Abstract: A method of cleaning airfoils and related turbine engine components that have a crust-like debris deposited on the surface thereof. This method involves subjecting at least the portion of the component having the deposit of the crust-like debris to sufficient laser shock peening to cause the debris on the surface thereof to be loosened therefrom so that the loosened debris can be removed from the component. This loosened debris can then be removed from the component, such as by passing a cleaning fluid through the portion of the component that is subjected to the laser shock peening.

Abstract: A method of cleaning airfoils and related turbine engine components that have a crust-like debris deposited on the surface thereof. This method involves subjecting at least the portion of the component having the deposit of the crust-like debris to sufficient laser shock peening to cause the debris on the surface thereof to be loosened therefrom so that the loosened debris can be removed from the component. This loosened debris can then be removed from the component, such as by passing a cleaning fluid through the portion of the component that is subjected to the laser shock peening.

Abstract: The present invention includes a method of repairing an annular metallic article and the repaired article itself which has an axially extending annular support and a projection generally radially extending therefrom. The projection has an associated operating radial height as measured from a radially facing annular first surface of the support and an associated shape. An upper portion of the projection is removed forming a stub extending away from the first surface and having a bonding surface at a stub end spaced apart from the first surface. A metallic material is metallurgically bonded to the bonding surface forming an annular heat affected zone in the stub bounded by the bonding surface. A first portion of the metallic material is removed to restore the projection to the operating height and shape. At least one annular outer surface of the tooth extending over at least a portion of the heat affected zone is laser shock peened, preferably after the first portion of the metallic material is removed.

Abstract: A crack weld repair and method, particularly, for a gas turbine engine blade or other metallic component in the engine, providing a metallic substrate, a metallic filler bonded onto a substrate bond surface on the metallic substrate, and a region having deep compressive residual stresses imparted by laser shock peening extending into the substrate beneath the substrate bond surface. One embodiment provides a laser shock peened surface below the weld material filled void in a damaged area of the component forming a region of deep compressive residual stresses imparted by laser shock peening (LSP) extending from the laser shock peened surface into the component. Optionally, the surface over the repaired area of the weld filled void may also be laser shock peened forming a second region of deep compressive residual stresses imparted by laser shock peening (LSP) extending from the laser shock peened surface into the weld repair.

Abstract: A crack weld repair and method, particularly, for a gas turbine engine blade or other metallic component in the engine, providing a metallic substrate, a metallic filler bonded onto a substrate bond surface on the metallic substrate, and a region having deep compressive residual stresses imparted by laser shock peening extending into the substrate beneath the substrate bond surface. One embodiment provides a laser shock peened surface below the weld material filled void in a damaged area of the component forming a region of deep compressive residual stresses imparted by laser shock peening (LSP) extending from the laser shock peened surface into the component. Optionally, the surface over the repaired area of the weld filled void may also be laser shock peened forming a second region of deep compressive residual stresses imparted by laser shock peening (LSP) extending from the laser shock peened surface into the weld repair.

Abstract: An airfoil and a band or platform member of a vane segment, such as of a turbine engine, are bonded at a non-linear clearance slot formed between a shelf in the band and an end and edge of the airfoil. A reservoir bead of a bonding alloy slurry is deposited at one slot opening, a metallic powder is packed into the slot, and another reservoir bead is applied at a slot second opening substantially to close the slot and entrap the powder therein. Then the reservoir beads and powder are heated to flow material of the beads into the clearance slot. This bonds the airfoil and band securely at a deep pocket or blind slot.

Abstract: A wide gap braze repair, particularly for a gas turbine engine vane or a component in the hot section of the engine. The repair is characterized by a braze filled void in a damaged area of the component, a laser shock peened surface over the repaired area of the braze filled void, and a region of deep compressive residual stresses imparted by laser shock peening (LSP) extending from the laser shock peened surface into the repair.

Abstract: A braze material is provided for repairing an article, and particularly components formed from cobalt and nickel-base superalloys, such as gas turbine engine components. The braze material is composed of high melt particles distributed within a braze alloy. The braze alloy can be any suitable bonding material of the type used to repair components that must operate at high temperatures. The particles are single crystal, directionally solidified or equiaxed particles formed from a superalloy or ceramic material, or mixtures thereof. Importantly, the particles have an aspect ratio (length to width) of at least 4:1. The braze material can be provided and used in the form of a slurry, a presintered preform, a plasticized tape, or in a powdered form.

Abstract: A method for forming a blade tip on a turbine blade of a gas turbine engine includes providing a powder alloy from a family of environmentally-resistant powder alloys and forming the blade tip by melting and fusing the powder alloy to the turbine blade. The blade tip alloys preferably have a chemical composition of, in weight percent, about 14 to about 18 percent chromium, about 6.45 to about 6.95 percent aluminum, about 9.75 to about 11.45 percent cobalt, about 5.95 to about 6.55 percent tantalum, about 1.85 to about 2.35 percent rhenium, about 0.05 to about 1.75 percent hafnium, about 0,006 to about 0.03 percent zirconium, about 0.02 to about 0.11 percent carbon, up to about 1.1 percent silicon, up to about percent 0.01 percent boron, with the balance being nickel and typical impurities.

Abstract: Gas turbine engine blade with a metallic airfoil having a radially outer tip extending chordwise between a leading edge and a trailing edge and at least one laser shock peened surface extending radially along at least a portion of the tip and a region having deep compressive residual stresses imparted by laser shock peening (LSP) extending into the airfoil from the laser shock peened surface.

Abstract: A family of environmentally-resistant alloys is provided which are suitable for forming a blade tip for a turbine blade of a gas turbine engine. The blade tip alloys preferably have a chemical composition of, in weight percent, about 14 to about 18 percent chromium, about 6.45 to about 6.95 percent aluminum, about 9.75 to about 11.45 percent cobalt, about 5.95 to about 6.55 percent tantalum, about 1.85 to about 2.35 percent rhenium, about 0.05 to about 1.75 percent hafnium, about 0.006 to about 0.03 percent zirconium, about 0.02 to about 0.11 percent carbon, up to about 1.1 percent silicon, up to about percent 0.01 percent boron, with the balance being nickel and typical impurities.

Abstract: A wide gap braze repair, particularly for a gas turbine engine vane or a component in the hot section of the engine. The repair is characterized by a braze filled void in a damaged area of the component, a laser shock peened surface over the repaired area of the braze filled void, and a region of deep compressive residual stresses imparted by laser shock peening (LSP) extending from the laser shock peened surface into the repair.

Abstract: A composite weld wire, for use in repairing an article of a Co base alloy, comprises the sintered product of a mixture, by weight, of about 50-90% of the Co base alloy and about 10-50% of a Ni base alloy consisting essentially of, by weight, about: 1.5-2.5% B, 2-5% Al, 2-4% Ta, 14-17% Cr, 8-12% Co, with the balance Ni and incidental impurities. Conveniently, the alloys initially are in powder form. A repaired Co base alloy article including a surface discontinuity, such as a crack or void, comprises a welded repair at the discontinuity using the weld wire. In another form, the article includes a first diffusion bonded repair alloy at the discontinuity and a second repair alloy welded over the first repair alloy using the composite weld wire. One form of a method for repairing the article includes first removing oxides from the discontinuity, diffusion bonding the first repair alloy at the discontinuity, and then welding the second repair alloy over the first repair alloy using the composite weld wire.

Abstract: A metallic article and method for producing such an article, having a metallic substrate, at least one metallic layer sprayed onto a laser shock peened surface area of the substrate, and a region having deep compressive residual stresses imparted by laser shock peening extending into the substrate from the laser shock peened surface. The metallic substrate and or layer may be made from an alloy such as a Cobalt or a Nickel based superalloy. The substrate may be made from Nickel Base forgings or Titanium base forgings. An exemplary embodiment of the present invention is a gas turbine engine rotor component such a disk and, more particularly, a turbine disk suitable for use in a hot section of a gas turbine engine. The invention may be used for new or refurbished parts to restore dimensions of the component and, in particular, radial dimensions.

Abstract: A series of braze materials for brazing superalloy substrates at effective brazing temperatures above about 2300.degree. F. is described. The braze materials are formulated as mixtures of cobalt- and nickel-base alloy powders. Each such braze material contains at least two components, one of which is predominantly liquid at the effective brazing temperature, and one of which remains substantially solid at that temperature. The brazing materials solidify by an isothermal solidification process. Unless otherwise limited by the temperature capability of the superalloy substrate being joined, these brazing alloys provide joints that have useful strength at temperatures significantly higher than joints made with prior art brazing alloys.

Abstract: A superalloy article is fabricated by casting a high melting temperature superalloy composition and then refurbishing the primary defects that are found in the surface of the cast piece. The article is refurbished by excising the primary defects and a surrounding portion of metal by grinding, filling the excised volume with metal of the same composition as the cast article by welding or a similar technique, smoothing the surface around any resulting filler metal defects, and applying a cladding powder to the surface from which the filler metal defects are removed. The cladding powder is applied by painting a binder onto the surface and then dusting cladding powder onto the binder before it has dried. The cladding powder is a mixture of particles of a high melting temperature superalloy and particles of a lower melting temperature metal. The article is heated to a preselected temperature, depending on the alloy, to melt and subsequently solidify the cladding powder.

Abstract: An improved mixture of alloy powders is provied for use in treating a preselected article alloy, for example, to repair or join multiple components of the article. The mixture has at least three distinct groups of alloy powders which together define a mixture composition range, with each alloy powder of the groups characterized by a composition and melting range different from the others and from the article alloy. In a preferred form, the mixture composition range comprises, by weight, 15-30% Cr, 1.5-6% W, 0.4-4% Al, 1-11% Ti, 1-6% Ta, up to 1.5% B, up to 0.5% Si, up to 0.2% Zr, up to 3% Mo, up to 0.3% Hf, up to 6% Cb, up to 2% Re, with the balance selected from Co and Ni along with incidental impurities.