Abstract: A multi-component braze filler alloy comprising at least 70% by weight MarM509A superalloy with the remainder MarM509B superalloy is diffusion brazed to a CM247 alloy base substrate, such as a gas turbine blade or vane. It is shown that generally higher braze temperatures lead to improved results including the possibility of re-welding such a brazed component, resulting in a re-repaired brazed component capable of continued commercial service.

Abstract: A multi-component braze filler alloy comprising 60-70% by weight CM247 superalloy and BRB braze alloy is diffusion brazed to a CM247 alloy base substrate, such as a gas turbine blade or vane. The substrate/braze interface may be subsequently weld-repaired without de-melting and migrating the braze alloy from the interface. The weld zone and surrounding area are solidification crack resistant. After the alloy composition is brazed to the base substrate the component may be returned to service. Thereafter the component remains repairable by welding or re-brazing, if needed to correct future in-service defects.

Abstract: A multi-component braze filler alloy comprising at least 70% by weight MarM509A superalloy with the remainder MarM509B superalloy is diffusion brazed to a CM247 alloy base substrate, such as a gas turbine blade or vane. It is shown that generally higher braze temperatures lead to improved results including the possibility of re-welding such a brazed component, resulting in a re-repaired brazed component capable of continued commercial service.

Abstract: A multi-component braze filler alloy comprising 60-70% by weight CM247 superalloy and BRB braze alloy is diffusion brazed to a CM247 alloy base substrate, such as a gas turbine blade or vane. The substrate/braze interface may be subsequently weld-repaired without de-melting and migrating the braze alloy from the interface. The weld zone and surrounding area are solidification crack resistant. After the alloy composition is brazed to the base substrate the component may be returned to service. Thereafter the component remains repairable by welding or re-brazing, if needed to correct future in-service defects.

Abstract: A method of repairing a turbine blade having a radially extending outer wall defining an internal cavity width and a blade tip. The method comprises removing at least a portion of the blade tip to form a repair surface and providing a tip cap having a radially outer side with an outer width that may be less than the internal cavity width, and having a radially inner side with an inner width that is substantially equal to or greater than the internal cavity width. The tip cap is positioned at the repair surface, and the tip cap is welded to the repair surface using a ductile welding material. A cap peripheral portion is formed by build-up welding around the tip cap, and a squealer portion is formed by build-up welding on the cap peripheral portion.

Abstract: A method of build-up welding including depositing of a weld material on a substrate in a series of weld passes in side-by-side relation to form a first weld layer, wherein substantially all weld passes forming the first weld layer are deposited in a first pass direction. Subsequently, a series of weld passes are deposited in side-by-side relation on the first layer to form a second weld layer, wherein substantially all weld passes forming the second weld layer are deposited in a second pass direction opposite to the first pass direction. Each weld pass of each layer may be deposited at a location where it is restrained on no more than one lateral side extending parallel to the weld pass.

Abstract: A method of servicing an airfoil for use in a gas turbine engine. The airfoil assembly is defined by a base material and includes an airfoil and a platform from which the airfoil extends. A predetermined amount of the base material is removed from the airfoil assembly proximate to a fillet area of the airfoil assembly via water jet material removal. The fillet area comprises a junction between the airfoil and the platform and is located at an intersection between the airfoil and the platform. A remainder of the base material comprising base material of the airfoil assembly other than proximate to the fillet area is left intact.

Abstract: A waterjet ablation process is performed to remove a volume of material from a service area of a component, the volume of material including at least one defect and any oxides and contaminants located at the service area. After performing the waterjet ablation process, the service area of the component is repaired by a welding or brazing process to restore material to the service area. The component is put into service in an engine without requiring affixation of a replacement coupon to the component.

Abstract: A multi-component braze filler alloy comprising 60-70% by weight CM247 superalloy and BRB braze alloy is diffusion brazed to a CM247 alloy base substrate, such as a gas turbine blade or vane. The substrate/braze interface may be subsequently weld-repaired without de-melting and migrating the braze alloy from the interface. The weld zone and surrounding area are solidification crack resistant. After the alloy composition is brazed to the base substrate the component may be returned to service. Thereafter the component remains repairable by welding or re-brazing, if needed to correct future in-service defects.

Abstract: A multi-component braze filler alloy comprising at least 70% by weight MarM509A superalloy with the remainder MarM509B superalloy is diffusion brazed to a CM247 alloy base substrate, such as a gas turbine blade or vane. It is shown that generally higher braze temperatures lead to improved results including the possibility of re-welding such a brazed component, resulting in a re-repaired brazed component capable of continued commercial service.

Abstract: A method of repairing a turbine blade having a radially extending outer wall defining an internal cavity width and a blade tip. The method comprises removing at least a portion of the blade tip to form a repair surface and providing a tip cap having a radially outer side with an outer width that may be less than the internal cavity width, and having a radially inner side with an inner width that is substantially equal to or greater than the internal cavity width. The tip cap is positioned at the repair surface, and the tip cap is welded to the repair surface using a ductile welding material. A cap peripheral portion is formed by build-up welding around the tip cap, and a squealer portion is formed by build-up welding on the cap peripheral portion.

Abstract: A method of build-up welding including depositing of a weld material on a substrate in a series of weld passes in side-by-side relation to form a first weld layer, wherein substantially all weld passes forming the first weld layer are deposited in a first pass direction. Subsequently, a series of weld passes are deposited in side-by-side relation on the first layer to form a second weld layer, wherein substantially all weld passes forming the second weld layer are deposited in a second pass direction opposite to the first pass direction. Each weld pass of each layer may be deposited at a location where it is restrained on no more than one lateral side extending parallel to the weld pass.

Abstract: A method of servicing an airfoil for use in a gas turbine engine. The airfoil assembly is defined by a base material and includes an airfoil and a platform from which the airfoil extends. A predetermined amount of the base material is removed from the airfoil assembly proximate to a fillet area of the airfoil assembly via water jet material removal. The fillet area comprises a junction between the airfoil and the platform and is located at an intersection between the airfoil and the platform. A remainder of the base material comprising base material of the airfoil assembly other than proximate to the fillet area is left intact.

Abstract: A friction stir welding method including: feeding a filler material through a first passage in a friction stir weld tool and into a substrate during friction stir welding of the substrate; and rotating the filler material with respect to the substrate while feeding the filler material. In this method, heat generated by rotational frictional contact of the filler material contributes to plasticization of the filler material.

Abstract: A friction stir welding method including: feeding a filler material through a first passage in a friction stir weld tool and into a substrate during friction stir welding of the substrate; and rotating the filler material with respect to the substrate while feeding the filler material. In this method, heat generated by rotational frictional contact of the filler material contributes to plasticization of the filler material.