Abstract: The invention relates to a method for repairing a superficial damaged area in a metal component formed as a result of a loss of material, whereby the damaged area is filled by way of a high-temperature soldering process. In order to improve the durability of the filling, an active solder is used during the high-temperature soldering process.

Abstract: A directionally solidified nickel-base superalloy article has a defect therein extending parallel to the solidification direction. The article is repaired by removing any foreign matter present in the defect, and then heating the article to a repair temperature of from about 60 to about 98 percent of the solidus temperature of the base material in a chamber containing a protective gas that inhibits oxidation of the base material. The defect is filled with a filler metal while maintaining the article at the repair temperature. The filling is accomplished by providing a source of the filler metal of substantially the same composition as the base material of the directionally solidified article, and melting the filler metal into the defect progressively while moving the source of the filler metal relative to the article in a direction parallel to the solidification direction.

Abstract: Brazed structures comprising hollow components having a closure component bonded thereto by a metallic brazing alloy for closing off an end of the hollow component are disassembled by locating a wire transport material in the hollow component and covering the open face of the hollow component with a wire fiber material. Heat is then applied to liquefy the brazing alloy which is drawn up into the metal wire fiber material by capillary affect created by the wire transport material.

Abstract: A method is disclosed for applying solder mask to an area respective of a plurality of receiving pads on a Printed Circuit Board. The solder mask can be at least partially removed during the component removal process exposing the conductor, via and annular ring. The exposed conductor, via and annular ring can cause defects and unreliable solder joints should the solder flow along the conductor and into the via. A small stencil can be used to apply solder mask in a desirable pattern to a selective area of a PCB. Alternatively, an elastomeric transferring apparatus can be used. Various methods can be included to assist in aligning the applicator to the desired area such as an overlaid, dual imaging system.

Abstract: A method for applying at least one bond coating on a surface of a metal-based substrate is described. A foil of the bond coating material is first attached to the substrate surface and then fused thereto, e.g., by brazing. The foil is often initially prepared by thermally spraying the bond coating material onto a removable support sheet, and then detaching the support sheet. Optionally, the foil may also include a thermal barrier coating applied over the bond coating. The substrate can be a turbine engine component.

Abstract: A flash circuit board in a lens-fitted photo film unit includes a board part, and a battery contact part connected to the board part by solder. A part exchanging apparatus for the circuit board includes an eliminating unit, which melts the solder, and removes the battery contact part from the board part while the solder is melted. An assembling unit mounts an unused battery contact part on the board part. The unused battery contact part has an unused form of the first battery contact part. A soldering unit connects the unused battery contact part to the board part by use of solder.

Abstract: A printed circuit board comprises plural electronic parts, a printed-wiring board for mounting the plural electronic parts mounted thereon, and soldered portions provided on the printed-wiring board, wherein the soldered portion connects electrically the printed-wiring board and the electronic part by solder, and a soldered portion to be restored is assigned according to a failure data derived in a preliminary reliability test of a printed circuit board, and the assigned soldered portion is subjected to re-soldering. A method for restoring a printed circuit board comprises steps: recovering a printed circuit board used in market having plural electronic parts mounted through solder at soldered portions provided on a printed-wiring board, assigning soldered portions to be restored according to a failure data derived in a preliminary reliability test of a same printed circuit board, and carrying out a re-soldering at the assigned soldered portion.

Abstract: A process of brazing cracks and gaps in a single crystal article which takes places isothermally under the following conditions: the temperature of the isothermal solidification is between TLiqidus, Braze+5*(wt-%BBraze) and (Tsolidus, base material−70*(wt-%BBraze)), while (wt-%B*wt-%Cr) is between 15 and 40 and (Tsolv.&ggr;′, base material−TLiqidus, Braze) is above 140° C. This results in an homogeneous &ggr;/&ggr;′-microstructure of the isothermal solidified, brazed joint with mechanical properties similar to those of the base material.

Abstract: A method is available for repairing metallic components such as gas turbines, which have mechanically weight-carrying grooves, where the longitudinal edges of the grooves which exist on the component surface are largely in a plane and their actual contour deviates, at least locally, due to removal and/or displacement the component material from the desired contour. The method begins with abrasive blasting of the groove surfaces, followed by closing of the open groove ends by build-up welding, and subsequent filling of the grooves with soldering powder. The soldering powder is heated to liquefaction, then cooled and solidified in a vacuum, and the desired contour of the groove is then machined.

Abstract: Discarded printed circuit boards are sorted according to the alloying elements in solder used on the printed circuit boards. After sorting, the printed circuit boards are heated to melt the solder, and the molten solder is collected.

Abstract: Preforms for use in base metal repair are formed by thermally spraying preferably a blend of a braze alloy and a high temperature alloy onto a separation sheet thereby forming a preform sheet. The separation sheet is removed from the preform sheet and the preform sheet is cut to form individual preforms which can be brazed directly onto a worn area of a high temperature alloy part such as a jet engine part.

Abstract: A process for reconditioning worn or out-of-spec components, in particular titanium components and components which in partial areas are designed to receive further components in a positively locking and dimensionally accurate manner, e.g., as grooves, for which purpose the relevant partial areas are machined until a predetermined dimension is reached, spare parts which correspond to the machined partial areas and have the same geometry minus a predetermined soldering gap are produced from a material which is of the same type as the material of the component, and a soldering medium is introduced between machined walls of the partial area and spare part, which are fixedly joined to the component by a soldering process, after which, if necessary, the partial area(s) in question is/are dimensionally accurately machined.

Abstract: A method for the manufacturing or repair of a superalloy gas turbine component including a liquid phase diffusion bonding process wherein the brazing heat treatment used for the diffusion bonding of a powder material to the component is accomplished by a heat cycle that is performed on the component for another purpose. A manufacturing solution heat treatment, a pre-weld heat treatment, a post-weld heat treatment, or a rejuvenating heat treatment may be used as the brazing heat treatment. The composition of the powder material is selected so that a desired set of material properties is achieved when the powder material is subjected to the dual-purpose heat cycle. In one embodiment, a 50/50 mixture of AM775 and IN939 powder is diffusion brazed to an IN939 superalloy component using a heat treatment which also functions as the post-casting solution heat treatment for the IN939 component.

Abstract: A method, an apparatus (150), and a prefabricated replacement tube (108) are provided for repairing a defect (112) in a tube (102), such as in a waterwall (100). In the method, a replacement tube (108) is prefabricated having a wall (116), a central opening (114) extending through a portion thereof, and a predetermined length. A length of the tube (102), including the defect (112), equal to the predetermined length is removed. The replacement tube (108) is positioned between stubs (126, 128) of the tube (102), and a rotatable torch (152) of an automated welding apparatus (150) inserted through the opening (114) to align with a joint between an end (118, 120) of the replacement tube and a stub (126, 128). The torch (152) is rotated to join it to the stub (126, 128) along the entire joint. The torch (152) is then removed, turned 180 degrees, and reinserted to weld the remaining joint.

Abstract: A HVOF process is used for applying brazing materials to repair surfaces of a substrate such as a turbine blade. The brazing material is applied in powdered form and is free of binders and adhesives. The brazing materials may be any one or more of a nickel based, cobalt based or ferrous based high temperature brazing material. Alloys of these elements may be used together with a temperature depressing melting point element such as boron or silicon.

Abstract: The method comprises introducing a tip (40) of a solid phase welding tool (126) between adjacent surfaces of a crack (132) formed in an aircraft skin. The tool (126) is then operated to produce a friction stir weld so as to weld the adjacent surfaces together and thereby repair the crack (132). Apparatus for performing the method comprises a base (50) having carriage (55) thereon, the arm (76) being pivotally mounted on the carriage (55) and supporting the friction stir welding tool (126). The position of an arm (76) can be adjusted by a screw (94) which drives the rotating tip (40) of friction stir welding tool (126) into the crack (132) to be repaired. The carriage (55) is then moved along the base (50) to draw the tip (40) along the crack. The apparatus is portable and is particularly useful for repairing a cracked skin on an aircraft.

Abstract: A method and apparatus for retaining heat at a pin-in-hole rework site on a printed circuit board during solder fountain rework of the board. A preheated heat retention plate is attached to the rework side of the printed circuit board. The heat retention plate covers a substantial portion of the board surface. During rework of the printed circuit board, the heat retention plate minimizes the temperature gradient between the rework site of the printed circuit board and the remainder of the printed circuit board. During the rework, the heat retention plate can be heated by an active heater in order to maintain a constant temperature gradient between the rework site of the board and the remainder of the board. By minimizing the escape of heat from the rework site, the number of solder cycles required to rework the board is decreased, resulting in reduced board rework times and increased board longevity.

Abstract: A method of repairing a part, such as a rotating disk/drum rotor of a gas turbine engine. The method includes: heating a contact area of a wrought material and a contact area of a wrought part; and pressing the contact area of the material against the contact area of the part to bond the parts. A method of making a rotating part of a gas turbine engine, comprising: heating a contact area of a wrought material and a contact area of a wrought part; and pressing the contact area of the material against the contact area of the part to bond the parts. The methods may include a subsequent heat treatment to provide the desired strength properties to the joint between the material and the part.

Abstract: A directionally solidified nickel-base superalloy article has a defect therein extending parallel to the solidification direction. The article is repaired by removing any foreign matter present in the defect, and then heating the article to a repair temperature of from about 60 to about 98 percent of the solidus temperature of the base material in a chamber containing a protective gas that inhibits oxidation of the base material. The defect is filled with a filler metal while maintaining the article at the repair temperature. The filling is accomplished by providing a source of the filler metal of substantially the same composition as the base material of the directionally solidified article, and melting the filler metal into the defect progressively while moving the source of the filler metal relative to the article in a direction parallel to the solidification direction.

Abstract: A multifunctional weld fixture is provided having a base receiving a component and a plurality of locator tabs disposed around its outer edge. A circumferential array of expansion feet are movably attached to the top surface of the base. A disk-shaped wedge is disposed in sliding engagement with the expansion feet. A cover supports a portion of the component and seals against the component to create an enclosed plenum. The same fixture may be used to expand the component to compensate for shrinkage after the weld is compete.

Abstract: A self-adhesive flexible circuit for printed circuit assembly repair is provided. The flexible circuit comprises a carrier film, a circuit trace and an adhesive. The flexible circuit is placeable on a printed circuit board having a circuit assembly and allows simple repair of boards not designed or manufactured correctly and which contain undesirable short or open circuits or misrouted traces. The flexible circuit allows for placement in a desired location, adherence to the circuit board using its own adhesive. The flexible circuit can then be electrically attached, i.e. solder or conductively adhered, to the board.

Abstract: A method of repairing cracks, imperfections, and the like in a cast article of superalloy composition having a directionally oriented microstructure and growth axis. An aperture, usually frustois created in the article in the location of the crack or imperfection. A plug, having a second directionally oriented microstructure having a directional microstructure with a growth axis and a superalloy composition substantially identical to the article superalloy composition, is created. Such plug further possesses an inner end, an outer end, and a surface therebetween. The plug is inserted into the aperture whereby the plug growth axis is oriented in alignment with the article growth axis. Bonding material is applied between the surfaces of the plug and the aperture, before or after insertion of the plug into the aperture. The article is thereafter heated such that the bonding material joins the surface of the plug and the aperture.

Abstract: A method of repairing gas turbine engine components is provided. The method includes removing the damaged portion and fabricating an insert to match the removed portion. The insert is precision machined and crystallographically matched to the original component, and then bonded to this component using transient liquid phase bonding techniques and suitable heat treatment.

Abstract: The present invention relates to a method for repairing components formed from a single crystal nickel based superalloy. The method comprises the steps of applying a repair alloy to at least one portion of a component formed from the single crystal nickel based superalloy and heating the component with the repair alloy thereon to a temperature that avoids recrystallization and repair zone incipient melting of the single crystal nickel based superalloy. Following the heating step, the component is preferably rapidly cooled and subjected to an aging treatment.

Abstract: A directionally solidified nickel-base superalloy article has a defect therein extending parallel to the solidification direction. The article is repaired by removing any foreign matter present in the defect, and then heating the article to a repair temperature of from about 60 to about 98 percent of the solidus temperature of the base material in a chamber containing a protective gas that inhibits oxidation of the base material. The defect is filled with a filler metal while maintaining the article at the repair temperature. The filling is accomplished by providing a source of the filler metal of substantially the same composition as the base material of the directionally solidified article, and melting the filler metal into the defect progressively while moving the source of the filler metal relative to the article in a direction parallel to the solidification direction.

Abstract: A process (30) for the repair of a component part (36,66) incorporating a cold spray process step (50) for depositing material particles (54) to fill a discontinuity (40) in the part surface (42) or to create a desired surface geometry (78) on the part (66). The cold spray process may be controlled to provide a grit blasting effect prior to depositing the material in order to remove contaminants (48) from the surface of the part. The material deposited (56) by the cold spray process may form a joint (78) between an insert (72) and the part (66). The process may be used to repair parts made of directionally solidified (DS) or single crystal (SC) base material (44) without causing a re-crystallization of the base material. The process may further be used to deposit repair material (56) over a braze material (22).

Abstract: A method for soldering pipes configures the pipes being soldered such that water running through the pipes is not permitted to pool in the pipes. The method also configures the pipes to facilitate sealing of the pipes after the soldering is completed.

Abstract: An article includes turbulation material bonded to a surface of a substrate via a bonding agent, such as a braze alloy. In an embodiment, the turbulation material includes a particulate phase of discrete metal alloy particles having an average particle size within a range of about 125 microns to about 4000 microns. Other embodiments include methods for applying turbulation and articles for forming turbulation.

Abstract: In a soldering process for treating tears, recesses, or other material defects in the surface of thermally and mechanically highly stressed components of gas turbines, a nickel foam is applied together with the soldering powder, which can also be mixed with another filler. After this, a heat treatment of the soldering process is performed.

Abstract: A HVOF process is used for applying brazing materials to repair surfaces of a substrate such as a turbine blade. The brazing material is applied in powdered form and is free of binders and adhesives. The brazing materials may be any one or more of a nickel based, cobalt based or ferrous based high temperature brazing material. Alloys of these elements may be used together with a temperature depressing melting point element such as boron or silicon.

Abstract: An undersize repair region of a gas turbine engine stationary shroud is repaired with a sufficient mass of a repair material. The repair material includes a first fraction of a first powder of a first alloy component, and a second fraction of a second powder of a second alloy component. The first alloy component and the second alloy component have different solidus temperatures. The repair material is placed in the repair region. The repair material and the repair region are heated to melt the repair material but not the repair region, and thereafter the repair material and the repair region are cooled to solidify the repair material.

Abstract: A tubular receptacle receives a flammable composition providing a heat source for the purpose of heating and expanding railroad rail segments defining a fracture at their ends. The receptacle is of a pliable nature and may include a fuse. The flammable composition includes alcohol and a petroleum product along with fragments of synthetic plastic fibers. A method is disclosed for utilizing the heat source.

Abstract: A hole (3) formed in a superalloy turbine blade (12) is sealed by providing a superalloy plug (4), machining the hole to be of a configuration can receive the plug therein, and bonding the plug to the turbine blade. The plug can be of a threaded or unthreaded configuration and can be of a tapered or straight configuration. The plug is bonded to the hole by applying a bonding catalyst to one or both of the plug and the hole or by positioning the bonding catalyst therebetween, and providing appropriate treatment to the bonding catalyst, such as heating or other treatment, to cause the bonding catalyst to form a bond between the plug and the turbine blade to form a joint therebetween. Any of a variety of known bonds can be employed to form the joint. The plug additionally may be pre-cooled prior to insertion thereof into the hole in the turbine blade, or alternatively may be of a coefficient of thermal expansion that is greater than that of the turbine blade.

Abstract: A method for cooling electrical components on a substrate during a rework process. A block of a porous, thermally conductive material, saturated with a liquid, is positioned on an electrical component to be cooled. During the rework processing of an adjacent electrical component, the liquid in the porous, thermally conductive block vaporizes, thereby maintaining the temperature of the electrical component below its reflow temperature. A second thermally conductive block, in thermal contact with the porous, thermally conductive block, and the substrate on which the electronic component to be cooled is attached, is positioned between the electronic component to be cooled and the electronic component undergoing rework. A supply of liquid is provided to the porous, thermally conductive block to maintain the temperature of the electronic component to be cooled at a predetermined level for a specified period of time.

Abstract: A method for repairing/manufacturing an integrally bladed rotor for a turbine or turbo engine, in which, in the case of a repair, at least one vane section to be replaced is removed leaving a stub section to which a replacement vane section is to be welded, and, in the case of manufacturing, a carrier to be provided with vanes has stubs projecting over its peripheral surface, to each of which a vane is to be welded, includes the steps of: arranging an inductor around the front face of the stub section or stub; positioning a replacement vane section or vane at a small radial distance from and aligned with the stub section or stub; and welding the replacement vane section or vane to the stub section or stub, respectively, in a protective gas atmosphere by exciting the inductor with high-frequency current and moving the opposing heated part surfaces together.

Abstract: A method for reworking integrated circuit (IC) wafers having copper-metallized bond pads covered by deposited layers of a barrier metal and a bondable metal. After identifying the wafers with off-spec metal layers, the wafers are chemically etched using selective etchants consecutively until the metal layers over the bond pads are removed without damaging the copper metallization. Replacement metal layers are finally deposited over the bond pads. Specifically, the bondable metal, such as gold, is selectively removed by a cyclic dithio-oxamine compound, dissolved in tetra-hydro-furane or acetone. The barrier metals, such as nickel and palladium, are removed by a mixture of inorganic and organic oxidizing acids.

Abstract: The invention relates to a method for repairing a superficial damaged area (2) in a metal component (1) formed as a result of a loss of material, whereby the damaged area (2) is filled by way of a high-temperature soldering process.

Abstract: Castings for gas turbine parts exposed on one side to a high-temperature fluid medium have cast-in bumps on an opposite cooling surface side to enhance heat transfer. Areas on the cooling surface having defectively cast bumps, i.e., missing or partially formed bumps during casting, are coated with a braze alloy and cooling enhancement material to salvage the part.

Abstract: A welding bead 50 is formed along to a jointing potion 40 using friction stir welding on a first frame member 20 and a second frame member 30, each of which is a hollow extruded molded base member made of an aluminum alloy A6N01 material. When a defect exists in this welding bead 50, the welding bead including this defect is moved by a grinding processing and then a mending zone is formed. In this mending zone, a mending bead is formed using TIG welding. The welding rod used in this TIG welding is made of the same material as the base member of the frame member, and so the composition of the welding bead is formed homogeneously. In the friction stir welding portion, a hairline processing is performed, so that a surface having a beautiful appearance, in which a boundary between the frame members and traces of the defect are inconspicuous, can be obtained.

Abstract: A method of removing rib plugs from steam generator tubes in energy producing units such as nuclear reactors includes the removal of the expander element or mandrel from the expanded part of the rib plug, TIG welding a bead on the available internal surface of the plug in a spiral manner from the bottom to the top thereof to relax the rib plug from its forced contact with the tube and removal of the rib plug as a unit from the tube after it has cooled down from the welding process.

Abstract: A method and system for cleaning a metal article. The system is used to employ a method that comprises placing the article in a means defining a chamber; subjecting the article to a gaseous atmosphere in the means defining a chamber, where the gaseous atmosphere consisting essentially of carbon, hydrogen, and fluorine; and subjecting the article to the gaseous atmosphere at a temperature in a range from about 815° C. to about 1100° C. to clean the article.

Abstract: The present invention relates to a new type of lining with two layers, one of which, obtained by welding deposit, can be used for the protection of internal surfaces of chemical equipment capable of abide pressures lower than 100 MPa, in processes for the direct synthesis of urea. The present invention also relates to an original method for the preparation and installation of this lining, by the assembly of laminar elements with two layers, obtained by welding deposit on relatively thin stainless steel plates, so as to avoid significant distorsion effects on the plate itself.

Abstract: A process (30) for the repair of a component part (36, 66) incorporating a cold spray process step (50) for depositing material particles (54) to fill a discontinuity (40) in the part surface (42) or to create a desired surface geometry (78) on the part (66). The cold spray process may be controlled to provide a grit blasting effect prior to depositing the material in order to remove contaminants (48) from the surface of the part. The material deposited (56) by the cold spray process may form a joint (78) between an insert (72) and the part (66). The process may be used to repair parts made of directionally solidified (DS) or single crystal (SC) base material (44) without causing a re-crystallization of the base material. The process may further be used to deposit repair material (56) over a braze material (22).

Abstract: A method for applying a wear coating on a surface of a substrate is described. A foil of the wear coating is first attached to the substrate surface, and then fused to the surface, e.g., by brazing. The wear coating may be formed from a carbide-type material. The substrate is very often a superalloy material, e.g., a component of a turbine engine. A method for repairing a worn or damaged wear coating applied over a substrate is also described, along with related articles of manufacture.

Abstract: A process and apparatus for removing flip chips with C4 joints mounted on a multi-chip module by applying a tensile force to one or more removal member bonded to the back of one or more flip chips during heating of the module to a temperature sufficient to cause the C4 joints to become molten. The tensile force can either be a compressed spring, or a bi-metallic member which is flat at room temperature and becomes curved when heated to such temperature, or a memory alloy whose original shape is curved and which is bent flat at room temperature but returns to its original curved shape when heated to such temperature. An adhesive is used to bond the removal member to the chip to be removed and is a low temperature, fast curing adhesive with high temperature tolerance after curing.

Abstract: Friction Pull Plug Welding (FPPW) is a solid state repair process for defects up to one inch in length, only requiring single sided tooling (OSL) for usage on flight hardware. Early attempts with FPPW followed the matching plug/plate geometry precedence of the successful Friction Push Plug Welding program, however no defect free welds were achieved due to substantial plug necking and plug rotational stalling. The dual chamfered hole has eliminated plug rotational stalling, both upon initial plug/plate contact and during welding. Also, the necking of the heated plug metal under a tensile heating/forging load has been eliminated through the usage of the dual chamfered plate hole.

Abstract: A damaged area of a metal sheet, such a conveyor belt, is repaired by affixing frames to upper and lower sides of the sheet, and rotating a center element that is rotatably mounted in one of the frames, whereby a chip-removing cutting blade disposed on the center element cuts a piece out of the metal sheet following a number of rotations of the center element. The same mechanism is used to cut a correspondingly shaped replacement piece from a metal replacement sheet. The replacement piece is then positioned in the hole cut in the sheet to be repaired, and the center element carrying the cutting blade is replaced by a center element carrying a welding device. The welding device welds a joint between the replacement piece and the sheet as the center element is rotated. Inert shielding gas is supplied above and below the weld joint during the welding operation, and support rollers keep the sheet and the replacement piece flush with each other during the welding operation.

Abstract: A method and apparatus is described for reworking a printed circuit board having plugged vias and plated through holes. The printed circuit board, supported by a movable local support, is heated from only the bottom side by a heating device near the area on the PCB that contains the plated through hole or holes to be reworked. The heating device is removed when the solder in the plugged PTH is completely melted. At that time, blast air is turned on to remove and blow off the excess solder in the PTH. The compressed air is more effective in displacing the molten solder than is vacuuming, and has less chance of damaging the PCB than do conventional reworking methods, due to the non-contact nature of the invention.

Abstract: Method of repairing metallic components having weight-carrying grooves, whose actual contour, after the removal or displacement of the component material, deviates from the desired contour, by applying a metallic additional material to the actual contour as well as by the removing machining to the desired contour.

Abstract: A core for molding apparatus includes inner surface configurations for improving the cooling of injected plastic material.