Abstract: A method of producing a welded joint between components of a turbomachine is described, in particular for the repair of components, wherein components are welded to one another along common edges in such a way that a pocket-like recess is incorporated in a first component, in particular in a replacement part, with which recess the first component is slipped onto a second component, in particular a component to be repaired, such that the second component bears with an end edge on a base of the pocket-like recess, and that the first component and the second component are then welded to one another. According to the invention, at least one cutout is incorporated in the first component in addition to the pocket-like recess in order to minimize heat transfer and the formation of component deformations during the subsequent welding of the components.

Abstract: A system for restoring a metal component with a brazing alloy, the system comprising an induction coil configured to extend around a portion of the metal component and at least a portion of the brazing alloy, a motion assembly configured to cause relative movement between the metal component and the induction coil along a first axis, and a heat exchanger assembly supported by the motion assembly and configured to form a thermal gradient along the metal component in a direction along the first axis.

Abstract: A method of hole defect repair includes removing one or more defects at or near a desired hole shape in a substrate by removing a non-concentric portion of the substrate proximate the desired hole shape, and welding a filler material to the substrate after removing the non-concentric portion of the substrate.

Abstract: Various braze alloy compositions are described, along with methods for using them. In one instance, a boron-free, high-temperature braze alloy includes selected amounts of chromium, hafnium, and nickel. The braze alloy can be used, for example, as a component in a wide gap braze mixture where a higher or lower melting point superalloy and/or brazing powder is used. The braze alloys may permit joining or repairing of superalloy articles with complex shapes, and may be used in high temperature applications. In some other braze alloy embodiments, a nickel- or cobalt-based braze composition can contain selected amounts of boron, but includes restricted amounts of chromium.

Abstract: A dental material composition for attaching a metal structure to a dental coping in the preparation or repair of a dental restoration which includes a component of high-fusing temperature metal particles in a range of between 1-10 weight percent, a component of low fusing temperature metal particles having a melting temperature below the melting temperature of the high-fusing particles in excess of at least 90 weight percent and preferably above about 95 weight percent of the total composition with the low fusing temperature metal particles composed primarily of gold, a small measure of borate fluxes in a range of between 0.1 to 2.0% by weight of the total composition and a volatile binder.

Abstract: An example method of repairing an airfoil includes securing a cap to an end portion of a worn airfoil and securing additional material to the cap. The method includes altering some of the cap to form a desired airfoil contour.

Abstract: A weld process cuitable for repairing precipitation-strengthened superalloys, and particularly gamma prime-strengthened nickel-based superalloys. The process entails forming a weldment in a cavity present in a surface of an article formed of a precipitation-strengthened superalloy. The cavity has a root region and a cap region between the root region and the surface of the article. A solid body formed of a superalloy composition is placed in the root region of the cavity so as to occupy a first portion but not a second portion of the root region. A first filler material formed of a solid solution-strengthened superalloy is then weld-deposited in the second portion of the root region. Subsequently, a second filler material formed of a precipitation-strengthened superalloy is weld-deposited in the cap region of the cavity.

Abstract: A system or method of repairing railroad rails which includes a head, upright and base sections. The method includes at least the following steps: identifying and locating a defect in the rail, removing the defect by removing material from the rail surrounding the defect in at least the head section so as to form a void and a rail void interface while maintaining continuity of the rail, filling the void with molten metal having a high carbon content and causing the molten metal and the rail void interface to bond. The molten metal may be produced by gas shielded arc welding. The carbon content of the molten metal is near that of the rail to decrease carbon migration from the rails.

Abstract: An annular facing is machined in an inside surface of the spherical wall around the periphery of a zone where the wall has a bore for securing the tube passing therethrough. A first welding material is deposited in the facing, and the bore is made by drilling through a portion of the spherical wall that is surrounded by the facing. The tube is engaged tightly in the bore, and a second welding material is deposited in the facing at the periphery of the tube in order to weld the tube to the first welding material. At least one of the operations of depositing the first and second welding materials in the facing is performed automatically by causing a welding torch to turn around the axis of the bore while moving the torch in a direction that is parallel to the axis of the bore and while causing it to pivot about an axis that is orthogonal to the axis of the bore while rotation is taking place.

Abstract: A process for repairing a turbine component of a turbomachine, as well as a sintered preform used in the process and a high gamma-prime nickel-base superalloy component repaired thereby. The sintered preform contains a sintered mixture of powders of a cobalt-base braze alloy and a cobalt-base wear-resistant alloy. The braze alloy constitutes at least about 10 up to about 35 weight percent of the sintered preform and contains a melting point depressant such as boron. The preform is formed by mixing powders of the braze and wear-resistant alloys to form a powder mixture, and then sintering the powder mixture. To use the preform, a surface portion of the turbine component is removed to expose a subsurface portion, followed by diffusion bonding of the preform to the subsurface portion to form a wear-resistant repair material containing the braze alloy dispersed in a matrix of the wear-resistant alloy.

Abstract: A method of joining or repairing metal surface structures. Joinder and/or repair of metal or metal-polymer laminate panels may be carried out using so-called “cold metal transfer” gas metal arc welding techniques. Moreover, suitable zinc-copper-aluminum alloys may improve weldability, durability and strength. The reduced thermal input permits effective weld formation at the metal sheet layers without giving rise to temperature gradient sufficient to significantly damage the interior elements.

Abstract: A method for repairing an article comprises providing an article, providing a repair material, and joining said repair material to said article. The repair material comprises, in atom percent, at least about 50% rhodium; up to about 49% of a first material, said first material comprising at least one of palladium, platinum, iridium, and combinations thereof; from about 1% to about 15% of a second material, said second material comprising at least one of tungsten, rhenium, and combinations thereof; and up to about 10% of a third material, said third material comprising at least one of ruthenium, chromium, and combinations thereof. The repair material comprises an A1-structured phase at temperatures greater than about 1000° C., in an amount of at least about 90% by volume.

Abstract: A solder repairing apparatus includes a stage designed to place the surface of at least a specific part of an object along a reference plane within a specific spot defined on the stage. A heating unit applies a thermal energy to the specific spot. A dividing plate is designed to move into the specific spot in a vertical attitude perpendicular to the reference plane. The dividing plate exhibits a low solder wettability. The solder melts in response to the application of the thermal energy. When the dividing plate in the vertical attitude enters the specific spot, the dividing plate gets into the solder. Since the dividing plate exhibits a low solder wettability, the dividing plate repels the solder. The solder is divided into two parts. The division of the solder reliably eliminates a short circuit in the electronic circuit.

Abstract: A method for creating a soldered joint to contacts of a piezoelectric actuator and polarizing the piezoceramic layers of the piezoelectric actuator has the steps of Polarization and soldering of the joint which are performed simultaneously such that the duration of the process is reduced.

Abstract: A semi-automatic method for reconditioning an articulated connector while it is still mounted to the end structure of a rail car is disclosed. The female connector is mounted to a fixture and subsequently appropriately aligned. Weld metal is automatically applied to the worn portion of the female connector while attached to the aligned fixture. The excess weld metal is then automatically machined away so that the connector falls within the required dimensions. A measurement of the weld area can again be taken to ensure that the specified dimensions have been achieved.

Abstract: Accordingly, the present invention provides a method for joining metallic members, which can be used to join component sub-assemblies. Further, the present invention provides a method for repairing a component by replacing a damaged portion and re-inserting a replacement section. In general, the present invention provides in one embodiment a method for joining metallic members comprising: preparing a surface of a first metallic member, thereby providing an oxide-free surface; preparing a surface of a second metallic member, thereby providing an oxide-free surface; applying pressure to the first and second metallic members, thereby forcing the surface of the first metallic member and the surface of the second metallic member together and forming a joint area; sealing an outer edge of the joint area; and subjecting the members to a hot isostatic process operation.

Abstract: A brazing material for brazing tungsten/carbide/cobalt substrates (e.g., wear pads) to substrates comprising titanium or alloys thereof (e.g., fan or compressor blades). The brazing material includes gold, nickel, copper, and titanium present in respective amounts to provide a post-braze hardness of between 450 and 600 KHN to thereby increase the impact resistance of the braze joint. The substrates may be brazed by induction heating at temperatures less than about 1800° F. (982° C.).

Abstract: A detachment jig is placed on a printed circuit board. Advancement of an inclined surface of the detachment jig is received on a solder bump of solid state disposed between the printed circuit board and an integrated circuit chip package. The solder bump melts to remove restraint to the advancement of the inclined surface, so that the inclined surface advances into a space between the printed circuit board and the chip package in response to the melt of the solder bump. A force to lift the chip package in the direction perpendicular to the surface of the printed circuit board acts on the chip package after the solder bump has completely melted down. Detachment of an electrically conductive pad is thus reliably prevented on the printed circuit board. The chip package can solely be removed without inducing detachment of the electrically conductive pad on the printed circuit board.

Abstract: A method for manually reattaching solder balls onto a plurality of contact areas arranged in a pattern on a device to be reballed is provided. First, a single use preform with a plurality of solder balls arranged in a pattern corresponding to the pattern of contact areas on the device is provided. The solder balls are held in respective apertures in the preform by an adhesive layer on the preform that defines a closed end of the apertures and are partially exposed on one side of the preform. A solder paste or paste flux is applied to, at least, the contact areas of the device. The device is manually aligned with the exposed solder balls of the preform and the device and the exposed balls of the preform are manually brought into contact. The aligned device and preform are heated to reflow the solder balls onto the land areas of the device. The preform including the adhesive layer is then removed from the device with the solder balls being retained on the device.

Abstract: A process for heating a braze alloy by microwave radiation so that heating of the alloy is selective and sufficient to cause complete melting of the alloy and permit metallurgical bonding to a substrate on which the alloy is melted, but without excessively heating the substrate so as not to degrade the properties of the substrate. The process entails providing metallic powder particles having essentially the same metallic composition, with at least some of the particles being sufficiently small to be highly susceptible to microwave radiation. A mass of the particles is then applied to a surface of a substrate, after which the mass is subjected to microwave radiation so that the particles within the mass couple with the microwave radiation and sufficiently melt to metallurgically bond to the substrate. The microwave radiation is then interrupted and the mass is allowed to cool, solidify, and form a solid brazement.

Abstract: A braze formulation includes a novel promoter and a metal filler. The promoter includes a blend of potassium tetrafluoroaluminate and potassium tetrafluoroborate. The braze may be used for repairing cracks in a substrate. The braze has a low melt point, removes oxides from within cracks and has improved penetration into cracks for repair.

Abstract: A process for repairing a turbine component of a turbomachine, as well as a sintered preform used in the process and a high gamma-prime nickel-base superalloy component repaired thereby. The sintered preform contains a sintered mixture of powders of a cobalt-base braze alloy and a cobalt-base wear-resistant alloy. The braze alloy constitutes at least about 10 up to about 35 weight percent of the sintered preform and contains a melting point depressant such as boron. The preform is formed by mixing powders of the braze and wear-resistant alloys to form a powder mixture, and then sintering the powder mixture. To use the preform, a surface portion of the turbine component is removed to expose a subsurface portion, followed by diffusion bonding of the preform to the subsurface portion to form a wear-resistant repair material containing the braze alloy dispersed in a matrix of the wear-resistant alloy.

Abstract: A process for soldering an electronic component onto a support which includes at least one heat drain for the component. The method uses a solder paste which incorporates a stripping flux activated at a first temperature, and a solder alloy melted at a second temperature. The process includes preheating the support on the face opposite the component through the heat drain up to the first temperature, placing the component on the support with the solder paste, heating the component by applying a hot gas at a sufficiently high temperature to bring the solder alloy to the melting temperature.

Abstract: A method for welding superalloy components at ambient temperature conditions while reducing the propensity of the superalloy material to crack as a result of the weld. A root pass region of the weld is formed using a filler material that exhibits ductility that is higher than that of the base superalloy material. The ductile material mitigates stress in the root region, thereby preventing the formation of cracks. A remaining portion of the weld is formed using a filler material that essentially matches the base superalloy material. The method may utilize a pre-weld heat treatment to grow a gamma prime precipitate phase in the superalloy material, a chill fixture to remove heat during welding, a relief cut to reduce stress in the root region, and a conventional post-weld heat treatment.

Abstract: A method for repairing a metal component having a crack, the method comprising depositing a brazing material into the crack of the metal component, and exposing the metal component to a plurality of heating cycles. Each successive heating cycle has a temperature that is less than a temperature of a previous heating cycle, and a duration that is at least as long as a duration of the previous heating cycle. The plurality of heating cycles comprises an initial heating cycle having a temperature sufficient to at least substantially melt the brazing material within the crack.

Abstract: The present invention has as its object the provision of a restoration method for a deteriorated part, which is capable of easily and reliably repairing and restoring a deteriorated part generated in a metal member to reliably prolong the lifetime of the metal member. Specifically, a local heating step of locally heating a deteriorated part C by a main heater 25 and pressure-welding the deteriorated part C by a compression force by thermal expansion and a peripheral heating step of heating the periphery and vicinity of a heated region HA1 in the local heating step by a sub heater 26 are carried out, followed by carrying out a cooling step of cooling the heated region HA1 by the main heater 25 and a heated region HA2 by the sub heater 26 at the same time.

Abstract: Disclosed is a piston reset apparatus for a multichip module that includes a base with multiple projections and two unit associating pegs extending from opposite ends of the base, a hat disposed upwardly of the base and including multiple adjustable pistons vertically adjustable within the hat, each of the plurality of adjustable pistons being disposed in alignment with one of the multiple projections, a mass equivalent plate disposed upwardly of the hat and being configured to hold a spring loaded sleeve, the spring loaded sleeve including a plurality of springs, each of the springs being aligned with and configured to apply pressure upon one of the multiple pistons, a spring loaded clamp disposed upwardly of the plate and including a spring loaded portion and a retaining portion, the retaining portion defining two cavities configured to fixedly associate with an associating groove defined by each of the unit associating pegs.

Abstract: Disclosed is a method and apparatus for the correction of defective solder bump arrays arranged in a plurality of cavities in a mold. In the method, a faulty solder bump is searched, identified and located (i.e., its position is determined) in an arrangement of solder bumps disposed in cavities of a mold and the faulty solder bump is subsequently replaced by a prefabricated solder bump. The apparatus for carrying out the method comprises a mold holder, a scanning and locating device for finding and locating faulty solder bumps and a repair device for replacing the faulty solder bump by a prefabricated solder bump.

Abstract: A method of repairing a turbine component seal land includes: (a) removing material along substantially the entire seal land to provide a preform-receiving face; (b) locating a repair preform along and engaged with said preform-receiving face; (c) brazing the preform to said preform-receiving face; (d) and finish machining an exposed face of the preform to specifications, thereby providing a repaired seal land.

Abstract: A method and apparatus for the fabrication and/or repair of an integrally bladed rotor, specifically of an integrally bladed gas turbine rotor, is disclosed. At least one rotor blade is joined to a main rotor body for fabrication and/or repair. The joining is carried out by diffusion welding.

Abstract: A clamp assembly connects a diffuser adapter or lower ring to a diffuser tail pipe of a jet pump diffuser in a boiling water nuclear reactor. The clamp assembly includes at least two clamp segments shaped generally corresponding to an exterior circumference of the diffuser, a swivel link affixed at each end of each of the clamp segments, and at least two connecting bands pivotably secured to the swivel links between the ends of the clamp segments. The clamp segments each includes a locking assembly engageable with the diffuser adapter or lower ring and the diffuser tail pipe. The clamp assembly structurally replaces/repairs the weld joining the diffuser adapter or lower ring and the diffuser tail pipe.

Abstract: In accordance with the present invention, a process for repairing metal workpieces, such as turbine engine components, is provided. The process comprises the steps of forming a braze paste containing a first nickel base alloy material containing boron and chromium and a second nickel base alloy material containing chromium and cobalt, applying the brazing paste to an area of the metal workpiece containing at least one crack, and subjecting the workpiece and the brazing paste to a brazing cycle by heating the brazing paste and the workpiece, preferably to a temperature in the range of from 2000 to 2200 degrees Fahrenheit. During the brazing cycle, the brazing paste flows into and fills the at least one crack and thus repairs the metal workpiece.

Abstract: In accordance with the present invention, a process for repairing metal workpieces, such as turbine engine components, is provided. The process comprises the steps of forming a braze paste containing a first nickel base alloy material containing boron and chromium and a second nickel base alloy material containing chromium and cobalt, applying the brazing paste to an area of the metal workpiece containing at least one crack, and subjecting the workpiece and the brazing paste to a brazing cycle by heating the brazing paste and the workpiece, preferably to a temperature in the range of from 2000 to 2200 degrees Fahrenheit. During the brazing cycle, the brazing paste flows into and fills the at least one crack and thus repairs the metal workpiece.

Abstract: The present invention provides methods and materials for use in repairing a worn component having thin walls. One kind of thin wall may be the wall of a cylindrical portion of the component where such wall has a worn inner surface and an opposite outer surface. The method includes the steps of preparing the outer surface of the component for cold spraying; cold spraying material onto the outer surface so as to form a strengthening coating; reaming the inner surface so as to create a repair surface with a repair diameter greater than the inner diameter; and installing an insert on the repair surface. The thickness of the coating is selected so as to impart a desired degree of strength to the wall. The method allows the repair of expensive aluminum castings that would otherwise, because of the thin wall construction, not be suitable for repair.

Abstract: Novel materials and methods for repairing/reclassifying superalloy components are described herein. These materials are non-traditional blends of materials having a much higher base material content than traditional repair/reclassification materials. In embodiments used to repair/reclassify nickel-based components, these materials may comprise about 5-18.9 weight percent of a low melting point alloy and about 81.1-95 weight percent of a base material. In embodiments used to repair/reclassify cobalt-based components, these materials may comprise about 15-30 weight percent of a low melting point alloy and about 70-85 weight percent of a base material. These materials can be used to repair surface defects and/or build up worn or eroded areas of a component to meet precise dimensional and metallurgical requirements. These materials create robust repaired components having a dense, isothermally solidified structure having minimal borides and a high re-melt temperature.

Abstract: A repair pre-soldering structure on a circuit board and a method thereof are proposed. A leave out on a circuit board without any pre-soldering is repaired by a micro-depositing process by applying micro droplets on the circuit board, or a short circuit formed by a pre-soldering with higher height is repaired by a micro-corrosion process. Therefore, the present invention improves fine rate of fabrication and avoids increasing fabricating time due to rework the circuit board, fabrication costs, and so on.

Abstract: A method for vertical removal of excess solder from a circuit substrate includes the use of a sacrificial circuit substrate with a plurality of pads and vias that are solder-wettable. The pads and vias of the sacrificial circuit substrate are placed in vertical proximity to the excess solder of the circuit substrate. The excess solder is heated until it is liquid, wherein the excess solder is wicked vertically onto the pads and into the vias of the sacrificial circuit substrate. Thereafter, the sacrificial circuit substrate is lifted from the proximity of the circuit substrate while the solder is in a liquid, taking the excess solder with it but leaving a predetermined amount on the circuit substrate.

Abstract: A method of restoring dimensions to an article includes the steps of providing an article having a section requiring dimensional restoration, providing a preform having first and second layers made from different materials, and joining the preform to the article.

Abstract: A hollow airfoil is fabricated by providing a casting mold assembly including a casting mold, a casting core, and a standoff spacer that prevents the casting core from contacting the casting mold to define a casting space. A first nickel-base superalloy is cast into the casting space and solidified to form the hollow airfoil. The presence of a through-hole extending through a wall of the hollow airfoil is identified, and the through-hole is closed by welding using a second nickel-base superalloy, without using any freestanding closure element.

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.

Abstract: A method of repairing a braze joint and the resulting joint includes removing an unsuitable portion of a first joining material in a joint between a first member and a second member of an aerospace assembly and cleaning the joint. A stripping solution is used to remove the unsuitable portion of the first joining material. A first cleaning solution is used to clean the joint, and the joint is further cleaned using a second cleaning solution. During a rebrazing step, a second joining material moves into a void left by the removed unsuitable portion from the removal step to form a new joint between the first member and the second member that includes the remaining first joining material and the second joining material.

Abstract: A method of repairing a discrepancy in a casting, weldment or other workpiece comprised of a material characterized by thermoplastic properties includes excising the discrepancy by cutting, milling, or otherwise removing workpiece material surrounding the discrepancy so as to remove the discrepancy and form a cylindrical hole in the workpiece. The method further includes placing a cylindrical plug in the cylindrical hole and moving a friction stir welding tool around the circumference of the plug to weld the plug to the workpiece.

Abstract: The method of the invention enables a coating to be made on at least one face to be protected of a metal substrate and/or article in order to improve its performance in terms of resistance to wear by friction, in particular at high temperature. The method comprises the following steps: providing a flexible sheet derived from at least one plate obtained by the technique of casting a strip by silkscreen printing from a viscous material made of a binder and a metal powder of a superalloy; cutting said flexible sheet to the dimensions of said face to be protected of a metal substrate and/or article in order to constitute a preform; placing said preform on said face to be protected of a metal substrate and/or article; and raising the assembly to a temperature enabling a coating to be formed by establishing a bond between said preform and said face to be protected.

Abstract: A method and electrical structure for separating electronic components from one another joined by solder interconnections. An electronic module is joined to a substrate via a solder interconnection, whereby the electronic module has an electrical heating component residing within a bottom layer thereof adjacent a solder interconnection. Preferably, a chip carrier is joined to a board whereby the chip carrier has an electrical mesh plane for heating adjacent the solder interconnection. Resistive heat is generated within this electrical heating component either by applying an electrical current to the electrical heating component, or by non-contact inductively heating the layer in which such electrical heating component resides to generate resistive heat within the electrical heating component. The resistive heat is transferred to the solder interconnection to allow for localized melting of the solder interconnection and removal of the electronic components from one another.

Abstract: A system and method of using friction stir welding and friction stir processing to perform crack repair or preventative maintenance of various materials and structures, wherein the structures include pipeline, ships, and nuclear reactor containment vessels, wherein the friction stir welding and processing can be performed on various materials including metal matrix composites, ferrous alloys, non-ferrous alloys, and superalloys, and wherein the friction stir welding and processing can be performed remotely and in harsh environments such as underwater or in the presence of radiation.

Abstract: A process for refurbishing a worn surface of a shroud support component of a turbomachine, as well as a shroud support component refurbished with the process. The process generally entails removing a surface region of the worn surface so as to define a repair surface on the component. A braze tape formed from a slurry to comprise a braze material and a wear-resistant alloy is then applied to the repair surface, followed by a heat treatment to cause the braze tape to diffusion bond to the repair surface so as to define a built-up surface. The built-up surface is then machined to define a wear-resistant coating on the component.

Abstract: On production of a component, two primary pieces must often be fixed together to give one piece. In order to achieve the above, it is important that the two primary pieces are oriented in a particular manner during the fixing process, which provides some difficulties. According to the invention, a plug body is fixed to the component by a mounting, whereby the position of the plug body relative to the component remains unchanged during a fixing process.

Abstract: An apparatus for semi-automatically reconditioning an articulated connector while it is still mounted to the end structure of a rail car is disclosed. The apparatus is mountable to the connector and measures to find areas and amounts of wear on portions of the connector. The apparatus then applies weld metal to the worn portion of the connector. The excess weld metal is automatically machined away by the apparatus so that the connector falls within the required dimensions. The apparatus can again measure the weld area to ensure that the specified dimensions have been achieved. A method of aligning an articulated connector to a reconditioning fixture is also disclosed. The method includes securing the fixture to the connector and the use of gauges and tools to appropriately align the objects.

Abstract: A welding material composition, which is a nickel based super alloy having ?? phase and chromium carbides precipitated. The composition comprising 18 to 25% by weight of Co, 15 to 20% by weight of Cr, 1.5 to 5.5% by weight of Al, 5 to 14% by weight of W, 0.05 to 0.15% by weight of C, 0 to 0.02% by weight of B, 0 to 1% by weight of at least one of Ta, Nb, Ti, Mo, Re and Fe, 0 to 0.5% by weight of at least one of V, Zr, rare earth elements and Y, 0 to 1% by weight of Mn, 0 to 0.5% by weight of Si, and the balance being Ni.

Abstract: A method for repairing a component within a SWET box is provided. The method includes providing a SWET box that has a divided interior volume that defines a welding chamber within the interior that is smaller than a total volume of the interior SWET box, positioning a component to be repaired within the welding chamber, introducing protective gas into the SWET box, and controlling the flow of protective gas into the SWET box to facilitate minimizing the consumption of the protective gas within the SWET box.