Abstract: A method to repair a turbomachine including: assign blades and a shroud in a row of the turbomachine to a group; measure, for each blade in the group, a clearance between a tip surface of the blade and a surface of the shroud facing the tip surface; remove the blades and shroud from the row; calculate a difference between the clearance of associated each blade and a design clearance; determine, for each blade, if the difference may be minimized by adding material to the surface of the shroud; adding material to the surface of the shroud, wherein the addition of material to the facing surfaces results in the shroud having at least one dimension that exceeds an original design dimension of the shroud sections, and installing the group of the blades and the shroud with the added material to a row of a turbomachine, wherein at least one of the blades has at least one dimension that does not conform to an original design specification for the blade.

Abstract: A method to repair a turbomachine including: assign blades and a shroud in a row of the turbomachine to a group; measure, for each blade in the group, a clearance between a tip surface of the blade and a surface of the shroud facing the tip surface; remove the blades and shroud from the row; calculate a difference between the clearance of associated each blade and a design clearance; determine, for each blade, if the difference may be minimized by adding material to the surface of the shroud; adding material to the surface of the shroud, wherein the addition of material to the facing surfaces results in the shroud having at least one dimension that exceeds an original design dimension of the shroud sections, and installing the group of the blades and the shroud with the added material to a row of a turbomachine, wherein at least one of the blades has at least one dimension that does not conform to an original design specification for the blade.

Abstract: Various aspects include a composite turbomachine component and related methods. In some cases, a method includes: identifying a location of potential or actual structural weakness in a body of a turbomachine component, the body including a first material having a first thermal expansion coefficient; forming a slot in the location of the body, the slot extending at least partially through a wall of the turbomachine component; and bonding an insert to the body at the slot to form a composite component, the insert including a second material having a second thermal expansion coefficient differing from the first thermal expansion coefficient by up to approximately ten percent, the second material consisting of a nickel-chromium-molybdenum alloy, wherein after the bonding the insert is configured to reduce the potential or actual structural weakness in the body.

Abstract: A process of treating a component includes mechanically removing surface debris from a base coating of the component, identifying at least one surface feature in the base coating, and applying an overlay coating layer over the surface feature of the base coating without stripping off the base coating. A process of treating a gas turbine component includes mechanically removing surface debris from a base coating of the gas turbine component, identifying at least one surface feature in the base coating of corrosion pits, dents, spalls, and combinations thereof, and applying an overlay coating layer over the surface feature of the base coating without stripping off the base coating. A treated gas turbine component includes a gas turbine component substrate and a base coating on the gas turbine component substrate having at least one healed surface feature. The healed surface feature includes an overlay coating layer on the base coating.