Abstract: An apparatus and method are provided for an adaptive machining and weld repair process for repairing airfoils, damage to an airfoil leading edge and tip. First, damaged material is machined away from a damaged airfoil edge so as to expose a weld surface. New material is laser deposited on the weld surface so as to create a weld-repaired airfoil having actual dimensions. The actual dimensions of the weld-repaired airfoil are automatically measured using a CMM system so as to generate an actual geometry. The actual geometry is deformed so as to develop a deformation geometry. The component is then machined according to the deformation geometry.

Abstract: The present invention provides an apparatus and method for an adaptive machining and weld repair process useful for repairing airfoils, particularly damage to an airfoil leading edge and tip. The process first machines away damaged portions of an airfoil. Filler material is then added to the machined area through a process such as laser welding. At this point, the actual profile of the welded airfoil is measured using a Coordinate Measuring Machine. This data is then used to generate a “deformation” profile, an airfoil profile that approximates the ideal shape of the airfoil. The airfoil is then machined using the date of the deformation profile to produce that shape. The adaptive technology minimizes the amount of stock on material that needs to be removed by hand. The technique thereby significantly reduces costly manual processing.