Abstract: A blade for a gas turbine includes a removed portion space, and further includes an airfoil portion defining the removed portion space, the airfoil portion formed from a base material, and a replacement component formed to fill the removed portion space. The replacement component is formed from a material that includes 50%-80% base material, 0%-30% braze material, and 0%-8% aluminum. A braze joint is formed between the airfoil portion and the replacement component to attach the replacement component to the airfoil portion and fill the removed portion space.

Abstract: A method of repairing a component includes removing a damaged portion from the component to leave a first interface surface that is defined by a continuous curve, mixing a powdered base material and a binder to define a mixture, and printing the mixture into a desired shape without melting the base material. The method also includes removing the binder from the desired shape, solid-state sintering the desired shape to form a replacement piece having a second interface surface that is defined by the continuous curve, and attaching the second interface surface to the first interface surface to replace the damaged portion of the component.

Abstract: According to one embodiment, a gas recovering apparatus includes a casing and a tube. The casing is provided with an inlet through which a gas flows in, a first outlet for discharging a first gas containing a gas to be recovered of the gas, and a second outlet for discharging a second gas other than the first gas of the gas. The casing is evacuated via the first outlet. The tube is provided in the casing from the inlet to the second outlet, and has a high permeability to the first gas and a low permeability to the second gas.

Abstract: A repair method for self-detecting and self-healing of corrosion defects in metals can achieve self-detecting and self-healing repair of an initial corrosion defect and be used to repair a micron-level corrosion defect. Furthermore, the self-detecting and self-healing repair method can be used to effectively repair an initial corrosion defect in a large-sized high-precision structural component, thus effectively improving the service safety of the high-precision metal structural component and prolonging the service life of the same.

Abstract: An assembly is provided for a gas turbine engine. This gas turbine engine assembly includes a split case structure. The split case structure includes a first wall, a second wall, a first case segment and a second case segment. The first wall extends axially along and circumferentially about an axial centerline. The second wall extends axially along and circumferentially about the axial centerline. The second wall is radially outboard of and axially overlaps the first wall. The first case segment is configured to form a first portion of the first wall and a first portion of the second wall. The second case segment is configured to form a second portion of the first wall and a second portion of the second wall. The second case segment is circumferentially adjacent and attached to the first case segment at a joint.

Abstract: Methods and structures are provided for implementing embedded wire repair for printed circuit board (PCB) constructs. A repair wire layer is provided within the PCB stack with reference planes on opposite sides of the repair wire layer. When a repair connection is required, an appropriate plated through hole (PTH) is drilled to form the repair connection using the repair wire layer.

Abstract: A turbine exhaust case assembly has an exhaust case and a bearing housing mounted in the exhaust case. A plurality of fasteners secures the bearing housing to the exhaust case. A spacer is mounted between the fasteners and one of the bearing housing and the exhaust case. The fasteners are welded to the spacer, thereby locking the fasteners against rotation.

Abstract: A component has an edge extending in a first direction. The component includes a filler disposed in the component. The filler has at least a first portion and a second portion. The first portion extends in a second direction from the edge into the component. The second portion of the filler extends from the first portion in a third direction. The second direction is substantially orthogonal to the first direction.

Abstract: It is an objective of the invention to provide a steam turbine rotor that is capable of both reducing SCC susceptibility and improving LCF life thereof. There is provided a steam turbine rotor, comprising a rotor disk in a low pressure final stage L-0, and another rotor disk in a plurality of stages including a stage L-1 positioned closer to a high pressure side than the low pressure final stage L-0, the rotor disk in the low pressure final stage L-0 and the rotor disk in a plurality of stages including the stage L-1 being joined by welding, wherein a material of both the rotor disk in the low pressure final stage L-0 and the rotor disk in a plurality of stages including the stage L-1 is a 12Cr steel and has a tensile strength of 900 to 1200 MPa.

Abstract: A method for creating a blade (11) for a turbo-engine and such a blade are disclosed. Components (19) of the blade are produced by an additive production method such as selective laser melting or fusion, while a main body (18) is produced by casting, for example. The blade components (19) may consist of a different material than the basic body (18). The components or body may carry functions such as serving as drainage slots (24). Expense related to the use of additive production methods occurs only for the components (19) in which a complicated geometry, for example, must be implemented. The remaining components in the form of the main body (18), comprising the blade (27), the blade foot (28) and the blade head (29), can be cost-effectively implemented as a cast part or a sheet metal part.

Abstract: Modified turbine components include an original turbine component comprising an outer wail enclosing an internal cavity, wherein the outer wall has an original portion removed therefrom to expose the internal cavity, and, an internally cooled supplemental element joined to the outer wall that replaces the original portion removed from the outer wall and re-encloses the internal cavity. The internally cooled supplemental element comprises one or more cooling channels that circulate air from the internal cavity through at least a portion of the internally cooled supplemental element.

Abstract: A method for repairing damage to the coating of an aircraft fuselage, the coating being made of fiber-reinforced composite material. This method comprising making a cut-out in the fuselage with a substantially parallelepipedal outline around the damage and drilling a circular hole substantially centered on the intersection of the sides of the outline of the parallelepiped of the cut-out at each of the corners of the outline before the cutting out operation.

Abstract: A method for salvaging a surface of a pin-bore assembly associated with a carrier is provided. The method includes inserting a sleeve within a bore of the carrier. The method also includes installing a retention mechanism that secures the sleeve within the bore of the carrier.

Abstract: A remanufactured planet carrier is disclosed having a first plate and a second plate spaced apart from and oriented generally parallel to the first plate. Supports join and support the first and second plates. The remanufactured planet carrier further has a plurality of first pin bores in the first plate and a plurality of second pin bores in the second plate. The first pin bores are parallel and generally aligned with the second pin bores. A cylindrical member extends from a central axis of the second plate away from the first plate with a shaft bore formed within the cylindrical member. The first and second pin bores and the shaft bore each have a surface layer with a hardness of at least about 180 BHN and a strength of at least about 500 MPa.

Abstract: Disclosed is a method for repairing a receiving hook for guide vanes, wherein the receiving hook is arranged in a housing of a turbomachine. The method comprises removing first material in a region of the receiving hook, which region extends over the circumference of the housing and thereafter applying second material in or on a region which extends over the circumference of the housing. The application of second material is performed using localized heat.

Abstract: Golf club heads comprising weighted materials that can be added, removed, and moved in order to change the weight and center of gravity of the club. In some instances, the weighted material is a polymer composition comprising metal and having a specific gravity greater than about 4. Also disclosed are methods of modifying the center of gravity of a golf club head and methods of manufacturing golf club heads.

Abstract: An apparatus and method for performing repair on the floor or side wall of a swimming pool or of a large body of liquid by creating a workable space without fully draining the water or liquid. The apparatus utilizes a sturdy solid tube to create a separation between the area enclosed within the tube and body of liquid outside. A guiding lid with multiple openings allows a specific tool to be guided into the tube for conducting repairs. A draining assembly drains the liquid enclosed within the tube. A drier assembly creates a dry workable space within the tube. A repair assembly is used to conduct a specific repair operation including spray painting, filling up holes, filling in caulking to cover up cracks, sanding within the workable space. An inspection assembly is used to remotely inspect the surface that needs repair.

Abstract: A method for repairing or reconditioning a damaged component includes working the damaged component by removing a damaged region from the damaged component while creating a cutout corresponding to the damaged region so as to provide a worked component. The worked component is measured and a computer-aided design (CAD) model of a replacement piece based on the measuring and is configured to be inserted into the cutout of the worked component is created. The replacement piece is produced based on the CAD model. The replacement piece and the worked component are connected by joining.

Abstract: A method for repairing a degraded bolt hole in a casing flange by reaming and removing at least some corrosion on an inside and around the hole to form a reamed hole, mounting the flange to float relative to upper and lower electrodes of a welding machine, radially and axially clamping an area of the flange surrounding the reamed hole, placing upper and lower filler slugs in the reamed hole, placing the electrodes against upper and lower filler slugs and applying a welding current through the electrodes while applying pressure to the filler slugs with the electrodes and resistively heating and melting the filler slugs to form a weldment, and pulsing the welding current on and off. Pulsing may be performed with progressively increasing amounts of current. In situ tempering under the pressure of the electrodes may be performed on a substantially liquid pool formed by the welding current.

Abstract: A preform, for repairing an abradable seal component of a gas turbine engine, includes a multilayer stack that has a first layer and a second layer. The first layer is operative to bond the multilayer stack to a structural substrate of an abradable seal. The first layer includes structural material that corresponds to a material of the structural substrate and braze material that is compatible with the structural material. The second layer includes an abradable material. The multilayer stack is operative to bond to the structural substrate of the abradable seal component during a brazing process such that the second layer forms a replacement abradable layer of the abradable seal component.

Abstract: A method is provided for repairing a turbine nozzle assembly with an insert and a support structure. The method includes positioning the insert on the support structure of the turbine nozzle assembly; and plug welding the insert to the support structure of the turbine nozzle assembly.

Abstract: A method of remanufacturing an injector involves an original lead extending from an overmold block. A milling cutter is used to mill a cavity into the overmold block to provide access to the original lead. The milling cutter splits the original lead into a remainder portion and a discard portion. A replacement lead is inserted into the overmold block to overlap with the remainder portion, and the overlapping leads are soldered to each other. The exposed overlap area is encapsulated with filling material. The original lead is preferably cut such that a tip of the remainder portion is angled, pointed, or otherwise shaped to increase the surface area that is exposed at the tip. The increased exposed surface area increases the area over which the replacement lead and the remainder portion make contact with each other when overlapping. Greater contact between the soldered leads strengthens their connection.

Abstract: A crack-resistant member for preventing crack propagation, a method of preventing crack propagation, and method of assembly a tower are provided. The crack-resistant member includes at least one insert attached to at least one removed portion at a predetermined location along a girth weld and adjacent a heat affected zone of the tower. The at least one insert is positioned perpendicular to a weld direction and intersecting the girth weld. The at least one insert prevents crack propagation in the girth weld of the tower.

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: 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: 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: A method for bonding airfoil sections includes aligning upper and stub airfoil sections having upper airfoil pressure and suction sides and stub airfoil pressure and suction sides respectively, pressing together upper and stub airfoil cross sections at upper and stub airfoil distal ends of the upper and stub airfoil sections respectively, and then resistance welding, preferably solid state resistance welding, the upper and stub airfoil sections together along the upper and stub airfoil cross sections by passing electrical current across the upper and stub airfoil cross sections. The upper and stub airfoil sections may be clamped between pressure and suction side upper airfoil electrodes and between the stub airfoil pressure and suction sides respectively. The method may be performed while the stub airfoil section is attached to an airfoil carrier such as a rotor disk rim, a gas turbine engine drum, or a gas turbine engine blade platform.

Abstract: A method for forming pockets of a drill bit includes inserting a displacement plug in a cutter pocket defined by a substrate of a drill bit. A hardfacing material is applied to the substrate and the displacement plug using a plasma arc welding torch. The heat from the plasma arc welding torch reduces an oxide layer on the outer surface of the displacement plug, and the molten hardfacing material flows over the displacement plug and wets against the displacement plug. The displacement plug is then removed to reveal a final cutter pocket configured to receive a cutter compact. The cutter compact is secured to the final cutter pocket by brazing.

Abstract: A method of repairing an integrally bladed rotor includes the steps of placing a support collar around at least a leading and trailing edge portions of the blade stub, and performing linear friction welding to add a replacement airfoil to the blade stub. The linear friction welding is generally along a direction between the leading and trailing edges. In addition, the support collar leading and trailing edge portions are connected together.

Abstract: A method and apparatus for fixturing an airfoil stub during linear friction welding are described. Critical clamping support structures are manufactured by a direct digital manufacturing process such as direct metal laser sintering to minimize time and expense of the process.

Abstract: A method for repairing a degraded bolt hole in a casing flange by reaming and removing at least some corrosion on an inside and around the hole to form a reamed hole, mounting the flange to float relative to upper and lower electrodes of a welding machine, radially and axially clamping an area of the flange surrounding the reamed hole, placing upper and lower filler slugs in the reamed hole, placing the electrodes against upper and lower filler slugs and applying a welding current through the electrodes while applying pressure to the filler slugs with the electrodes and resistively heating and melting the filler slugs to form a weldment, and pulsing the welding current on and off. Pulsing may be performed with progressively increasing amounts of current. In situ tempering under the pressure of the electrodes may be performed on a substantially liquid pool formed by the welding current.

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: Methods for repairing abradable seals of gas turbine engines include providing an abradable seal component of a gas turbine engine, the seal component having a structural substrate; providing a first preform to restore the structural substrate; and providing a second preform to form an abradable layer of the component. Preforms include a multilayer stack having a first layer and a second layer.

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.

Abstract: A method of manufacturing a fuel injector having high-flow orifices in its tip includes removing a bulb from a fuel injector tip having at least one spray orifice with a first diameter, and friction welding a slug to the fuel injector tip, including forming a fused interface of material of the slug and material of the fuel injector tip. The method further includes modifying the slug subsequent to friction welding the slug to the fuel injector tip, including forming a new bulb from the slug having at least one spray orifice therein with a different diameter than that of the removed bulb. A remanufactured fuel injector, and fuel injector tip, includes an injector tip body having a first tip portion of a first material and a second tip portion of a material compatible for friction welding with the first material.

Abstract: A method of repairing an aperture and adjacent defect wherein one or more defects proximate an aperture are removed from the base material proximate the aperture in an arc shape. An insert containing a profile that corresponds to the arc shaped section of the base material removed is welded to the base material. The weld is accomplished with a single curved path. Next, the insert is removed to create a repaired aperture and a surrounding section that has essentially the same dimensions as the aperture and surrounding section prior to the repair.

Abstract: A method for external repair of a leak in an in-service fluid containment vessel in which a fluid venting device is affixed to the outer surface of the fluid containment vessel so as to enable venting of the leaking fluid to the atmosphere during the remainder of the method steps. A composite repair material is applied over the fluid venting device and the fluid containment vessel and allowed to cure. During the curing period, fluid leaking from the fluid containment vessel is vented to the atmosphere. After curing of the composite repair material, a sealant is provided to the leak by way of the fluid venting device.

Abstract: A method of adding material to a nickel-based superalloy component, such as a gas turbine rotor disk, without damaging the underlying material and without creating an unacceptable level of cracking. The method is advantageously applied in the repair of Alloy 706 turbine rotors having experienced operating failures in the steeple region of the disk. Once the damaged material is removed, replacement nickel-based superalloy material is added using a welding process that protects both the underlying material and the replacement material. The replacement material may be added by welding, with the preheat temperature maintained no lower than 100° C. below the aging temperature of the deposited alloy and with the interpass temperature maintained below the solution annealing temperature of the alloy. Alternatively, the replacement material may be preformed and welded to the original material using a friction welding process.

Abstract: A method for repairing or reconditioning a damaged component includes working the damaged component by removing a damaged region from the damaged component while creating a cutout corresponding to the damaged region so as to provide a worked component. The worked component is measured and a computer-aided design (CAD) model of a replacement piece based on the measuring and is configured to be inserted into the cutout of the worked component is created. The replacement piece is produced based on the CAD model.

Abstract: A method for repairing damaged bolt holes in a flange having a plurality of circumferentially spaced bolt holes therein, with each bolt hole defining a center axis and the flange defining an outer diameter edge. The method includes removing parent material of the flange in a first pattern, and metallurgically joining a replacement detail to the parent material of the flange a location where the parent material of the flange was removed in the first pattern. The first pattern is bounded by first, second, third and fourth points. The first point corresponds to the center axis of a first of the plurality of bolt holes, the second point corresponds to center axis of a second of the plurality of bolt holes, and the third and fourth points are defined at the outer diameter edge of the flange circumferentially spaced from each other.

Abstract: An environmentally responsible system and method of reusing discarded guardrail materials to provide affordable, high-strength barriers and fencing. Discarded guardrails, guardrail posts, and guardrail blockouts are resized and reconfigured to provide barriers for use in alternative applications, such as agrifencing, where the high-strength, durability, and low cost of these formerly DOT-approved guardrail materials provide superior performance to wood and thin metal barriers. The invention also greatly increases the return on investment of state DOTs by providing an aftermarket for used guardrail materials, thereby allowing state DOTs to recover much of the initial costs, which can then be used to offset future costs in order facilitate more highway improvement projects.

Abstract: A method for restoring blade dovetails to their original shape comprising the steps of removing damaged material from a blade dovetail at a damage site, physically depositing a metal at the damage site in an amount sufficient to replace the removed damaged material, and machining the blade dovetail to the original shape.

Abstract: A method for joining fluid carrying steel pipes together including the following steps. Identifying a subject pipe section to be replaced and intercepting the fluid flow by fastening stoppers inside of pipe portions upstream and downstream from the subject pipe section. Removing the subject pipe section, leaving in place upstream and downstream pipe portions. Inserting along each of the first and second pipe portions a protective stopper and chamfering the edges of those pipe portions and then mounting first and second sliding sleeves with sealing rings thereover. Removing the protective stoppers from the pipe portions and positioning between those pipe portions a new connection piece. Displacing the first and second sliding sleeves onto the connection piece so that sealing rings are arranged on the connection piece and fixing the sliding sleeves to the pipe portions and to the connection piece.

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: The apparatus requires a replacement board capable of replacing the existing bulb.

Abstract: A method for restoring a crack formed within a turbo charger engine transition section, the method including preparing a crack in the transition section to receive a material within the crack, applying the material within the crack, and retaining structural integrity of the transition section proximate the crack while at least one of preparing the crack and applying the material.

Abstract: A method of replacing a damaged blade (12A) of an integrally bladed rotor assembly (10) including a disc (14) and a plurality of blades (12) extending outwardly from the disc (14) includes the steps of; removing the damaged blade (12A) to leave a blade stub (16) projecting from the disc (14); depositing a collar (22) of metal around the blade stub (16) at a position physically separated from the disc (14); attaching a replacement blade (12B) to the stub (16) by linear friction welding; and removing the collar (22). A body (20) of a material may be deposited between the disc (14) and the collar (22) to protect the disc (14) from damage.

Abstract: A method of repairing a vessel bottom head penetration of a nuclear reactor is presented, said penetration comprising a tube fastened to the internal wall of the vessel bottom head by an internal weld bead and emerging outside the vessel bottom head, forming a groove. The method consists inter alia in preparing a mock-up representative of the vessel bottom head penetration to be repaired and in depositing this mock-up on site in an irradiation-free zone, in fastening two half-inserts to this mock-up in the groove, each half-insert having a profile corresponding to the half-profile of the groove, in forming, again on this mock-up, automatically and by remote control, a weld bead in the groove, in carrying out a dimensional check and, after validation of this weld bead, in carrying out the steps of fastening the two half-inserts and forming a weld bead automatically, directly in the groove of the vessel bottom head penetration to be repaired.

Abstract: A method for retrofitting a piece of equipment having a flexible track assembly is disclosed and may include disassembling an existing idler shaft from an idler gear and from at least one bearing block attached to the piece of equipment. The method may also include attaching a sleeve within the opening of the idler gear. A new idler shaft may then be positioned within an opening of at least one of the bearing blocks and within an opening in the sleeve. The new idler shaft and idler gear being configured such that the new idler shaft, idler gear, and sleeve rotate together. The method may then include placing at least one bushing liner within the opening of at least one bearing block and attaching a retaining device to at least one end of the new idler shaft to retain the new idler shaft axially.

Abstract: A method and apparatus for the production of compacted powder elements. More specifically, the improvement of tooling for powder compaction equipment, and the processes for making such tooling. The improvement comprises the use of a ceramic tip or similar component in high wear areas of the tooling, particularly center pins. Moreover, the use of such ceramic components enables reworking and replacement of the worn tool components.