Methods for repairing turbine components

1. A method for repairing a turbine component with a distressed portion, comprising the steps of:

machining the turbine component into a first intermediate turbine article such that the distressed portion is removed; and

rebuilding the first intermediate turbine article into the turbine component with an additive manufacturing process, wherein the turbine component includes internal passages, and wherein the rebuilding step includes rebuilding at least some of the internal passages with the additive manufacturing process;

encapsulating the turbine component with an encapsulation layer, wherein the encapsulating step includes encapsulating within the internal passages;

consolidating the turbine component and the encapsulation layer, wherein the encapsulating step includes converting surface connected defects to internal defects prior to the consolidating step, and wherein the consolidating step includes hot isostatic pressing; and

removing the encapsulation layer after the machining, rebuilding, encapsulating, and consolidating steps.

2. The method of claim 1 , wherein the machining step includes machining the turbine component to predetermined dimensions.

3. The method of claim 1 , wherein the rebuilding step includes direct metal laser fusing a powdered metal onto the first intermediate turbine article.

4. The method of claim 3 , wherein the rebuilding step includes:

defining a three-dimensional model of the turbine component; and

converting the three-dimensional model to a plurality of slices that each define a cross-sectional layer of the turbine component.

5. The method of claim 4 , wherein the fusing step includes melting the powdered metal to form the turbine component in successive layers according to the three-dimensional model.

6. The method of claim 5 , wherein the melting step includes melting the powdered metal with a laser beam having a power of approximately 50 to 500 Watts.

7. The method of claim 3 , wherein the rebuilding step includes positioning the first intermediate turbine article into a bed of the powdered metal.

8. The method of claim 3 , wherein the rebuilding step includes depositing a layer of the powdered metal onto the first intermediate turbine article with a roller or wiper.

9. The method of claim 1 , wherein the rebuilding step includes metallic additive manufacturing using a high energy density beam, the high energy density beam including at least one of laser beam, electron beam, plasma jet, or electric arc.

10. The method of claim 1 , wherein the rebuilding step includes direct metal laser fusing a powdered Nickel-based superalloy onto the first intermediate turbine article.

11. The method of claim 1 , wherein the rebuilding step includes rebuilding the internal passages with walls having a thickness of 0.25 mm to 1 mm.

12. The method of claim 1 , wherein the encapsulating step includes encapsulating the turbine component with the encapsulation layer having a thickness of approximately 10 μm to approximately 100 μm.