion.

Abstract: A modification process and modified article are disclosed. The modification process includes locating an area in an article, removing the area by machining to form a machined region, inserting a modification material into the machined region, securing the modification material to the article, machining the modification material flush with a geometry of the article, and applying a coating over at least a portion of the article. Another modification process includes locating an area under a suction side leading edge tip shroud fillet of an airfoil, removing the area by machining to form a hole, inserting a modification material having improved material properties as compared to an original base material into the hole, securing the modification material in place, machining the modification material and the airfoil to form a new fillet contour, and applying a coating over at least a portion of the airfoil. Also disclosed is the modified article.

Abstract: Methods for modifying a turbine buckets include removing at least an original outer edge for an entire length of the slash face of the turbine bucket and adding a new material to the slash face to build a new outer edge, wherein the new outer edge extends the entire length of the slash face.

Abstract: A method of locally inspecting and repairing a coated component is provided. The method includes determining an area of interest on the coated component, wherein the area of interest has little to no visible damage. The method also includes removing a coating proximate the area of interest to expose a base material of the coated component. The method further includes inspecting the area of interest for damage to the base material.

Abstract: According to one aspect, a fixture for an airfoil shroud having a first end edge, a second end edge, a leading edge, a trailing edge, a radially outer side and a radially inner side with respect to a rotor axis of a bucket having the airfoil shroud is provided. The fixture includes a base plate, a first member extending from the base plate configured to locate and abut the first end edge, a second member extending from the base plate configured to locate and abut a side of a seal rail, a third member extending from the base plate configured to locate and abut the radially outer side of the airfoil shroud and a template recess formed in the base plate proximate the first end edge to define a geometry of a relief cut in the trailing edge of the airfoil shroud.