Abstract: An airfoil comprises a substrate, a residual abrasive coating and a supplemental abrasive coating. The substrate extends along a tip section of the airfoil, from a leading edge to a trailing edge. The residual abrasive coating comprises a two-phase abrasive and metal matrix material bonded to the substrate, on the tip section of the airfoil. The supplemental abrasive coating comprises a two-phase abrasive and metal matrix material bonded to the residual abrasive coating and to the substrate adjacent the residual abrasive coating, on the tip section of the airfoil. The supplemental abrasive coating restores the airfoil to a nominal tip height in the tip section.

Abstract: An airfoil comprises a substrate, a residual abrasive coating and a supplemental abrasive coating. The substrate extends along a tip section of the airfoil, from a leading edge to a trailing edge. The residual abrasive coating comprises a two-phase abrasive and metal matrix material bonded to the substrate, on the tip section of the airfoil. The supplemental abrasive coating comprises a two-phase abrasive and metal matrix material bonded to the residual abrasive coating and to the substrate adjacent the residual abrasive coating, on the tip section of the airfoil. The supplemental abrasive coating restores the airfoil to a nominal tip height in the tip section.

Abstract: A method for a repair process includes the steps of subjecting a substrate coated with at least one protective metallic coating to a nitric acid solution and then subjecting the substrate with the at least one protective metallic coating to a hydrochloric acid solution to remove the at least one protective metallic coating from the substrate. The substrate includes about 5 wt %-15 wt % chromium, about 2 wt %-8 wt % cobalt, about 2 wt %-6 wt % tungsten, about 0.5 wt %-2.5 wt % titanium, about 8 wt %-16 wt % tantalum, about 2 wt %-8 wt % aluminum, hafnium in an amount no greater than 1 wt %, and a remainder of nickel.

Abstract: A method for a repair process includes the steps of subjecting a substrate coated with at least one protective metallic coating to a nitric acid solution and then subjecting the substrate with the at least one protective metallic coating to a hydrochloric acid solution to remove the at least one protective metallic coating from the substrate. The substrate includes about 5 wt %-15 wt % chromium, about 2 wt %-8 wt % cobalt, about 2 wt %-6 wt % tungsten, about 0.5 wt %-2.5 wt % titanium, about 8 wt %-16 wt % tantalum, about 2 wt %-8 wt % aluminum, hafnium in an amount no greater than 1 wt %, and a remainder of nickel.

Abstract: A method for repairing defects in a gas turbine component that comprises a substrate and an existing coating on the substrate. The article includes cooling holes having a predetermined air flow requirement and an outer shaped portion and an inner metering portion. The method comprises removing the existing coating and recoating the surface of the article with a nonoriginal coating. After the nonoriginal coating is applied onto the component, the cooling holes that meet a predetermined inspection criteria are reworked to remove the excess nonoriginal coating deposited in the outer shaped portion of the cooling holes. The reworking is done by receiving an electrode, having only a shaped portion with a preselected shape, in the outer shaped portion of the cooling holes thus restoring the cooling holes to the predetermined air flow requirement.

Abstract: Foreign material is dislodged from a hard to reach region of an object by passing a rigid elongated tubular guide in close proximity to the hard to reach region. The upper tip of the guide is bent so that it can be directed at the hard to reach region and a wire is passed through the guide into the hard to reach region. The lower portion of the wire that extends outwardly from the bottom of the guide and the wire is rotated at a speed sufficient to dislodge unwanted foreign material from the hard to reach region.

Abstract: The present invention relates to a method and a device for cleaning internal passageways within a component, such as a component to be used in an engine. The device for cleaning the internal passageway includes a first probe having a longitudinal axis and at least one nozzle oriented at an angle, preferably perpendicular, to the longitudinal axis. In a preferred embodiment, the first probe has two nozzles, both oriented perpendicular to the longitudinal axis, and offset 180 degrees from each other. The device further includes a second probe having a longitudinal axis and a nozzle in a tip end, which nozzle is oriented along the longitudinal axis. Preferably, the first and second probes are connected to a common manifold.

Abstract: The present invention relates to a method and a device for cleaning internal passageways within a component, such as a component to be used in an engine. The device for cleaning the internal passageway includes a first probe having a longitudinal axis and at least one nozzle oriented at an angle, preferably perpendicular, to the longitudinal axis. In a preferred embodiment, the first probe has two nozzles, both oriented perpendicular to the longitudinal axis, and offset 180 degrees from each other. The device further includes a second probe having a longitudinal axis and a nozzle in a tip end, which nozzle is oriented along the longitudinal axis. Preferably, the first and second probes are connected to a common manifold.

Abstract: The present invention relates to a method for repairing turbine engine components, such as vanes and blades, which have airfoils. The method broadly comprises removing oxidation debris from portions of the component by blending areas exhibiting thermal barrier coating spall and/or oxidation damage, removing a ceramic insulating layer from the component, and blending surfaces of the component where nicks, dents, and/or cracks are located. If the component has a depleted aluminum zone, the depleted zone is either removed or replenished. Further, a tip portion of the component, if damaged, is restored and tip abrasives are applied to restore the component's cutting ability. Thereafter, a ceramic coating is applied to the component.

Abstract: The present invention relates to a method and a device for cleaning internal passageways within a component, such as a component to be used in an engine. The device for cleaning the internal passageway includes a first probe having a longitudinal axis and at least one nozzle oriented at an angle, preferably perpendicular, to the longitudinal axis. In a preferred embodiment, the first probe has two nozzles, both oriented perpendicular to the longitudinal axis, and offset 180 degrees from each other. The device further includes a second probe having a longitudinal axis and a nozzle in a tip end, which nozzle is oriented along the longitudinal axis. Preferably, the first and second probes are connected to a common manifold.

Abstract: The present invention relates to a method for repairing turbine engine components, such as vanes and blades, which have airfoils. The method broadly comprises removing oxidation debris from portions of the component by blending areas exhibiting thermal barrier coating spall and/or oxidation damage, removing a ceramic insulating layer from the component, and blending surfaces of the component where nicks, dents, and/or cracks are located. If the component has a depleted aluminum zone, the depleted zone is either removed or replenished. Further, a tip portion of the component, if damaged, is restored and tip abrasives are applied to restore the component's cutting ability. Thereafter, a ceramic coating is applied to the component.

Abstract: A method for repairing defects in a gas turbine component that comprises a substrate and an existing coating on the substrate. The article includes cooling holes having a predetermined air flow requirement and an outer shaped portion and an inner metering portion. The method comprises removing the existing coating and recoating the surface of the article with a nonoriginal coating. After the nonoriginal coating is applied onto the component, the cooling holes that meet a predetermined inspection criteria are reworked to remove the excess nonoriginal coating deposited in the outer shaped portion of the cooling holes. The reworking is done by receiving an electrode, having only a shaped portion with a preselected shape, in the outer shaped portion of the cooling holes thus restoring the cooling holes to the predetermined air flow requirement.

Abstract: A method for preparing a protectively coated, apertured article to be recoated reduces the likelihood that the apertures will become constricted as a consequence of subsequent recoating. The invention, described in the context of a gas turbine engine blade (12) having transpiration cooling passages (34), includes the step of diffusing an auxiliary coating (52) into an existing coating (28) and into the exposed substrate material (26) at the periphery of the passages to form a diffusion zone (54). The blade is then subjected to a stripping agent so that the diffusion zone (54) any undiffused existing coating, and any undiffused auxiliary coating are removed. The method causes a compensatory enlargement of the mouth (44) of each passage so that excess coating that accumulates in the passage mouths during subsequent recoating does not restrict the flow capacity of the passages.

Abstract: A method for preparing a protectively coated, apertured article to be recoated reduces the likelihood that the apertures will become constricted as a consequence of subsequent recoating. The invention, described in the context of a gas turbine engine blade (12) having transpiration cooling passages (34), includes the step of diffusing an auxiliary coating (52) into an existing coating (28) and into the exposed substrate material (26) at the periphery of the passages to form a diffusion zone (54). The blade is then subjected to a stripping agent so that the diffusion zone (54) any undiffused existing coating, and any undiffused auxiliary coating are removed. The method causes a compensatory enlargement of the mouth (44) of each passage so that excess coating that accumulates in the passage mouths during subsequent recoating does not restrict the flow capacity of the passages.

Abstract: A repair coating for superalloy articles, such as gas turbine engine components, includes a volatile organic carrier or water-based carrier, a fluxing agent, a thickening agent, balance a filler mix. The filler mix consists of at least two distinct particulate components. The mix includes a first particulate component having a composition which approximates that of the article being repaired. The mix also includes a second particulate component having a composition approximating that of the article and a melting point depressant, such as boron. This melting point depressant is substantially in excess of that in the article and sufficient to provide melting of a portion of the mix at a processing temperature below the melting temperature of the article. The above filler mix is blended with the other constituents to form the repair coating which is applied to an article.

Abstract: A process for closing cooling holes of an airfoil includes the steps of providing an airfoil having a plurality of cooling holes, closing desired holes of said plurality of cooling holes by applying an ultraviolet curable material over the holes.

Abstract: A cleaning method for gas turbine engine airfoils includes a step of immersing an ultrasonic agitator, such as a welding horn, into a tank with a cleaning solution and a step of directing the ultrasonic agitator onto the portion of the airfoil having the crust layer. A subsequent step of high pressure water jet spray removes the crust debris. The cleaning method of the present invention significantly increases the power density of the ultrasonic cleaning.

Abstract: A repair coating for superalloy articles, such as gas turbine engine components, includes a volatile organic carrier or water-based carrier, a fluxing agent, a thickening agent, balance a filler mix. The filler mix consists of at least two distinct particulate components. The mix includes a first particulate component having a composition which approximates that of the article being repaired. The mix also includes a second particulate component having a composition approximating that of the article and a melting point depressant, such as boron. This melting point depressant is substantially in excess of that in the article and sufficient to provide melting of a portion of the mix at a processing temperature below the melting temperature of the article. The above filler mix is blended with the other constituents to form the repair coating which is applied to an article.

Abstract: A method for removing a predetermined amount of material from the inner surface of a circular article which deviates from a true circular configuration. The outer surface of the article is touch probed to determine its true location in space, and the data are stored in a computer memory. These data are then compared to engineering design data to establish the location of the surface to which material removal is desired. A control computer compares the measured data with the design data, and sends commands to the machine control system, causing the machine to remove the excess material down to the desired dimension. Any deviations from circular are compensated for by moving the article radially relative to the cutting tool as the article moves circumferentially relative to the cutting tool.

Abstract: A procedure is described for the repair of gas turbine engine turbine components which involves the repair of cracks and other defects and the replacement of worn or eroded material followed by the laser melting of a thin layer of metal on the surface of the component in those areas requiring reconfiguration to return to the original dimensions. The reconfiguration by laser melting is also useful for new articles which are out of tolerance, and generally for shaping objects from metal sheet or plate.