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 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 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 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).

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.