Abstract: A process of welding fittings to ends of a double wall pipe comprising forming a first welded joint between an inner pipe and an inner receiver of a first fitting; forming a second welded joint between an outer pipe and an outer receiver of the first fitting; forming a third welded joint between the outer pipe and an outer receiver of a second fitting; and forming a fourth welded joint between the inner pipe and an inner receiver of the second fitting.

Abstract: A method of reworking or repairing a component includes removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity that results in a through hole; sealing the through hole with a backing; and at least partially filling the cavity with a multiple of layers of a multiple of laser powder deposition spots, each of the multiple of laser powder deposition spots formed of a filler alloy, a first layer of the multiple of layers includes a perimeter of the multiple of laser powder deposition spots that overlap a wall of the cavity and the backing.

Abstract: A method of reworking an aerospace component includes removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity. The cavity is then at least partially filled with a multiple of layers of discrete laser powder deposition spots of a filler alloy. A cast component for a gas turbine engine includes a cast component non-fusion weldable base alloy with a cavity filled with a multiple of layers of laser powder deposition spots of a filler alloy. The filler alloy may be different than the non-fusion weldable base alloy. A layer of non-fusion weldable base alloy is at least partially within the cavity and over the filler alloy.

Abstract: A laser cladding head comprises a protective housing, a focal array, a turning mirror, and a powder nozzle. The housing extends along a primary axis from a proximal end to a distal end. The focal array is situated at the proximal end and oriented to receive and focus collimated light in a beam directed substantially along the primary axis. The turning mirror is situated at the distal end and disposed to redirect the beam in an emission direction, towards a target point separated from the turning mirror by a working distance of at most a tenth the focal length. The turning mirror is a nonfocal reflective surface indexable to alter an impingement location of the beam on the turning mirror. The powder nozzle is situated at the distal end and receives and directs weld material towards the target point for melting.

Abstract: The present disclosure relates generally to a system and method for applying a metallic coating. A first metallic coating may be applied to a portion of a total surface of a part and a second metallic coating may be applied to substantially the total surface. The metallic coating may be applied to a vane cluster for use in a turbomachine.

Abstract: A process of welding fittings to ends of a double wall pipe comprising forming a first welded joint between an inner pipe and an inner receiver of a first fitting; forming a second welded joint between an outer pipe and an outer receiver of the first fitting; forming a third welded joint between the outer pipe and an outer receiver of a second fitting; and forming a fourth welded joint between the inner pipe and an inner receiver of the second fitting.

Abstract: A method of reworking or repairing a component includes removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity that results in a through hole; sealing the through hole with a backing; and at least partially filling the cavity with a multiple of layers of a multiple of laser powder deposition spots, each of the multiple of laser powder deposition spots formed of a filler alloy, a first layer of the multiple of layers includes a perimeter of the multiple of laser powder deposition spots that overlap a wall of the cavity and the backing.

Abstract: A method of reworking or repairing a component includes removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity that results in a through hole; sealing the through hole with a backing; and at least partially filling the cavity with a multiple of layers of a multiple of laser powder deposition spots, each of the multiple of laser powder deposition spots formed of a filler alloy, a first layer of the multiple of layers includes a perimeter of the multiple of laser powder deposition spots that overlap a wall of the cavity and the backing.

Abstract: A method of reworking an aerospace component includes removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity. The cavity is then at least partially filled with a multiple of layers of discrete laser powder deposition spots of a filler alloy. A cast component for a gas turbine engine includes a cast component non-fusion weldable base alloy with a cavity filled with a multiple of layers of laser powder deposition spots of a filler alloy. The filler alloy may be different than the non-fusion weldable base alloy. A layer of non-fusion weldable base alloy is at least partially within the cavity and over the filler alloy.

Abstract: A method is provided for reworking a component. The method includes at least partially filling a cavity in a non-fusion weldable base alloy with a multiple of layers of a multiple of laser powder deposition spots formed of a filler alloy. Each of the multiple of laser powder deposition spots at least partially overlaps at least one of another of the multiple of laser powder deposition spots. The filler alloy may be different than the non-fusion weldable base alloy.

Abstract: A method of reworking an aerospace component includes removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity. The cavity is then at least partially filled with a multiple of layers of discrete laser powder deposition spots of a filler alloy. A cast component for a gas turbine engine includes a cast component non-fusion weldable base alloy with a cavity filled with a multiple of layers of laser powder deposition spots of a filler alloy. The filler alloy may be different than the non-fusion weldable base alloy. A layer of non-fusion weldable base alloy is at least partially within the cavity and over the filler alloy.

Abstract: A weld clad layer having a substantially equiaxed grain microstructure may be formed by forming a repair area in a substrate, depositing a first layer of laser deposition spots in the repair area, and depositing a second layer of laser deposition spots over the first layer of laser deposition spots. The first layer of laser deposition spots may comprise a first laser deposition spot and a second laser deposition spot adjacent to the first laser deposition spot. The first laser deposition spot may solidify prior to deposition of the second laser deposition spot. The first layer of laser deposition spots may comprise titanium or titanium alloy.

Abstract: A process for solid state deposition of a material onto a workpiece includes the steps of providing a rod of metallic deposition material, exerting pressure at one end of the rod to move the metallic deposition material into a deposition zone, rotating the rod while the pressure is being exerted to generate frictional heat when the rod contacts a surface of the workpiece, and raising the temperature of the metallic deposition material to reduce the amount of frictional heat which needs to be generated during the rotating step and to produce a microstructure which is substantially free of porosity and which has a fine grain size.

Abstract: A laser cladding system comprises a cladding head and a gas system. The cladding head extends along a primary axis, and comprises a mirror and a powder nozzle both situated at a distal end of the head. The powder nozzle directs weld material at a target point, and the mirror directs a beam of collimated light at the target point. The gas system comprises a high-speed gas nozzle and a gas knife. The high-speed gas nozzle produces a gas sheath coaxial with the beam in a region between the mirror and target point, shielding the mirror from debris and backspatter. The gas knife redirects the gas sheath away from the target point and redirects debris and molten backspatter away from an interior of the laser cladding head.

Abstract: A laser cladding head comprises a protective housing, a focal array, a turning mirror, and a powder nozzle. The housing extends along a primary axis from a proximal end to a distal end. The focal array is situated at the proximal end and oriented to receive and focus collimated light in a beam directed substantially along the primary axis. The turning mirror is situated at the distal end and disposed to redirect the beam in an emission direction, towards a target point separated from the turning mirror by a working distance of at most a tenth the focal length. The turning mirror is a nonfocal reflective surface indexable to alter an impingement location of the beam on the turning mirror. The powder nozzle is situated at the distal end and receives and directs weld material towards the target point for melting.

Abstract: A method of forming a hybrid component having an axis of rotation includes forming a first substrate having a first interface surface and a first average grain size, forming a second substrate having a second interface surface and a second average grain size different from the first average grain size, and inertia welding the first and second substrates at a junction of the first and second interface surfaces to form a solid-state joint between the first and second substrates.

Abstract: A method of forming a hybrid component having an axis of rotation includes forming a first substrate having a first average grain size, forming a second substrate having a second average grain size different from the first average grain size, positioning an interlayer on one of the first and second substrates, positioning a portion of the first substrate adjacent a portion of the second substrate such that the interlayer extends between the portion of the first substrate and the portion of the second substrate, heating the first and second substrates and the interlayer at a temperature below the melting points of the first and second substrates to melt the interlayer, and isothermally solidifying the interlayer to form a solid-state joint between the portions of the first and second substrates.

Abstract: A method is provided that involves a component including a first fastener aperture that extends through the component. During the method, the component is machined to enlarge the first fastener aperture to provide an enlarged aperture. The component is friction plug welded to plug the enlarged aperture with friction plug welded material. A second fastener aperture is machined in the friction plug welded material, where the second fastener aperture extends through the component.

Abstract: A nickel braze alloy may include less than about 2.0 wt. % aluminum, about 18.0-23.0 wt. % cobalt, about 12.0-15.0 wt. % chromium, about 3.8-4.5 wt. % molybdenum, about 0.8-1.5 wt. % niobium, about 1.8-3.0 wt. % tantalum, less than about 2.0 wt. % titanium, about 2.0-3.5 wt. % tungsten, about 0.8-1.2 wt. % boron, about 0.02-0.10 wt. % carbon, about 0.03-0.06 wt. % zirconium, and a balance of nickel and minor amounts of impurities.

Abstract: An example method of attaching an airfoil for an integrally bladed rotor includes placing a support collar in an installed position around at least a leading edge and trailing edge of an airfoil stub to be repaired in an integrally bladed rotor. The support collar and the airfoil stub together have a midline that is positioned between opposing, laterally outer surfaces of the airfoil stub when the support collar is in the installed position. The method performs linear friction welding to add a replacement airfoil to the airfoil stub.