Abstract: A method for repairing a blade tip of a turbine blade based on welding below and above a designated depth recommended for repair of turbine blades. A damaged portion of the turbine blade is inspected to identify a standard cut portion and an angled cut portion. The standard cut portion is damaged above a standard cut line and the angled cut portion is damaged below the standard cut line. The damaged portion of the turbine blade is removed. The standard cut portion is removed using a first removal process and the angled cut portion is removed using a second removal process. The angled cut portion is built up with a first weld repair process. The angled cut portion is built up to the standard cut portion. The standard cut portion and the angled cut portion are built up with a second weld repair process.

Abstract: A method for repairing a blade tip of a turbine blade based on a dual fusion weld process for portions of a tip plate and a mechanical locking bead over the tip plate. A damaged portion of blade is removed. The damaged portion is removed at an initial cut level. An undamaged portion of the turbine blade exists as a base below the initial cut level. A replacement section is rebuilt via laser cladding. The replacement section is machined to form a tip pocket. A tip plate is placed in the tip pocket. The tip plate comprises at least a first portion and a second portion. The tip plate is welded using a dual fusion weld process comprising a first weld process and a second weld process. A squealer tip is built using a welding process that forms a mechanical locking bead over the tip plate.

Abstract: A method for repairing a blade tip of a turbine blade based on welding below and above a designated depth recommended for repair of turbine blades. A damaged portion of the turbine blade is inspected to identify a standard cut portion and an angled cut portion. The standard cut portion is damaged above a standard cut line and the angled cut portion is damaged below the standard cut line. The damaged portion of the turbine blade is removed. The standard cut portion is removed using a first removal process and the angled cut portion is removed using a second removal process. The angled cut portion is built up with a first weld repair process. The angled cut portion is built up to the standard cut portion. The standard cut portion and the angled cut portion are built up with a second weld repair process.

Abstract: The present invention discloses various methods for repairing a side seal region of a transition duct aft frame region. Embodiments of the present invention include application of a braze filler material to worn locations of seal teeth, brazing of a braze preform to the seal teeth or removal of a worn seal tooth and brazing of material compatible with the transition duct to form a replacement tooth of the side seal. The transition duct is brazed in a furnace in an incremental heated process which elevates the transition duct to a temperature where the braze filler material adheres to the side seal region while also providing a stress relief to the transition duct.

Abstract: The present invention discloses various methods for repairing a side seal region of a transition duct aft frame region. Embodiments of the present invention include application of a braze filler material to worn locations of seal teeth, brazing of a braze preform to the seal teeth or removal of a worn seal tooth and brazing of material compatible with the transition duct to form a replacement tooth of the side seal. The transition duct is brazed in a furnace in an incremental heated process which elevates the transition duct to a temperature where the braze filler material adheres to the side seal region while also providing a stress relief to the transition duct.

Abstract: A composite turbine blade and a method of manufacture thereof is disclosed. The composite turbine blade comprises a turbine blade portion comprising a first material and a first tip plate comprising a second material. The turbine blade portion has an exterior wall and an interior wall surrounding a hollow interior cavity, and a top surface extending from the exterior wall to the interior wall bounding an orifice that is fluidly connected to the hollow interior cavity. The first tip plate may be attached to the turbine blade along the top surface and extending from proximate the exterior wall of the turbine blade across the orifice to cover the orifice.

Abstract: A method for repairing a blade tip of a turbine blade based on a dual fusion weld process for portions of a tip plate and a mechanical locking bead over the tip plate. A damaged portion of blade is removed. The damaged portion is removed at an initial cut level. An undamaged portion of the turbine blade exists as a base below the initial cut level. A replacement section is rebuilt via laser cladding. The replacement section is machined to form a tip pocket. A tip plate is placed in the tip pocket. The tip plate comprises at least a first portion and a second portion. The tip plate is welded using a dual fusion weld process comprising a first weld process and a second weld process. A squealer tip is built using a welding process that forms a mechanical locking bead over the tip plate.

Abstract: A composite turbine blade and a method of manufacture thereof is disclosed. The composite turbine blade comprises a turbine blade portion comprising a first material and a first tip plate comprising a second material. The turbine blade portion has an exterior wall and an interior wall surrounding a hollow interior cavity, and a top surface extending from the exterior wall to the interior wall bounding an orifice that is fluidly connected to the hollow interior cavity. The first tip plate may be attached to the turbine blade along the top surface and extending from proximate the exterior wall of the turbine blade across the orifice to cover the orifice.

Abstract: A composite turbine blade and a method of manufacture thereof is disclosed. The composite turbine blade comprises a turbine blade portion comprising a first material and a first tip plate comprising a second material. The turbine blade portion has an exterior wall and an interior wall surrounding a hollow interior cavity, and a top surface extending from the exterior wall to the interior wall bounding an orifice that is fluidly connected to the hollow interior cavity. The first tip plate may be attached to the turbine blade along the top surface and extending from proximate the exterior wall of the turbine blade across the orifice to cover the orifice.

Abstract: A process for filling openings, including blind holes, through-holes, and cavities, in high temperature components. The process entails forming a powder mixture by mixing particles of at least a base alloy and a second alloy that contains a sufficient amount of a melting point depressant to have a lower melting temperature than the base alloy. The powder mixture is combined with a binder and compacted to form a compacted preform, which is then heated to remove the binder and form a rigid sintered preform. The sintered preform is produced, or optionally is further shaped, to have a cross-sectional shape and dimensions to achieve a clearance of up to 200 micrometers with the opening, after which the preform is placed in the opening and diffusion bonded within the opening to form a brazement comprising the particles of the base alloy dispersed in a matrix formed by the second alloy.

Abstract: A composite turbine blade and a method of manufacture thereof is disclosed. The composite turbine blade comprises a turbine blade portion comprising a first material and a first tip plate comprising a second material. The turbine blade portion has an exterior wall and an interior wall surrounding a hollow interior cavity, and a top surface extending from the exterior wall to the interior wall bounding an orifice that is fluidly connected to the hollow interior cavity. The first tip plate may be attached to the turbine blade along the top surface and extending from proximate the exterior wall of the turbine blade across the orifice to cover the orifice.

Abstract: Improved compositions are described for the protection of gas turbine parts at elevated temperatures. The compositions are of the MCrAlY type, wherein M is selected from nickel, or a combination of nickel with cobalt, iron, or combinations thereof. The compositions further comprise ruthenium, rhenium, or a combination thereof, a Group 4 metal (e.g., hafnium, zirconium, titanium), and can further include silicon and/or germanium, where the composition results in improved aluminum diffusion properties. Also disclosed herein are articles comprising the composition.

Abstract: A method for applying a seal strip to a surface of a turbine component by accelerating solid particles to a velocity sufficient to cause the solid particles to plastically deform and bond to the surface and each other when impacted on the surface, and impacting the solid particles on the surface so as to cause the solid particles to deform and bond to the surface and each other to form the seal strip on the surface.

Abstract: A process for repairing a damaged portion of a thermal barrier coating on a turbine engine component includes sintering a mixture comprising particles of a bond coat and particles of a brazing alloy to form a composite preform; depositing a thermal barrier coating on the composite preform; contacting the composite preform with the deposited thermal barrier coating with an uncoated surface of the damaged portion of the turbine engine component; and heating the composite preform with the deposited thermal barrier coating to a temperature effective to form a brazed joint between the composite preform and the uncoated surface of the damaged portion of the turbine engine component.

Abstract: A process for filling openings, including blind holes, through-holes, and cavities, in high temperature components. The process entails forming a powder mixture by mixing particles of at least a base alloy and a second alloy that contains a sufficient amount of a melting point depressant to have a lower melting temperature than the base alloy. The powder mixture is combined with a binder and compacted to form a compacted preform, which is then heated to remove the binder and form a rigid sintered preform. The sintered preform is produced, or optionally is further shaped, to have a cross-sectional shape and dimensions to achieve a clearance of up to 200 micrometers with the opening, after which the preform is placed in the opening and diffusion bonded within the opening to form a brazement comprising the particles of the base alloy dispersed in a matrix formed by the second alloy.

Abstract: A method for welding and brazing a metallic component, such as, for example, a metallic component in a turbine, such as a bucket or blade. The method includes the steps of welding the metallic component to create a welded component; covering the welded component with a braze material to create a braze-covered welded component; and subjecting the braze-covered welded component to stress relief treatment.

Abstract: Improved compositions are described for the protection of gas turbine parts at elevated temperatures. The compositions are of the MCrAlY type, wherein M is selected from nickel, or a combination of nickel with cobalt, iron, or combinations thereof. The compositions further comprise ruthenium, rhenium, or a combination thereof, a Group 4 metal (e.g., hafnium, zirconium, titanium), and can further include silicon and/or germanium, where the composition results in improved aluminum diffusion properties. Also disclosed herein are articles comprising the composition.

Abstract: A process for repairing a metal component includes sintering a mixture comprising particles of a coating composition and particles of a brazing alloy to form a composite preform; disposing the composite preform on an uncoated surface of the metal component; and heating the preform to a temperature effective to form a brazed joint between the composite preform and the metal component.