Abstract: The present invention provides an apparatus and method for an adaptive machining and weld repair process useful for repairing airfoils, particularly damage to an airfoil leading edge and tip. The process first machines away damaged portions of the airfoil. Next, the actual profile of the airfoil subsequent to the removal of the damaged material is measured using a Coordinate Measuring Machine. The data is then used to generate a deformation profile. Filler material is then added to the machined area using the data of the deformation profile to produce an airfoil that approximates the ideal shape of a restored airfoil. At this point, the actual profile of the welded airfoil is measured using the Coordinate Measuring Machine. The data is then used to generate a deformation profile and the airfoil is machined using the date of the deformation profile to produce that shape. The adaptive technology minimizes the amount of stock on material that needs to be removed by hand.

Abstract: An automated welding system is provided for welding a workpiece. The system includes a multiaxially movable arm, a fiber optic cable, a laser source, a focusing head, a focus lens, and a shield. The fiber optic cable is coupled to the arm. The laser source is coupled to the fiber optic cable and configured to supply laser light thereto. The focusing head includes a first end, a second end, and a passage extending therebetween. The shield has an inlet, an outlet and a cavity formed therebetween, and each of the inlet and the outlet has a diameter. The shield inlet is coupled to the focusing head and the shield inlet diameter is greater than the shield outlet diameter. The shield outlet diameter is sized to provide an opening through which the laser beam exits and prevents substantially all particles external to the focusing head passage from entering therein.

Abstract: A mask is provided for shielding a radially extending edge of an impeller vane during a weld repair process, where the impeller vane extends radially and axially outwardly from a shaft. The mask comprises a hub and a flange. The hub has an outer surface and an opening extending therethrough, and the opening is configured to allow the shaft to extend at least partially therethrough. The flange extends radially outwardly from the hub outer surface and is configured to shroud substantially all of the impeller vane radially extending edge.