Abstract: A method for reconditioning a hot gas path part of a gas turbine to flexibly adapt an operation regime of said gas turbine for subsequent operation intervals. The method includes providing a hot gas path part to be reconditioned; removing a predetermined area of the hot gas path part, resulting in a cutout at the hot gas path part; and manufacturing a coupon for insertion into the cutout to replace the removed area of the hot gas path part. The method further includes inserting the coupon into the cutout; and joining the hot gas path part with the coupon. The coupon is manufactured by a selective laser melting method resulting in a fine grain sized material with significantly improved low cycle fatigue lifetime. The hot gas path part is coated, at least in an area including the inserted coupon, with a metallic overlay with improved thermo-mechanical fatigue and oxidation lifetime.

Abstract: In a method for manufacturing an article (1), particularly a prototype of a product or component, a tool prototype or spare part, by using selected laser melting, for the application onto the article (1) of a layer (13) or portion of a second metallic material, which is different from the material of the first metallic powder (4), a tape (12), sheet (14), foil or three-dimensional pre-form (18) of a second material is applied to the article (1) and is heated by a focused laser or electron beam (6) to a specified temperature such that the tape (12), sheet (14), foil or pre-form, respectively, are made molten by the electron laser beam (6), wherein the focused beam (6) is applied to a given area corresponding to a selected cross-sectional area of the model of the article (1) under formation of a new layer or part made of second material integral with the article (1).

Abstract: A blade assembly having a modular structure, wherein the blade elements include at least a rotor blade airfoil, a footboard mounting part and a heat shield. The elements each have at its one ending an interchangeable connection for connection among each other, wherein the connection of the airfoil with respect to the other elements is based on a fixation in radial or quasi-radial extension compared to the rotor axis of the turbomachine. The assembling of the blade airfoil in connection with the footboard mounting part is based on a force-fit or form-fit fixation, or on use of a metallic and/or ceramic surface for the purpose of a friction-locked bonding actuated by adherence interconnecting, or on friction-locking with a detachable, permanent or semi-permanent fixation.

Abstract: The disclosure refers to a method of assembling or disassembling a rotor blade or guide vane assembly, wherein the rotor blade or guide vane includes an airfoil and additional structured peripheral members forming at least an inner and/or an outer platform of the rotor blade or guide vane. The airfoil includes at least one airfoil sub-structure designed for anchoring at least one superposed component for the purpose of a thermal protection. The connection between the airfoil sub-structure and the superposed component is supported on friction-locked device, wherein the airfoil sub-structure is formed by a spar and the superposed component includes at least one flow-charged outer shell. Connection between the spar or airfoil understructure and flow-charged outer shell is formed by a force-fit and/or a form-fit fixation or a shrinking joint, wherein the airfoil and additional structured peripheral members is formed by friction-locked device with a detachable, permanent or semi-permanent fixation.

Abstract: Method for manufacturing a braze joint gap for connecting a first part to a second part via brazing or soldering, comprising the steps of: adding microstructural elements to a first connecting surface of the first part to be connected to the second part via brazing or soldering; aligning the second part and the first part or an electrode part having a tool contour, which is identical to the contour of the first connecting surface; electro-chemically machining or precise electro-chemically machining a second connecting surface of the second part by polarizing the first part or the electrode part as a cathode and the second part as an anode.

Abstract: The invention relates to a method for producing a three-dimensional article or at least a part of such an article made of a gamma prime (??) precipitation hardened nickel base superalloy with a high volume fraction (>25%) of gamma-prima phase which is a difficult to weld superalloy, or made of a cobalt base superalloy, or of a non-castable or difficult to machine metal material by means of selective laser melting (SLM), in which the article is produced by melting of layerwise deposited metal powder with a laser beam characterized in that the SLM processing parameters are selectively adjusted to locally tailor the microstructure and/or porosity of the produced article or a part of the article and therefore to optimize desired properties of the finalized article/part of the article.

Abstract: A method for reconditioning a hot gas path part of a gas turbine in order to flexibly adapt an operation regime of said gas turbine for subsequent operation intervals is disclosed. The method includes providing a hot gas path part to be reconditioned; removing a predetermined area of said hot gas path part, resulting in a cutout at said hot gas path part; and manufacturing a coupon for being inserted into said cutout to replace said removed area of said hot gas path part. The method further includes inserting said coupon into said cutout; and joining said hot gas path part with said inserted coupon. The coupon is manufactured by a selective laser melting (SLM) method resulting in a fine grain sized material with significantly improved low cycle fatigue (LCF) lifetime. The hot gas path part is coated, at least in an area comprising said inserted coupon, with a metallic overlay with improved thermo-mechanical fatigue (TMF) and oxidation lifetime.

Abstract: A method for repairing a gas turbine component includes: identifying on the gas turbine component (10) a worn out location, where the gas turbine component (10) is damaged; removing the damaged location, thereby creating a missing zone (18); manufacturing an insert, which fits into the missing zone (18); putting the insert into the missing zone (18); adjusting the insert in the gas turbine component (10); and joining the adjusted insert to the gas turbine component (10).

Abstract: A method for repairing or reconditioning a damaged component includes working the damaged component by removing a damaged region from the damaged component while creating a cutout corresponding to the damaged region so as to provide a worked component. The worked component is measured and a computer-aided design (CAD) model of a replacement piece based on the measuring and is configured to be inserted into the cutout of the worked component is created. The replacement piece is produced based on the CAD model. The replacement piece and the worked component are connected by joining.

Abstract: The invention relates to a method for additively manufacturing an article made of a difficult-to-weld highly-precipitation-strengthened Ni-base super alloy that comprises Al and Ti in the sum of more than 5 wt.-% or a difficult-to weld carbide/solution-strengthened cobalt (Co)-base super alloy, whereby a metal particle mixture of at least a first phase and a second phase is provided as a starting material, said first phase of the mixture being a base material and said second phase of the mixture being a material which is a derivative of the first material and has relative to said material of said first phase an improved weldability, and whereby the metal particle mixture is processed by means of an additive manufacturing process which is one of selective laser melting (SLM), selective laser sintering (SLS), electron beam melting (EBM), laser metal forming (LMF), laser engineered net shape (LENS), or direct metal deposition (DMD).

Abstract: A process produces a 3-dimensional component (16) by selective laser melting (SLM), in which the component (16) is formed on a foundation with a surface, e.g., a platform (10) or a support, which in particular is a component of the same type which has already been produced previously, by successively melting layers of a first metal powder to form a sequence of stacked layers. The process is substantially simplified and made more flexible by virtue of the fact that the separation of the finished component (16) from the surface of the platform (10) or the support thereof is simplified by providing a separating layer (11) between the component (16) and the platform (10) or the support, this separating layer making it possible to separate the finished component (16) from the platform (10) or the support without damaging the finished component (16).

Abstract: A method for repairing or reconditioning a damaged component includes working the damaged component by removing a damaged region from the damaged component while creating a cutout corresponding to the damaged region so as to provide a worked component. The worked component is measured and a computer-aided design (CAD) model of a replacement piece based on the measuring and is configured to be inserted into the cutout of the worked component is created. The replacement piece is produced based on the CAD model.

Abstract: A gas turbine engine hot gas component repair method for defects that do not extend through the thickness of the component is provided. First defects are removed by machining a cavity in the surface of a component. Coupons, fittable within the cavities are manufactured, are for example coated with brazing medium on an inner surface and then joined to the component by joining means such as laser metal forming. The joint holds the coupon during later heat treatment, thereby eliminating a need for holding aids. Before heat treatment, a further brazing medium can be applied to the surface of the coupon overlapping onto the component. A single heat treatment, brazing the coupon to the component and, brazing the brazing medium to the outer surface of the coupon can, then be used to complete the repair.

Abstract: A process produces a 3-dimensional component (16) by selective laser melting (SLM), in which the component (16) is formed on a foundation with a surface, e.g., a platform (10) or a support, which in particular is a component of the same type which has already been produced previously, by successively melting layers of a first metal powder to form a sequence of stacked layers. The process is substantially simplified and made more flexible by virtue of the fact that the separation of the finished component (16) from the surface of the platform (10) or the support thereof is simplified by providing a separating layer (11) between the component (16) and the platform (10) or the support, this separating layer making it possible to separate the finished component (16) from the platform (10) or the support without damaging the finished component (16).

Abstract: In a method for repairing and/or upgrading a component (10?), preferably of a gas turbine, especially a blade (10?), which component has been deformed during operation, a simplification with cost advantages is achieved by a first nominal CAD model (M1) of the non-deformed component (10) being made available, by the deformed component (10?) being measured, and by the first CAD-model (M1), with the aid of the data determined on the deformed component (10?), being transformed into a second CAD model (M2) of the deformed component (10?) by morphing. A cutting line, which determines a cut-out in the component (10?), and also an insert piece, which can be inserted in the cut-out, is established in the second CAD model (M2).

Abstract: A method for repairing a gas turbine component includes: identifying on the gas turbine component (10) a worn out location, where the gas turbine component (10) is damaged; removing the damaged location, thereby creating a missing zone (18); manufacturing an insert, which fits into the missing zone (18); putting the insert into the missing zone (18); adjusting the insert in the gas turbine component (10); and joining the adjusted insert to the gas turbine component (10).

Abstract: In a method for manufacturing an article (1), particularly a prototype of a product or component, a tool prototype or spare part, by using selected laser melting, for the application onto the article (1) of a layer (13) or portion of a second metallic material, which is different from the material of the first metallic powder (4), a tape (12), sheet (14), foil or three-dimensional pre-form (18) of a second material is applied to the article (1) and is heated by a focused laser or electron beam (6) to a specified temperature such that the tape (12), sheet (14), foil or pre-form, respectively, are made molten by the electron laser beam (6), wherein the focused beam (6) is applied to a given area corresponding to a selected cross-sectional area of the model of the article (1) under formation of a new layer or part made of second material integral with the article (1).

Abstract: A method for repairing an ex-service gas turbine component (10) includes the steps of: removing a damaged section (13) from the gas turbine component (10), manufacturing a 3-D article, which fits in the gas turbine component (10) to replace the removed damaged section (13), and joining the gas turbine component (10) and the 3-D article inserted therein. Reduced cost, improved flexibility and productivity, and simplified handling are achieved by removing the damaged section (13) in the form of a cut-out section along a split line (14) as one single cut-out piece (15), measuring the cut-out piece (15) to obtain the actual non-parametric geometry data set of the cut-out piece (15), and manufacturing the 3-D article based on the geometry data set of the cut-out piece (15).