Abstract: A method for repairing a stationary turbine nozzle segment having at least one vane disposed between outer and inner structural bands includes providing an engine-run turbine nozzle segment having at least one vane disposed between outer and inner bands, wherein the outer band and the vanes are previously replaced components of the segment and the inner band is an original component of the segment; separating the inner band from the nozzle segment; repairing damage in the outer band and/or the vane; and joining the outer band and the vane to a newly manufactured replacement inner band segment. The replacement inner band segment includes: a structural inner band; and an integral structural collar adapted to receive an inner end of the at least one vane.

Abstract: A method for repairing a turbine nozzle segment having at least two vanes disposed between outer and inner bands includes the steps of separating the nozzle segment into a first singlet containing a repairable vane and a second singlet containing a non-repairable vane, and joining the first singlet to a newly manufactured singlet having a configuration that is similar to the second singlet.

Abstract: An assembly and method for welding an article, such as an air-cooled superalloy airfoil of a gas turbine engine nozzle. The method entails inserting a fixture into a cooling passage of the airfoil. The fixture is configured to close a first opening to the passage through which the fixture is inserted into the passage. The fixture is also configured to introduce a gas into the passage through a longitudinal row of ports. A through-wall crack in the airfoil is weld repaired while the gas flow is maintained to the cavity at a rate that sufficiently pressurizes the passage to prevent the molten filler material from entering the passage through the crack, while allowing the filler material to fill the crack.