Abstract: A method of repairing an integrally bladed rotor (IBR) may comprise: performing a vibratory analysis of a rotor module including a first inspected IBR with a potential repair shape for the IBR; determining an undesirable vibratory characteristic of a second inspected IBR in the rotor module; iterating the potential repair shape for the first IBR to eliminate the undesirable vibratory characteristic of the second inspected IBR; and repairing the first IBR with a selected repair shape based on determining the potential repair shape eliminates the undesirable vibratory characteristic.

Abstract: A method comprises: flowing a potted component in a liquid state over a tip of an airfoil, the tip of the airfoil having a coating disposed thereon, the coating comprising a metal plating and a plurality of protrusions, each protrusion in the plurality of protrusions extending from the metal plating; allowing the potted component to harden to form a hardened potted component; and removing the hardened potted component from the tip of the airfoil.

Abstract: A method can comprise: scanning a tip of an airfoil of a bladed rotor, the tip including a coating disposed thereon, the coating comprising a metal plating and a plurality of protrusions, each protrusion in the plurality of protrusions extending from the metal plating; comparing a coating parameter of the coating to a coating parameter threshold based on scanner data from the scanning; and determining whether the coating maintains sufficient coverage of the tip of the airfoil based on the comparing.

Abstract: A method can comprise: receiving an inspection data corresponding to a geometry of an inspected bladed rotor; performing a baseline evaluation based on the inspection data; determining a plurality of candidate repair profiles for a defect of the inspected bladed rotor; performing an updated evaluation for each candidate repair profile in the plurality of candidate repair profiles; selecting a selected candidate repair profile in the plurality of candidate repair profiles based on the updated evaluation for each candidate repair profile in the plurality of candidate repair profiles; and performing a repair based on the selected candidate repair profile.

Abstract: A method can comprise: determining, via a processor, whether serviceable limits are met for an inspected bladed rotor; generating, via the processor, a three-dimensional model including a repair blend profile for a defect in response to determining the inspected bladed rotor does not meet the serviceable limits; performing, via the processor, a first set of simulations on the three-dimensional model; determining, via the processor, whether a first set of results of the first set of simulations meet an experience based criteria; performing, via the processor, a second set of simulations on the three-dimensional model in response to a first result in the first set of results not meeting a first objective parameter in the experience based criteria; and determining, via the processor, whether a second set of results and the first set of results meet a deterministic criteria.

Abstract: A method can comprise receiving, via the processor, one of a point cloud and a three-dimensional model for an inspected integrally bladed rotor (IBR) and a defect including a defect shape, a defect size, and a defect location; performing, via the processor, a simulation of a rotor module in a gas turbine engine, the rotor module including the inspected IBR with a potential repaired defect; determining, via the processor, the potential repaired defect would produce an estimated life less than a design life for the inspected IBR; determining, via the processor, the estimated life would exceed a remaining life threshold for the inspected IBR; and generating, via the processor, a repair process for the potential repaired defect.

Abstract: A method of determining a repair method for a defect in a bladed rotor can comprise comparing the defect in a three-dimensional model of an inspected integrally bladed rotor (IBR) to a plurality of known defects from a repair database; determining the defect is matching a known defect in the plurality of known defects in the repair database; and generating a repair process associated with the known defect in response to determining the defect is matching the known defect. A method can also comprise determining a potential repair process; performing a structural simulation of a finite element model for the inspected IBR with the potential repair; performing an aerodynamic simulation of an aerodynamic model for the inspected IBR with the potential repair; and generating the potential repair process for the defect in response to determining the inspected IBR with the potential repair meets structural and the aerodynamic criteria.

Abstract: A method of repairing an integrally bladed rotor (IBR) may comprise: performing a vibratory analysis of a rotor module including a first inspected IBR with a potential repair shape for the IBR; determining an undesirable vibratory characteristic of a second inspected IBR in the rotor module; iterating the potential repair shape for the first IBR to eliminate the undesirable vibratory characteristic of the second inspected IBR; and repairing the first IBR with a selected repair shape based on determining the potential repair shape eliminates the undesirable vibratory characteristic.

Abstract: A method can comprise: determining a plurality of potential repair processes for the stack of IBRs, each repair process associated with a defect on an inspected IBR; generating a finite element model of the stack of IBRs with a potential repaired defect of each inspected IBR being modeled, a plurality of vane stages disposed between adjacent inspected IBRs, and an engine case; performing a structural analysis and an aerodynamic analysis; determining whether the stack of IBRs with the potential repaired defect of each inspected IBR meets a structural criteria and an aerodynamic criteria; and repairing each IBR in the stack of IBRs with the repair process for the potential repaired defect for each inspected IBR in the stack of IBRs in response to determining the stack of IBRs meets the structural criteria and the aerodynamic criteria.

Abstract: An article of manufacture may include a tangible, non-transitory computer-readable storage medium having instructions stored thereon that, in response to execution by a processor, cause the processor to perform operations comprising: commanding, via the processor, a first scan of a bladed rotor; generating, via the processor, a three-dimensional model based on a first set of data received from a first scanner; comparing, via the processor, the three-dimensional model to an acceptable three-dimensional model of the bladed rotor; determining, via the processor, areas of interest based on the comparison; and commanding, via the processor, a contact probe to perform a non-destructive inspection on the areas of interest.

Abstract: An article of manufacture may include a tangible, non-transitory computer-readable storage medium having instructions stored thereon that, in response to execution by a processor, cause the processor to perform operations comprising: commanding, via the processor, a first scan of a bladed rotor; generating, via the processor, a three-dimensional model based on a first set of data received from the first scan; comparing, via the processor, the three-dimensional model to an acceptable three-dimensional model of the bladed rotor; determining, via the processor, areas of interest based on the comparison; commanding, via the processor, a second scan of the areas of interest of the bladed rotor; and generating a final three-dimensional model based on the first scan and the second scan.

Abstract: A method comprises: flowing a potted component in a liquid state over a tip of an airfoil, the tip of the airfoil having a coating disposed thereon, the coating comprising a metal plating and a plurality of protrusions, each protrusion in the plurality of protrusions extending from the metal plating; allowing the potted component to harden to form a hardened potted component; and removing the hardened potted component from the tip of the airfoil.

Abstract: A process for repairing an aircraft engine component includes receiving a plurality of component measurements of a damaged component, comparing the plurality of component measurements of the damaged component to a finite element model of an ideal component, generating a finite element model of the damaged component based at least partially on the comparison, determining a corrective material removal operation based at least in part on the finite element model of the damaged component, and removing material from the damaged component according to the corrective material removal operation, thereby creating a repaired component.

Abstract: A bushing including a body portion including a cylinder portion having a bore there through configured to receive a bolt; a flange portion orthogonal and integral to the cylinder portion, the flange portion configured to abut a load bearing surface of a flange; a lip portion orthogonal to and integral to the flange portion proximate the cylinder portion, wherein the lip portion redistributes a flange load.

Abstract: A process for repairing an aircraft engine component includes receiving a plurality of component measurements of a damaged component, comparing the plurality of component measurements of the damaged component to a finite element model of an ideal component, generating a finite element model of the damaged component based at least partially on the comparison, determining a corrective material removal operation based at least in part on the finite element model of the damaged component, and removing material from the damaged component according to the corrective material removal operation, thereby creating a repaired component.

Abstract: A bushing including a body portion including a cylinder portion having a bore there through configured to receive a bolt; a flange portion orthogonal and integral to the cylinder portion, the flange portion configured to abut a load bearing surface of a flange; a lip portion orthogonal to and integral to the flange portion proximate the cylinder portion, wherein the lip portion redistributes a flange load.

Abstract: A bushing including a body portion including a cylinder portion having a bore there through configured to receive a bolt; a flange portion orthogonal and integral to the cylinder portion, the flange portion configured to abut a load bearing surface of a flange; a lip portion orthogonal to and integral to the flange portion proximate the cylinder portion, wherein the lip portion redistributes a flange load.

Abstract: A bracket assembly for a gas turbine engine includes a bracket base with a separation between a first bended feature and a second bended feature. A doubler is mechanically fastened adjacent to the separation. Another bracket assembly for a gas turbine engine includes a bracket base with a separation between a first bended feature and a second bended feature. A cushioned tube support is welded to the bracket base. A doubler is mechanically fastened adjacent to the separation. A method of assembling a bracket assembly for a gas turbine engine includes mechanically fastening a doubler to a bracket base adjacent to a separation between a first bended feature and a second bended feature.

Abstract: A case for a gas turbine engine incudes a radial flange with a partial scallop along an inner diameter of the radial flange. A case assembly for a gas turbine engine incudes a first case with a first radial flange with a partial scallop along an inner diameter of the first radial flange, the partial scallop adjacent to a first aperture through the first radial flange and a second case with a second radial flange with a second aperture through the second radial flange, the second radial flange mountable to the first radial flange at an interface such that the second aperture is axially aligned with the first aperture and a seal lip that extends from the second case interfaces with said first case at a longitudinal interface.

Abstract: A component of a gas turbine engine includes a plurality of first cooling holes extending between an outer surface and an inner surface of the component, the plurality of first cooling holes being filled with a filling agent, the filling agent being cured to solid form to block the flow of cooling fluid though the plurality of first cooling holes; a thermal barrier coating over the outer surface of the component and completely covering the cured filling agent; and a plurality of second cooling holes penetrating the thermal barrier coating and extending between the outer surface and the inner surface, the plurality of second cooling holes allowing cooling fluid to pass therethrough.