Abstract: A method of forming a component includes mixing a powdered base material and a binder to define a mixture, forming the mixture into a desired shape without melting the base material, removing the binder from the desired shape to define a skeleton, the volume of the skeleton being between 80 percent and 95 percent base material, and infiltrating the skeleton with a melting point depressant material to define a finished component, the finished component having less than one percent porosity by volume.

Abstract: A blade for a gas turbine includes a removed portion space, and further includes an airfoil portion defining the removed portion space, the airfoil portion formed from a base material, and a replacement component formed to fill the removed portion space. The replacement component is formed from a material that includes 50%-80% base material, 0%-30% braze material, and 0%-8% aluminum. A braze joint is formed between the airfoil portion and the replacement component to attach the replacement component to the airfoil portion and fill the removed portion space.

Abstract: A blade for a gas turbine includes a removed portion space, and further includes an airfoil portion defining the removed portion space, the airfoil portion formed from a base material, and a replacement component formed to fill the removed portion space. The replacement component is formed from a material that includes 50%-80% base material, 0%-30% braze material, and 0%-8% aluminum. A braze joint is formed between the airfoil portion and the replacement component to attach the replacement component to the airfoil portion and fill the removed portion space.

Abstract: A method of forming a component includes mixing a powdered base material and a binder to define a mixture, forming the mixture into a desired shape without melting the base material, removing the binder from the desired shape to define a skeleton, the volume of the skeleton being between 80 percent and 95 percent base material, and infiltrating the skeleton with a melting point depressant material to define a finished component, the finished component having less than one percent porosity by volume.

Abstract: A method (50) of installing a tip cap (42) onto a turbine blade (20). An open tip is prepared (52) by removing a tip cap from a used blade or during original blade manufacture. A tip cap base sheet (24) is formed (54) to cover at least most of the blade tip surface except for a margin (22). A root pass weld (28) is performed (58) around the periphery of the base sheet, thus welding the base sheet onto the blade tip surface. Cladding (34) is applied (60) to the base sheet and the blade tip surface, thus building and fusing the tip cap onto the blade tip, the tip cap formed of cladding and the base sheet. A squealer ridge (44) may then be formed on the tip cap by additive welding.