Abstract: A method of modifying a compressor wheel includes forming a stake-receiving feature having a reconditioned surface on a radial face of an axial slot in a rim of the compressor wheel. The forming includes removing stake marks in the radial face. A gas turbine wheel assembly includes a gas turbine wheel rotatable about an axis of a turbine and blades. A radial face of an axial slot in the gas turbine wheel includes a stake-receiving feature having a reconditioned surface. Material displaced at the reconditioned surface by staking axially retains a blade in the axial slot. A method of mounting a blade to a gas turbine wheel includes staking the base of the blade in the axial slot by displacing material at a reconditioned surface of a stake-receiving feature on a radial face of the axial slot to axially retain the base of the blade in the axial slot.

Abstract: A turbine component for use in a hot gas path of a gas turbine engine. The turbine component may include an outer surface, an internal cooling circuit, an adaptive cooling pathway in communication with the internal cooling circuit and extending through the outer surface, and a cooling plug having two or more materials positioned within the adaptive cooling pathway.

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: 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 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 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 handheld jig for placement on a radiator and associated method to repair broken welds of tabs of a radiator mounting cradle used to hold a radiator of a vehicle such as a HMMVE where the tabs may be pressed against angled surfaces of the radiator, the jig having a base, a first arm extending from the base, a second arm extending from the base, and a third arm extending from the base, the first arm, second arm and third arm each capable of holding an adjustable pin to selectively contact a tab of the cradle to press the respective contacted tabs against respective angled surfaces of the radiator.

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 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 repairing a metallic artefact (40) with an open defect in or on a metallic surface or substrate of the metallic artefact includes cold forging the open defect to close the open defect and thereafter laser cladding the cold forged defect with a plurality of laser clad beads (44) applied to the metallic surface or substrate to cover the cold forged defect with a cladded metal layer. Advantageously, in-situ repair of fluid-filled vessels, pipes or the like is made possible by the repair method, in some instances eliminates the need to shut equipment down thereby reducing downtime and the cost associated with lost production.

Abstract: A restoration process for restoring surface porosity defects on a component surface. The areas of a component surface having surface porosity defects are identified for restoration. The restoration surface is subsequently sprayed with a restoration spray to restore the surface porosity defects. The component surface is then finished to create a final component substantially free of surface porosity.

Abstract: A saw blade reconditioning method with a band saw blade member made from a portion of band saw blade material, a standard oscillating power tool blade shank having the serrated toothed blade portion removed and a butt welding fixture. The band saw blade member is locked into the jaws of one side of the welding fixture and the oscillating power tool blade shank is locked into the opposite side of the welding fixture. The butt welding tool is calibrated to ideal heat and feed rate for the blade shank to the band saw blade welding purposes. The leading edge of the oscillating power tool blade shank is welded to the trailing edge of the band saw blade member. The band saw blade member is trimmed on its left and right ends to form a smooth transition oscillating tool blade shank.

Abstract: The present invention is directed to methods for repairing pipes or pipe junctions. The methods include providing a launcher device having a bladder and a liner impregnated with a material capable of curing and hardening. The bladder includes a first end, a closed second end, and an opening proximal the closed second end. A portion of the bladder is positioned within the launcher device, a rope or a line is connected to the liner, and the rope or line is threaded through the opening in the bladder. The rope or the line is pulled until the liner is at least partially within the bladder, and the rope or line is removed. The pipe is repaired by positioning the liner against the wall of a pipe, and allowing a material capable of curing and hardening to cure and harden. The methods allow for the rapid reuse of the bladder.

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: Methods for repairing and restoring water manifold pipes, particularly locomotive diesel motor water manifolds exhibiting excessive corrosion around at least one water port. Exemplary methods include inserting a pipe segment into a selected water port and using the inserted pipe segment as a build-up or brazing form. Braze material is applied in one layers around and against the inserted pipe segment. Excess braze material and the pipe segment are thereafter removed in order to restore the manifold pipe to an original dimension.

Abstract: Systems and methods for providing localized heat treatment of metal components are provided. In this regard, a representative method includes: identifying a portion of a metal component to which localized heat treatment is to be performed; shielding an area in a vicinity of the portion of the metal component; and directing electromagnetic energy in the infrared (IR) spectrum toward the portion of the metal component such that the portion is heated to a desired temperature and such that the area in the vicinity of the portion that is subjected to shielding does not heat to the temperature desired for the heat treatment.

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 forming or remanufacturing a component to have an internal space. A refractory metal blocking element is formed, in situ, with at least a portion to be within the internal space. A material is added by at least one of welding, laser cladding, and diffusion brazing, the blocking element at least partially blocking entry of the material to the internal space. The blocking element is removed.

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.

Abstract: A method for repairing a crack in an electromechanical rotor (10), including forming a plurality of slots (12) on a periphery of a core portion (11) of an electromechanical rotor (10) along an axial direction thereof; inserting coils into the slots (12), respectively; forming a plurality of wedges for maintaining the coils in the slots (12), respectively; and forming a cut hole (20) at the core portion (11) from an outer surface of the core portion (11) so as to remove at least a deeper area of a crack created at the core portion (11) at a contacting surface between the corresponding wedge and the corresponding slot (12).

Abstract: A tube can be repaired from its interior surface by inserting into the tube a cylindrical repair member The cylindrical repair member is a memory metal which has a first martensitic size that is less than the internal diameter of the tube, and a second austenitic size that is at least as large as or larger than the internal diameter of the tube. The cylindrical repair member is inserted into the tube in the martensitic state and heated, causing it to revert to the austenitic state thereby expanding and covering said hole, forming a tight bond with the internal surface of the tube.

Abstract: A modular armored cab kit is provided for use on an armored vehicle that includes a cab body having a frame, an armored roof, an armored floor and a plurality of attachment elements, with the roof, floor and attachment elements being permanently attached to the frame. The cab kit further includes at least one non-armored panel, at least one non-armored door, at least one armored panel and at least one armored door, each for attachment to the cab body. The attachment elements facilitate field installation and removal of the panels and doors, wherein the non-armored panel and door are removably attached to the frame in a relatively low threat environment and are removed from the frame and replaced with the armored panel and door in a heightened threat environment.

Abstract: A method for repairing a gas turbine engine component includes the steps of repairing one of a suction side or a pressure side of the component; repairing internal geometry of the component after one of the suction side or the pressure side of the component is repaired; and repairing the other of the suction side and the pressure side of the component after the internal geometry of the component is repaired, wherein a backing material is utilized to preserve the internal geometry of the component when the other of the suction side and the pressure side of the component is being repaired.

Abstract: The pipe-lining material includes a pipe-shaped resin absorbent material impregnated with a liquid curable resin, and a tube that covers the pipe-shaped resin absorbent material and that can be removed from the pipe-shaped resin absorbent material. The curable resin impregnated in the pipe-shaped resin absorbent material is cured in a state in which the pipe-lining material is pressed against the internal peripheral surface of the existing pipe, the tube covering the pipe-shaped resin absorbent material of the pipe-lining material is removed from the pipe-shaped resin absorbent material after the curable resin impregnated in the pipe-shaped resin absorbent material has been cured, and the surface of the pipe-shaped resin absorbent material having the cured resin is used as the internal peripheral surface of the rehabilitated existing pipe.

Abstract: A method includes shrink fitting a ring member about a railroad wheel body and metallurically bonding the ring member to the railroad wheel body. A wheel assembly includes an inner portion obtained from a worn railroad wheel, a ring member disposed about the inner portion, and suitable electroplating material disposed on at least one of the faying surfaces. The wheel assembly may be heated under suitable conditions to provide diffusion bonding across interfacing faying surfaces to produce an integral wheel structure. Appropriate quenching, tempering, and finishing processes may be utilized to obtain desired properties. An article formed thereby includes an inner body portion obtained from a worn railroad wheel and a metallurically bonded outer circumferential portion. The outer portion may comprise a composition selected for desired wear characteristics.

Abstract: A restoration process for restoring surface porosity defects resulting from the casting process in metal cast products. The areas of a cast product having surface porosity defects are identified and the areas not containing surface porosity defects are masked using an adhesive, reusable, rubberized mask. The masked surface is subsequently cleaned and a metal spray is applied to the surface porosity defects. The mask is removed and the restored surface porosity defects are hand finished to create a cast product having less than 0.05% surface porosity.

Abstract: A method of producing a metallic component includes: providing a body made of a first alloy; providing a preform comprising a metallic powder made of a second alloy and formed in the shape of an extension of the body; and heating the preform with microwave energy to sinter the metallic powder together and to bond the preform to the body. The method may be used to make new components as well as to repair or modify existing components.

Abstract: A method of refurbishing components such as brake rotors and drums is disclosed. The method may involve identifying, sorting and cleaning used or worn components. The components may then be blasted with an abrasive material to prepare them for a metal deposition process. Metal may then be added to the components using an arc spray gun, for example. The component may then be cryogenically treated to improve the wear characteristics of the component. The component may then be machined to place the component within a specified configuration. Components may be refurbished repeatedly in this manner so as to utilize resources more efficiently and reduce waste. Moreover, the components may exhibit improved wear characteristics over components manufactured by other methods.

Abstract: Methods for repairing and restoring water manifold pipes, particularly locomotive diesel motor water manifolds exhibiting excessive corrosion around at least one water port. Exemplary methods include inserting a pipe segment into a selected water port and using the inserted pipe segment as a build-up or brazing form. Braze material is applied in one layers around and against the inserted pipe segment. Excess braze material and the pipe segment are thereafter removed in order to restore the manifold pipe to an original dimension.

Abstract: A method of weld repairing a superalloy material at ambient temperature without causing cracking of the base material. A superalloy material such as CM-247 LC, as is commonly used in gas turbine blade applications, is subjected to an overage pre-weld heat treatment in order to grow the volume percentage of gamma prime precipitate in the material to a level sufficient to permit ambient temperature welding without cracking. CM-247 LC material is heated in a vacuum furnace at a rate of about 0.5° C. per minute to an intermediate temperature of about 885° C. The material is then gas fan quenched to a temperature of about 52° C. to grow the gamma prime precipitate percentage to about 55%. A fusion repair weld may then be performed on the material at an ambient temperature using a filler material having a chemistry matching a chemistry of the base material.

Abstract: A method of repairing a crack in a component comprising a base material, in particular in a gas turbine blade, a suspension, which comprises a carrier liquid and at least one solid in the form of nanoparticles of the same material as the base material, being applied to the location to be repaired. A heat treatment of the component is carried out, the solid in the form of nanoparticles being melted and a bond with the base material being formed. During the heat treatment, the component is exposed to a thermal shock, in which a maximum temperature which corresponds to the melting temperature of the nanoparticles is reached. The nano size of the particles in the suspension causes a lowering of the melting point of these particles to take place, so that the structure of the base material does not change even at the melting temperature of the nanoparticles.

Abstract: A method for repairing a gas turbine stationary flowpath shroud. The method comprises providing a superalloy gas turbine stationary flowpath shroud that has previously been in service. The method further comprises preparing a restoration coating for application to the flowpath surface of the shroud by the steps of providing a precursor mixture comprising a higher-melting-point alloy component, a lower-melting-point alloy component, and a fugitive binder. A perform is prepared from the components and pre-sintered into a mildly curved form. The partially densified perform is applied to the flowpath surface and thermally bonded to the flowpath surface, forming a restoration coating.

Abstract: A method of repairing spline and seal teeth of a mated component is disclosed. The method includes a low energy input weld to deposit a repair material on the non-worn, non-pressure face of the splines while minimizing the HAZ grain size. The splined area of the component is then remachined to the original spline contour by removing original material from the worn, pressure face of the splines and excess repair material to produce a mated component with radially re-clocked splines that have original component material on the pressure face of the teeth.

Abstract: Methods for repairing gas turbine engine casings and repaired casings are provided. In this regard, a representative method for repairing a gas turbine engine casing includes: removing an annular portion of the engine casing; and attaching an annular replacement portion to the engine casing.

Abstract: A method for metallurgically bonding a stator bar to a coupling to reduce the incidence of leak paths resulting from corrosion. The stator bar comprises strands through which a liquid coolant can flow. Adjacent ends of the strands are received in an interior cavity of the coupling through an opening in the coupling. A joining material is provided on a first portion of the stator bar within the coupling opening and adjacent the ends of the strands. The first portion is heated to melt the joining material. At essentially the same time, a second portion of the stator bar outside the coupling is also heated. Once the joining material is suitably molten, the first portion is allowed to cool while the second portion remains heated, thereby causing the joining material nearest the ends of the strands to solidify first.

Abstract: A gas turbine rotor and a method for manufacturing a gas turbine rotor having integral blading, is disclosed. A rotor blade has a blade pan and a blade footing connected to the blade pan. The blade footing is designed with a V-shaped cross section in at least some portions and the blade footing is welded to a rotor mount by capacitor discharge welding.

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

Abstract: A method of sealing a generator stator bar and a stator bar end fitting receiving the end including the steps of: brazing the fitting to the end of the stator bar with a braze material; applying a metallic barrier coating material to the end of the stator bar in the fitting; heating the fitting at a temperature at least as hot as a liquidus temperature of the metallic coating material and cooler than a solids temperature of the braze material; coating the end of the stator bar in the fitting with liquid metallic barrier coating material, and solidifying the liquefied metallic coating material to form a metallic barrier coating on the end of the stator bar in the fitting.

Abstract: A method for repair soldering of multi-pole miniature plug connectors on printed circuit boards, having signal contact pins in the SMT design and shroud pins in the THR design. The plug connectors have shrouds whose shroud pins project out on the back of the printed circuit board. Preforms are glued onto the SMD signal contact pins, and the repair plug connectors are set into THR holes of the board with their shroud pins. The signal contact pins are soldered using SMT technology. Subsequently, the shroud pins are soldered from the back of the board. The solder connects with the solder eyes of the solder holes on the back of the board, as well as flows into the ring gap between the metallized inside walls of the solder holes and the shroud pins in the circuit board, and produces a material-lock connection. Finally, the shroud pins that project out are shortened.

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

Abstract: A BLISK having a damaged blade, with a repair region that has a thickness less than a specified thickness as a result of damage during manufacture or prior service, is repaired by depositing repair metal onto the repair region to increase its thickness to greater than its specified thickness dimension. Only the repair region is stress relieved by heating the repair region to a stress-relieving temperature of from about 1150° F. to about 1250° F. for a time of at least about 1 hour. The intentional manipulation of microstructure in only the thinner airfoil sections allows multiple repairs, which are not possible in the thicker sections of the BLISK. An alpha-case thickness of repair metal, preferably of at least about 0.0002 inches of repair metal, is removed from a surface of the repair region.

Abstract: A method of reconditioning a rotating blade (1) with a shroud (8) following the operation in a gas turbine, includes the application of a barrier (14) placed on the edge of the shroud (8) facing the edge of a shroud (8) of an adjacent blade having creep deformation. The barrier (14) prevents hot gas ingestion into a shroud cavity (10). It is pre-fabricated or built-up layer-by-layer by welding or laser cladding or other methods. Additionally, the mass of the shroud (8) is reduced in order to re-establish the initial mass of the shroud. A thermal barrier coating (15) is additionally applied to the surfaces of the shroud (8) that are exposed to the hot gas of the turbine. The method significantly increases the lifetime of the blade (1).

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

Abstract: Physical vapor deposition is utilized to deposit repair material on Ti alloy turbine components.

Abstract: A restoration process for restoring surface porosity defects in engine blocks cast using a high pressure die cast method. The areas of an engine block having surface porosity defects are identified and the areas not containing surface porosity defects are masked using an adhesive, reusable, rubberized mask. The masked surface is subsequently cleaned and a metal spray is applied to the surface porosity defects. The mask is removed and the restored surface porosity defects are hand finished to create an engine block having less than 0.05% surface porosity.

Abstract: A method of repairing a combustion turbine component having damage located at or near a cooling hole or hollow or geometrically complex portion of the component is provided. The method comprises forming a preparatory groove that extends from a surface of the component to the damaged area but does not extend to the cooling hole or hollow or geometrically complex portion of the component, the groove extending 40–90% the distance from the component to the damaged area; spraying a filler material into the groove with a micro-plasma torch at a current of less than 50 amperes; and filling the groove with the filler material such that the heated filler material substantially extends from the cooling hole or hollow or geometrically complex portion of the component to a surface of the component.