Abstract: Methods are provided for repairing a damaged section of an air-cooled turbine blade, the blade having a first wall, a second wall, a trailing edge, and a plurality of cooling holes, the plenum formed between the first and second walls and having a predetermined shape, and the plurality of cooling holes formed on the trailing edge in flow communication with the plenum and having predetermined shapes. In one embodiment, and by way of example only, the method includes the steps of injecting a filler material into the blade plenum and the plurality of blade cooling holes, the filler material capable of solidifying into the predetermined shapes of the blade plenum and blade cooling holes. Then, the damaged section of the blade is laser welded and machined to original dimensions. Next, the filler material is removed.

Abstract: The present invention provides an apparatus for automated laser welding repairs. The apparatus is adapted for use with components of gas turbine engines such as compressor and turbine airfoils and blisks. The apparatus comprises a dual means of providing filler material. The filler material may be provided through a wire feeder. Optionally, the filler material may be provided through a powder feeder.

Abstract: The present invention provides an apparatus for repairing turbine blades of a gas turbine engine by a laser welding operation. The method uses a miniaturized laser and related apparatus. The miniaturized laser is fed through a borescope access hole to a desired location such as a high pressure turbine blade. The laser is then powered and manipulated so as to perform the desired welding operation. Filler material may also be provided in situ to accomplish the welding procedure. The method realizes a significant cost savings to the vehicle operator in that repairs can be accomplished without the need to remove the engine or disassemble the engine.

Abstract: A 3-D adaptive laser powder fusion welding system provides for both modeling/gauging of a workpiece as well as repair, restoration, and/or manufacture thereof. By providing a work platform and apparatus support system, five degrees of control in the form of two linear axes and three rotational axes are provided. The sixth linear axis is controlled via the displacement of a laser powder fusion (LPF) welding head and a laser rangefinding head. The laser rangefinding head system enables the workpiece W to be modeled electronically or otherwise. Additionally, the rangefinding system enables a model part to serve as a template from which repairs or construction are affected. The LPF welding head then affects any repairs or manufacture that are needed on the workpiece W. The LPF welding head is powered by filler material. The entire system is generally controlled by computer which enable the operator to be separated from a generally hot and hostile welding environment.

Abstract: A one-step rapid manufacturing process is used to create three dimensional prototyping parts. Material such as metal, ceramics and the like powder, and wire, and the like, is delivered to a laser beam-material interaction region where it is melted and deposited on a substrate. The melted and deposited material is placed on a XYZ workstation. Three dimensional parts are created by moving the XYZ workstation relative to the laser beam while simultaneously feeding powdered alloys, first in the XY and then in the Z plane. Beam shaping focusing optics can be used to tailor the intensity distribution of the laser beam to the requirements of the deposition layers, and can be used to create parts with desired mechanical or thermodynamic properties. Additional beam splitting and recombining optics can be used to allow powder to be fed at a perpendicular angle to the substrate.

Abstract: A one-step rapid manufacturing process is used to create three dimensional prototyping parts. Material such as metal, ceramics and the like powder, and wire, and the like, is delivered to a laser beam-material interaction region where it is melted and deposited on a substrate. The melted and deposited material is placed on a XYZ workstation. Three dimensional parts are created by moving the XYZ workstation relative to the laser beam while simultaneously feeding powdered alloys, first in the XY and then in the Z plane. Beam shaping focussing optics can be used to tailor the intensity distribution of the laser beam to the requirements of the deposition layers, and can be used to create parts with desired mechanical or thermodynamic properties. Additional beam splitting and recombining optics can be used to allow powder to be fed at a perpendicular angle to the substrate.

Abstract: A one-step rapid manufacuring process is used to create three dimensional prototyping parts. Material such as metal, ceramics and the like powder, and wire, and the like, is delivered to a laser beam-material interaction region where it is melted and deposited on a substrate. The melted and deposited material is placed on a XYZ workstation. Three dimensional parts are created by moving the XYZ workstation relative to the laser beam while simultaneously feeding powdered alloys, first in the XY and then in the Z plane. Beam shaping focussing optics can be used to tailor the intensity distribution of the laser beam to the requirements of the deposition layers, and can be used to create parts with desired mechanical or thermodynamic properties. Additional beam splitting and recombining optics can be used to allow powder to be fed at a perpendicular angle to the substrate.