Abstract: A method for repairing a composite structure using pre-cured plugs. In accordance with one method, composite material is removed from a first composite laminate to form a cavity bounded by a tapered internal surface that extends from an opening at an outer mold line surface of the first composite laminate. In addition, a second composite laminate is machined to form a plug having a tapered surface. Then the plug is placed so that the tapered surface of the plug opposes the tapered internal surface of the first composite laminate. Thereafter, the tapered surface of the plug is bonded to the tapered internal surface of the first composite laminate. Optionally, a hole is drilled in the plug for receiving a fastener.

Abstract: An improved composite material used to connect, strengthen and/or repair concrete. The improved composite material includes a first fiber system including at least one fiber layer. Each fiber layer includes a plurality of fibers. The binding material can be used to optionally secure together the plurality of fibers. The improved composite material is positioned and secured in a slot cut in a concrete structure. The top edge of the improved composite material includes a recess portion.

Abstract: To reduce the processing time in the case of repairing of excessively countersunk bolt openings or surface damage in fiber composite workpieces, it is proposed to countersink the corresponding surface spot to produce a contact surface and a depression for a fiber composite insert body. The fiber composite insert body is placed onto the contact surface and is fixed on the fiber composite workpiece in the depression. In the case of an excessively countersunk bolt opening, a new bolt opening is drilled into the fiber composite insert body, which new bolt opening is subsequently countersunk to the correct countersunk bore depth. In the case of the method, a three-legged application tool can be used which positions and orients the fiber composite insert body correctly and presses it onto the fiber composite workpiece during the curing of the adhesive.

Abstract: A method of assembling an aircraft assembly having a first member and a second member includes drilling at least one first opening through the first member, the at least one opening having a first diameter, and drilling at least one second opening through the second member, the at least one second opening having the first diameter. The method also includes forming a chamfer on the at least one first opening and the at least one second opening, the chamfer having a chamfer diameter, and positioning the first and second members to align the at least one first opening and the at least one second opening. The method further includes drilling the at least one first opening and the at least one second opening to a second diameter, wherein the second diameter is greater than the first diameter.

Abstract: An additive manufacturing system may include a controller operably coupled to a vision system and an additive manufacturing machine. The controller may be configured to determine a workpiece-interface of each of a plurality of workpieces from one or more digital representations of one or more fields of view having been captured by a vision system and determining one or more coordinates of the workpiece-interface of respective ones of the plurality of workpieces, and to transmit one or more print commands to an additive manufacturing machine so as to additively print a plurality of extension segments on the workpiece-interface of respective ones of the plurality of workpieces, with the one or more print commands having been generated based at least in part on the one or more digital representations of the one or more fields of view.

Abstract: A method for testing whether a sealing method is effective may include the steps of testing a flow characteristic of the substrate, sealing the substrate, re testing the flow characteristic of the substrate, then comparing the before and after flow characteristics of the substrate to determine whether the sealing step was effective or to quantify a sealing effectiveness to the sealing step.

Abstract: Flow discouragers, flow path assemblies, and methods for assembling flow path assemblies are provided. For example, a discourager for discouraging fluid flow between adjacent first and second components comprises a first contact surface in contact with the first component; a second contact surface in contact with the second component; and a body connecting the first and second contact surfaces that includes a pocket for receipt of a retention member and a plurality of apertures defined therethrough between the first and second contact surfaces. An exemplary flow path assembly comprises adjacent first and second components and a flow discourager that includes first and second contact surfaces in contact with the first and second components, respectively. The first and second contact surfaces each have a three-dimensional geometric shape to maintain contact with the first and second components. Each discourager may be formed from a ceramic matrix composite material.

Abstract: A method of restoring a wheel (1) to compliance, the wheel having a plurality of ovalized bores (2). The method is characterized in that it includes at least a step of boring a first ovalized bore (2) with the help of a reamer (3) presenting a longitudinal pilot portion (3a) and a longitudinal cutter portion (3b), the cutter portion (3b) presenting teeth (4) defining a cutting diameter (D2), and the pilot portion (3a) presenting a pilot diameter (D1) strictly less than the cutting diameter (D2), the step of boring this first ovalized bore (2) consisting in inserting the reamer (3) into the first ovalized bore (2), beginning with the pilot portion (3a) and followed by the cutter portion (3b), the pilot diameter (D1) being such that it enables the reamer (3) to be guided in translation inside the first ovalized bore (2) for boring.

Abstract: A method of repairing a casing for a gas turbine engine, wherein the casing has a wall extending generally axially, and between at least one radially extending flange, the radially extending flange being formed with a plurality of bolt holes, includes the steps of removing a portion of the flange including at least one bolt hole. The removed portion is associated with a defect and a remaining portion of the flange includes at least one non-removed bolt hole. A replacement portion is obtained to replace the removed portion. The replacement portion is secured in an opening left in the flange by the removed portion. A repaired gas turbine engine casing is also disclosed.

Abstract: A method of treating a ceramic matrix composite article, including selecting an article having a ceramic composition formed by a process comprising an initial melt infiltration at an initial temperature with an initial infiltration material, whereby said article has at least one treatable feature. A portion of the ceramic composite is removed from a region abutting the treatable feature to form a treatment region. A treatment material including a reinforcing fiber is positioned in the treatment region and densified by a first melt infiltration with a first infiltration material including silicon. The first melt infiltration is performed at a first temperature lower than the initial infiltration temperature of the initial melt infiltration.

Abstract: Technical objective is to provide an in-pipe inspection robot for inspecting interior of a pipe, which can exert repulsive force to the pipe when the linear actuator is driven. To this purpose, the in-pipe inspection robot, which is moved inside the pipe to inspect the interior of the pipe, includes a linear actuator which is extendably and contractably driven, and a braking unit configured to fix a rear end of the linear actuator to an inner wall of the pipe and release a front end of the linear actuator from a fixed state, when the linear actuator is being extended, and release the rear end of the linear actuator from the fixed state and fix the front end of the linear actuator to the inner wall of the pipe, when the linear actuator is being contracted.

Abstract: Disclosed is a mechanical clamp useful for repairing localized damage in the wall of an enclosure such as a pressure vessel. The mechanical clamp is an apparatus having a cap having a convex side and a concave side wherein the concave side is adapted for positioning adjacent the wall of the enclosure. The apparatus further includes at least one rod attached securely in the cap for passing through at least one hole in the wall of the enclosure wherein each rod has a first end attached securely in the cap and a second end and each rod is threaded along a portion of the rod including the second end. The apparatus further includes a nut for attaching to the second end of each rod for securing the cap in place adjacent to the wall of the enclosure. Methods for applying the mechanical clamp are also disclosed.

Abstract: Embodiments of a method for controllably reducing of the flow area of a turbine nozzle component are provided, as are embodiments of turbine nozzle components having reduced flow areas. In one embodiment, the method includes the steps of obtaining a turbine nozzle component having a plurality of turbine nozzle flow paths therethrough, positioning braze preforms in the plurality of turbine nozzle flow paths and against a surface of the turbine nozzle component, and bonding the braze preforms to the turbine nozzle component to achieve a controlled reduction in the flow area of the turbine nozzle flow paths.

Abstract: A molding system for a swimming pool coping having a track for receiving a pool liner, the molding system including a molding platform having a flexible panel with a first side and a second side opposite the first side, at least one lip extending from the first side of the flexible panel configured to be received in the track of the swimming pool coping, a plurality of mold supports extending from the second side of the flexible panel and arranged in a row proximate a top of the flexible panel, each mold support having a top surface for supporting a mold block and a flange positioned at a first end of the mold support extending substantially perpendicularly from the top surface.

Abstract: Braze methods include providing a substrate comprising a pre-sintered preform disposed thereon, wherein the pre-sintered preform comprises a mixture comprising a base alloy comprising about 30 weight percent to about 90 weight percent of the mixture and a second alloy comprising a sufficient amount of melting point depressant to have a lower melting temperature than the base alloy. Braze methods further include at least partially covering the pre-sintered preform with a heat resistant material, wherein a melt temperature of the heat resistant material is higher than a melt temperature of the pre-sintered preform, and heating the pre-sintered preform on the substrate.

Abstract: The invention relates to a method for producing a plating (5) of a vane tip. Said method consists of the following steps: a) a vane having a vane tip which is arranged opposite the base of the vane (2) and which comprises a surface which points radially outwards is provided, and b) a porous layer (7) is applied to at least the surface (4) of the vane tip and/or c) a bulge (8) which increases the surface of the vane tip is applied to at least one part of the flanks of the vane tip, said flanks surrounding the surface of the vane tip, and d) the plating (5) is applied to the porous layer and/or the bulge. The invention also relates to corresponding vanes or gas turbines with corresponding vanes.

Abstract: A method of preventing a first door on an over-the-road vehicle from moving from a closed position into an open position. The first door has a first latch assembly that cooperates with a second latch assembly to releasably maintain the first door in its closed position. One of the first and second latch assemblies is maintained in place by at least one fastener extended into a first opening. With the at least one fastener loosened, the first locking assembly is placed on one of: a) one of the doors; or b) the vehicle frame after which a fastener is tightened into the first opening to thereby: i) maintain one of the first and second latch assemblies in place and secure the operatively placed first locking assembly. With the first door in the closed position, a locking device can be connected to the first locking assembly and another part on the vehicle to thereby maintain the first door in the closed position.

Abstract: A repair part enables rapid and efficient repair of damaged metal structures, in particular airframe fuselage skins having internal and external faces, without necessitating any additional thickness compromising the transmission of waves. To this end, the repair part includes a double internal/external plate adapted to be fastened to the internal face and the external face of the metal structure, respectively. The repair part also includes a central hub connecting the internal plate and the external plate and forming a groove between the plates. The part is constituted of a single composite material block, and a glass ply, lining the groove, may be positioned between the plates and the structure. The hub may have passing through it at least one orifice adapted to allow connections to pass through the structure.

Abstract: A method for repairing a gas turbine component includes: identifying on the gas turbine component (10) a worn out location, where the gas turbine component (10) is damaged; removing the damaged location, thereby creating a missing zone (18); manufacturing an insert, which fits into the missing zone (18); putting the insert into the missing zone (18); adjusting the insert in the gas turbine component (10); and joining the adjusted insert to the gas turbine component (10).

Abstract: A modification process and modified article are disclosed. The modification process includes locating an area in an article, removing the area by machining to form a machined region, inserting a modification material into the machined region, securing the modification material to the article, machining the modification material flush with a geometry of the article, and applying a coating over at least a portion of the article. Another modification process includes locating an area under a suction side leading edge tip shroud fillet of an airfoil, removing the area by machining to form a hole, inserting a modification material having improved material properties as compared to an original base material into the hole, securing the modification material in place, machining the modification material and the airfoil to form a new fillet contour, and applying a coating over at least a portion of the airfoil. Also disclosed is the modified article.

Abstract: In a method for repairing a machinery component, one or more defects are detected on the machinery component. At least one portion of the component is removed, wherein the at least one portion includes at least one of the one or more defects. One or more data points are determined for at least one slot, wherein the at least one slot is created by removing the at least one portion of the component. At least one repair coupon is generated from the one or more data points. The at least one repair coupon is attached with the at least one slot.

Abstract: A method of repairing a damaged notch fillet radius of a turbine blade shroud includes a replacement notch fillet radius and a hardface nugget. The damaged notch fillet radius is blended out and a hardface structure positioned proximate the damaged notch fillet radius is removed. A replacement notch fillet radius is formed with weld filler and the hardface nugget is welded to at least a portion of the replacement notch fillet radius.

Abstract: A device for repairing a casing holder of an aeronautical engine extending radially relative to the engine rotational axis and including a plurality of lips, each having a hole drilled therein and evenly distributed on the circumference of the holder. The device includes at least one reinforcement holder that can be attached to clean lips of the case holder via through-holes or blind-holes, the reinforcement holder having two orthogonal planes of symmetry. The device further includes a reconditioning holder mounted on the reinforcement holder via a first part using attachment means positioned in one of the planes of symmetry of the reinforcement holder.

Abstract: A compressor housing defines an inlet bore having a first inlet collar disposed therein. The inlet collar is connected to the housing with a first plurality of radially extending posts. The first plurality of posts is removed to detach the inlet collar from the housing, and the inlet collar is removed from the housing. The same or another inlet collar is concentrically located within a liner. The liner can be located at a radial distance around at least a portion of the inlet collar. The inlet collar is connected to the liner by radially inserting a second plurality of posts through the liner and into the inlet collar. An assembly of the liner containing the inlet collar is inserted into the inlet bore of the housing such that the inlet collar forms the inducer bore of the compressor housing.

Abstract: A method of repairing a damaged portion of a rotor blade includes filling the damaged portion with a filler material. A pre-cured patch assembly is applied over the damaged portion, the patch assembly including one or more laminate packs positionable at at least one of an upper rotor blade surface and a lower rotor blade surface and one or more overwrap plies positionable over the upper rotor blade surface and the lower blade surface. A repair structure for a damaged portion of a rotor blade includes a volume of fill material disposed at the damaged portion.

Abstract: A method for servicing a stator frame of a power generator includes removing a first stator core from a main housing of the frame. A support assembly including a plurality of rails and a trolley is used to insert second laminations of a second stator core into the main housing. The rails extend axially within a bottom portion of the main housing and provide support for the trolley and for the second laminations as they are being inserted into the main housing. The trolley is provided for axial movement on the rails for inserting the second laminations into the main housing.

Abstract: A process of preparing a turbine rotor wheel, a repair tool for machining a turbine rotor wheel, and a turbine rotor wheel are disclosed. The process includes providing the turbine rotor wheel, the turbine rotor wheel having a dovetail slot, a cooling slot, and a dovetail acute corner formed by the dovetail slot and the cooling slot and removing a stress region from the dovetail acute corner. The repair tool permits removal of strained material while also reducing the operating stress of the feature. The turbine rotor wheel includes a machined portion resulting in lower stress for the turbine rotor wheel.

Abstract: A method of refurbishing a rotor blade utilizing a waterjet and an apparatus therefore.

Abstract: A repair process for a composite material panel that forms part of a fuselage, wings, or stabilizers of an aircraft, with the panel having large dimensions and including irregular contours in some areas and edges prone to damages occurring from handling and assembly of the panel. The process a) locates the damage in the element of the composite material panel; b) sands the area that includes the damage in an area larger than the damage, makes a cut in the panel, having the cut of a same form as a piece that will serve to repair panel; c) places the piece in the cut, so that it is perfectly flush with the panel to be repaired; and d) attaches the piece to the composite material panel.

Abstract: One or more crack inhibitors can be installed to improve fatigue performance by producing stress states that prevent or inhibit crack initiation. Crack inhibitors can also prevent or retard crack growth. A mandrel can be used to radially expand the crack inhibitors to both induce compressive residual stresses and to form an interference fit between the crack inhibitor and a workpiece. The mandrel can be removed from the installed crack inhibitor, which is left in the workpiece to ensure proper stress states are maintained.

Abstract: The invention relates to a method for replacing the hoisting ropes of an elevator. By the method of the invention, the hoisting ropes (4) are replaced by first joining the old and new hoisting ropes (4a, 4b) together by their one ends by splicing the ends together around a common core strand (17), whereupon the new set (4b) of hoisting ropes is pulled into place by means of the old set (4a) of hoisting ropes.

Abstract: The present invention relates to a method of repairing a fiber composite solid member having a locally deteriorated surface area, such as having cracks or creases. The solid member may e.g. be a mold for the manufacturing of wind turbine blades or such blades. The method comprises machining a surface section comprising the locally deteriorated surface area in order to obtain a recess having a predefined depth and circumferential shape, placing a repair patch having a predefined thickness and circumferential shape matching the recess in the recess, and fastening the repair patch to the solid member by use of a binder material. At least some of the elastic and thermal properties of the repair patch and the binder material are so that after fastening, the repair patch and the binder material in combination have elastic and thermal properties which are substantially the same as the corresponding properties of the surface section before machining.

Abstract: A method is provided for reconditioning a turbomachine rotor, equipped with circumferentially extending grooves for accommodating blades retained in the grooves at a distance from each other by spacers. The method includes removing the blades and spacers from the grooves and hollowing out the exposed grooves, simultaneously widening the grooves to remove damage-inflicted material. At least one circumferentially extending lateral groove is introduced for accommodating a filler piece in the grooves to fill a gap between blades and hollowed-out rotor grooves. New spacers are provided which are matched to the hollowed-out grooves and have recesses which are matched to the introduced lateral grooves. Filler pieces are provided for inserting into the circumferentially extending lateral grooves and recesses of the new spacers. The blades and new spacers are inserted into the hollowed-out rotor grooves and corresponding filler pieces are inserted into the lateral grooves and matched recesses of the new spacers.

Abstract: A method of the present disclosure includes of repairing a core stiffened structure with structural foam. Another method includes splicing core members together using structural foam. Another method includes joining a core member to a structure using structural foam. Another method includes using structural foam to stabilize a core member during a machining process. Another method includes stabilizing a core member with structural foam to prevent the core member from crushing in autoclave pressure. The present disclosure further includes a core stiffened structure have a core member with structural foam therein.

Abstract: A process for cutting out a damaged area of an aircraft fuselage, in particular so as to repair the damaged area, includes in making at least one cut-out in the fuselage (20) so as to delimit a cut-out area (24) that encompasses the damaged area and that includes at least one flare-out, characterized in that it includes making a hole (34) at the flare-out of the cut-out area (24) with a tool whose diameter corresponds to that of the desired flare-out.

Abstract: A system and method for repairing a screen for use in the paper mill industry consists in using a small circular-shaped die or rotary cutter to cut through a multilayer wire. A first, small diameter punch die is used to cut through all of the damaged layers and then, each successive punch die is configured with a larger diameter and a flange that makes it go less deeply so that it cuts all but the bottom most damaged layer. The process is repeated for each layer with increasing diameter punch dies so that each hole is larger in diameter. In doing so, it is easy to reach the bottom most layer from the top, put in a patch and micro weld it and then move up to the next layer and still having room for the welding because of a larger hole still on the layer above it.

Abstract: It is possible to improve the workability and the stress corrosion resistance by easily performing a repairing operation in a nozzle repairing method and a nuclear reactor vessel. The repairing method includes: removing a first connection portion ((trepanned portion) 208) with respect to an in-core instrument tube (204) in a groove-welding portion (206); removing the in-core instrument tube (204) from a lower mirror (66); leaving and grooving a second connection portion ((existing welding portion) 211) with respect to the lower mirror (66) in the groove-welding portion (206); inserting a new in-core instrument tube (204A) into an attachment hole (203); and groove-welding (so as to form a new groove-welding portion (213)) the inner side of the lower mirror (66) so as to fix the new in-core instrument tube (204A).

Abstract: The present disclosure relates to a method for repairing a portion of an acoustic panel for a nacelle of an aircraft turbojet engine. The panel includes an acoustic skin in which a plurality of acoustic holes are drilled, a solid skin, and a cellular acoustic structure. The cellular acoustic structure, being arranged between the acoustic skin and the solid skin, has a plurality of cells, each of which has one or more drainage openings arranged in one or more of the walls forming each cell. The method includes a step of: defining a part of the acoustic panel to be cut; forming a cutting area closed by the acoustic skin; injecting a resin through the acoustic holes; positioning a replacement cellular acoustic structure in the cutting area and on the acoustic skin; forming a solid replacement skin on the replacement cellular acoustic structure.

Abstract: A method of repairing a turbomachine rotor wheel including a first outer circumferential edge extending to a second outer circumferential edge through a circumferential surface, a dovetail interface extending across the outer circumferential surface between the first and second outer circumferential edges, and a bucket mounted to the dovetail interface includes identifying a defect on one of the first and second outer circumferential edges of the rotor wheel adjacent the bucket, securing the bucket in the dovetail interface to substantially constrain axial movement, and removing a portion of the one of the first and second outer circumferential edges to remove the defect.

Abstract: A process of repairing a component, a repair tool for a component, and a component are disclosed. The process includes removing material from a region of the component. The removing forms a through-cut in the component, forms a partial-frustoconical geometry in the component, forms a substantially partial-frustoconical geometry in the component, forms a partial-spherical geometry in the component, forms a substantially partial-spherical geometry in the component, forms a partial-elliptical geometry in the component, forms a substantially partial-elliptical geometry in the component, forms a partial-cylindrical geometry in the component, forms a substantially partial-cylindrical geometry in the component, is in a direction substantially perpendicular to a surface of the component, is in a direction substantially inclined with respect to the surface of the component, or a combination thereof. The repair tool includes a securing mechanism and a cutting portion for removing a region.

Abstract: A method of repairing an article includes removing an undesirable section of the article, attaching a repair section to the article at a location from which the undesirable section has been removed, and mechanically working the repair section to achieve a reduction in a cross-sectional area of the repair section.

Abstract: Methods are provided for structurally repairing a component having a damaged internally threaded opening. The damaged internally threaded opening is machined to a predetermined diameter, thereby forming a machined opening. At least one notch is formed in the machined opening, thereby forming a notched opening. A selected amount of repair material is cold sprayed into the notched opening, including into the at least one notch. A plurality of internal threads is formed from the repair material to form a repaired internally threaded opening in the component. The repaired components are also provided.

Abstract: A method of repairing a damaged coated vane from a turbine module without removing the vane from the module is taught. The method includes locally removing the coating in the vicinity of the damage as well as any underlying damage in the superalloy substrate. A diffusible coating precursor is then applied to the damage site. A heat treating fixture is then mounted on the vane and repair site is heated to up to 2000° F. in an inert environment to interdiffuse the coating precursor and the substrate. After the diffusion anneal, the vane is cleaned and the module is returned to service.

Abstract: A method of rebuilding used cores comprising the steps of; cutting a used core substantially down the center at a midway cut thereby creating a left core and a right core. Further installing an extension unit in between the left core and right core, thereby forming a lengthened rebuilt core. Further, cutting the damaged ends off the rebuilt core to a selected finished length. The rebuilt core includes a left core obtained from a donor core; a right core obtained from a donor core; an extension unit sandwiched between the left core and the right core for rigidly joining together the left and right cores by connecting to one end of each of the cores.

Abstract: A method is provided for repairing a cylinder head having corrosion and erosion of the gasket sealing surface around the coolant inlet. The engine is disassembled and the corroded material is machined to a selected depth and width creating a pocket having a bottom wall surface and an annular side wall surface surrounding the coolant inlet port. An annular insert is provided having an annular outer side wall, a top wall, a bottom wall, and a central opening. The insert has a thickness greater than the depth of the machined pocket. An adhesive is applied the insert is pressed into the pocket. After curing of the adhesive, the top wall of the insert is machined to a dimension flush with the sealing surface of the head thereby creating a proper sealing surface for the subsequent seating of a replacement gasket.

Abstract: A pin removal assembly for use with an upper block of a crane includes a sheave support and a pin support. The upper block includes a frame, a plurality of sheaves, and a removable sheave pin that defines and axis of rotation for the sheaves and supports the sheaves within the frame. The pin removal assembly includes a sheave support mountable to the frame of the upper block and a pin support mountable to the frame of the upper block. The pin support is configured to support the sheave pin when the sheave pin is removed from the upper block.

Abstract: A method for repairing damaged valve stem assemblies includes enlarging a bore within a body of a valve stem to form an enlarged bore portion and creating a conical hole in an end of the valve stem body around the enlarged bore portion. Internal threads are created within the enlarged bore portion, and a valve stem repair extension is installed in the enlarged bore portion. The valve stem repair extension has a beveled surface that facilitates formation of a hermetic seal between the valve stem body and the valve stem repair extension. The steps of enlarging the bore and creating the conical hole may both be performed using a countersinking drill bit having a beveled cutting portion.

Abstract: Methods for repairing composite containment casings involving providing a composite containment casing having an integrated abradable system, the abradable system having at least one damaged portion, and including a sandwich structure, and at least one abradable layer, removing the damaged portion of the abradable system to leave a hole, shaping a sandwich structure segment to produce a shaped sandwich structure, placing the shaped sandwich structure into the hole in the abradable system, infusing a resin into the shaped sandwich structure, and curing the containment casing having the shaped sandwich structure, and applying at least one abradable layer to the shaped sandwich structure to produce the containment casing having a repaired integrated abradable system.

Abstract: A method for restoring a worn rail section includes cleaning a worn surface of a rail section to expose a clean metal surface, heating the rail section to a first temperature before welding, welding new metal on the clean metal surface of the rail section after heating the rail section to the first temperature, heating the rail section to a second temperature after the welding to heat-treat a heat-affected area caused by the welding, and shaping the rail section, wherein the welding is performed by a gas metal arc welding (GMAW) process.

Abstract: A method for repairing a gas turbine engine component includes applying a braze slurry to a first portion of the component, applying a pre-sintered preform to a second portion of the component that is different than the first portion, and brazing the component.