Abstract: An additive manufactured (AM) metal coupon for a turbomachine component is provided. The component includes an airfoil body having a pressure side, a suction side, a trailing edge, and a coupon opening. The AM metal coupon has an AM metal member with at least one slanted coupon side wall at an angle of less than 90° with an exterior surface of the AM metal member. The AM metal member also has a first porous region having a first porosity and a second porous region having a second porosity different than the first porosity. A braze material couples the AM metal coupon in the coupon opening in the airfoil body and infiltrates into at least one of the first porous region based at least on a characteristic of the first porosity and the second porous region based at least on a characteristic of the second porosity.

Abstract: A component includes a body and an additively manufactured (AM) metal coupon that includes at least one first porous region having a first porosity and may include any number of second porous regions having a second porosity different than the first porosity. A braze material couples the metal coupon in a coupon opening in the body. The braze material infiltrates into at least one of the first porous region based at least on a characteristic of the first porosity or any second porous region based at least on a characteristic of the second porosity. The different porosities can be customized to provide the first porous region and the second porous region with the braze material therein with different physical characteristic(s).

Abstract: A tool for removing a coating from an interior surface of a component. The tool includes a rotary device; a grinding attachment attached to the rotary device; a tool holder configured to: set an axial position of the grinding attachment coupled to the rotary device over the coating on the interior surface of the component; and set a radial position of the grinding attachment coupled to the rotary device, the radial position defining a cutting depth of the grinding attachment into the coating on the interior surface of the component; and a wheel assembly coupled to the tool holder for guiding the tool holder about an interior perimeter of the component.

Abstract: A method of repairing a superalloy component includes subjecting the superalloy component, including a repair area, to a phase agglomeration cycle, which includes stepped heating and controlled cooling of the component. The method further includes applying weld material to the repair area to create a weld surface; and covering the weld surface with brazing material. The component is then subjected to a braze cycle to produce a brazed component. The brazed component is cleaned, and the cleaned component is subjected to a restorative heat treatment to restore the microcrystalline structure and mechanical properties of the component.

Abstract: A method of brazing a treatment area of a load-bearing component includes applying a repair material over the treatment area of the component and positioning an induction brazing coil having a geometry corresponding to the treatment area over the repair material and the treatment area. The method further includes heating the repair material utilizing the induction brazing coil to a temperature sufficient to cause at least partial melting of the repair material, thereby effecting a brazed joint between the treatment area and the repair material.

Abstract: A method for treating a turbine diaphragm and a treated turbine diaphragm are provided. The method includes the step of removing a portion of the turbine diaphragm. The method further includes the step of forming a coupon having a geometry that corresponds to the portion of the turbine diaphragm removed. The method further includes joining the coupon to the turbine diaphragm. At least a portion of the coupon is a pre-sintered preform. The treated turbine diaphragm includes a substrate and a coupon joined to the substrate, wherein at least a portion of the coupon is a pre-sintered preform.

Abstract: A method of repairing a superalloy component includes subjecting the superalloy component, including a repair area, to a phase agglomeration cycle, which includes stepped heating and controlled cooling of the component. The method further includes applying weld material to the repair area to create a weld surface; and covering the weld surface with brazing material. The component is then subjected to a braze cycle to produce a brazed component. The brazed component is cleaned, and the cleaned component is subjected to a restorative heat treatment to restore the microcrystalline structure and mechanical properties of the component.

Abstract: A method of welding a superalloy component includes the following sequential steps. A welding step for welding a cavity using a filler metal in an inert atmosphere, where the cavity is located in the component. A covering step for covering the filler metal and a portion of the component with a weld filler layer in the inert atmosphere. The weld filler layer has a greater ductility than material comprising the component and/or material comprising the filler metal. A second covering step for covering the weld filler layer with a braze material, and subsequently performing a brazing operation. A heat treating step heat treats the component.

Abstract: A method of welding a superalloy component includes the following sequential steps. A welding step for welding a cavity using a filler metal in an inert atmosphere, where the cavity is located in the component. A covering step for covering the filler metal and a portion of the component with a weld filler layer in the inert atmosphere. The weld filler layer has a greater ductility than material comprising the component and/or material comprising the filler metal. A second covering step for covering the weld filler layer with a braze material, and subsequently performing a brazing operation. A heat treating step heat treats the component.

Abstract: A method for treating a turbine diaphragm and a treated turbine diaphragm are provided. The method includes the step of removing a portion of the turbine diaphragm. The method further includes the step of forming a coupon having a geometry that corresponds to the portion of the turbine diaphragm removed. The method further includes joining the coupon to the turbine diaphragm. At least a portion of the coupon is a pre-sintered preform. The treated turbine diaphragm includes a substrate and a coupon joined to the substrate, wherein at least a portion of the coupon is a pre-sintered preform.

Abstract: A method of brazing a treatment area of a load-bearing component includes applying a repair material over the treatment area of the component and positioning an induction brazing coil having a geometry corresponding to the treatment area over the repair material and the treatment area. The method further includes heating the repair material utilizing the induction brazing coil to a temperature sufficient to cause at least partial melting of the repair material, thereby effecting a brazed joint between the treatment area and the repair material.

Abstract: A repair patch for use with a turbine seal includes a shim having a first side and an opposite second side and a cloth seal having a first section and a second section. The cloth seal is coupled to the shim, such that the cloth seal is folded over a radial edge of the shim such that the first section substantially covers the first side and the second section substantially covers the second side. The second section includes an extension section that extends from the second side such that at least a portion of the cloth seal overlaps at least a portion of the turbine seal when coupled thereto.

Abstract: Mechanical and electrical characteristics of individual print cartridges are determined and used to generate control information for customizing control of each individual print cartridge. One or more characteristics including nozzle heater resistance, drop mass and drop velocity for individual print cartridges are determined and used to derive offset values for widths of pulses used to drive nozzle heaters in the individual print cartridges. While all three characteristics are preferably used, any one or two may also be used. Once determined, pulsewidths or offsets from nominal pulsewidths to improve or optimize printing using the print cartridges are stored in memory devices located on the print cartridges so that printers utilizing the print cartridges can retrieve the pulsewidth or offset data and utilize it in customizing or individualizing control of the print cartridges.

Abstract: An increased resolution thermal ink jet printhead construction and method for forming large array heater chips for thermal ink jet printheads is achieved by fabricating a unitary "megachip" in which multiple cells of electrical components are defined in a plurality of columnar patterns in a plane of a silicon wafer. Cells of a first column are vertically offset from cells of an adjacent column so as to overlap the gap between cells in the first column. The megachip is then formed by grouping at least one cell from each of two adjacent columns and dicing the wafer to remove the megachip.