Machine components and methods of fabricating and repairing

1. A method of fabricating a machine component comprising:

preparing at least a portion of a surface of the machine component for receiving a sintered preform such that metallurgical impurities are removed from the portion of the surface;

forming a pre-sintered preform hybrid hardface mixture comprising combining a predetermined portion of at least one hardfacing material with a predetermined portion of at least one brazing material;

forming a pre-sintered preform, the pre-sintered preform having a predetermined thickness;

forming a sintered preform having a porosity of less than 2% and based at least on dimensions of the machine component;

inserting a layer of material containing boron between the sintered preform and the machine component to facilitate a diffusion bond between the sintered preform and the machine component;

positioning the sintered preform on the machine component; and

fixedly coupling the sintered preform to at least a portion of the machine component via brazing, such that a diffusion bond is formed between the sintered preform and the machine component, wherein to fixedly couple the sintered preform, the machine component and the sintered preform is heated from room temperature to approximately 1200° F. at a rate of heat addition of approximately 25° F. per minute, and the machine component and the sintered preform are then heated at a holding temperature of approximately 1200° F. for a holding period of approximately 30 minutes.

2. A method of fabricating a machine component in accordance with claim 1 wherein preparing at least a portion of a surface comprises removing loose surface contaminants, applied coating materials, and surface irregularities from at least a portion of the surface of the machine component.

3. A method of fabricating a machine component in accordance with claim 1 wherein forming a pre-sintered preform comprises forming the pre-sintered preform mixture in a shape substantially similar to a flat plate.

4. A method of fabricating a machine component in accordance with claim 1 wherein forming a sintered preform comprises:

forming a sintered flat plate by sintering the pre-sintered preform via heating to a predetermined temperature for a predetermined time, the pre-sintered preform having a shape substantially similar to a flat plate with a predetermined thickness; and

extracting a sintered preform from the sintered flat plate, the sintered preform having predetermined dimensions.

5. A method of fabricating a machine component in accordance with claim 1 wherein positioning the sintered preform comprises tack welding at least a portion of the sintered preform to at least a portion of the surface of the machine component.

6. A method of fabricating a machine component in accordance with claim 1 wherein fixedly coupling the sintered preform comprises heat treating the machine component and the sintered preform, said heat treating comprising a heating cycle and a cooling cycle, the heating cycle having at least one rate of heat addition, at least one holding temperature and at least one holding period, the cooling cycle having at least one holding temperature and at least one holding period.

7. A method of fabricating a machine component in accordance with claim 1 , wherein said forming a pre-sintered preform hybrid hardface mixture further comprises combining a portion of at least one hardfacing material between approximately 90% by weight and approximately 60% by weight with a portion of at least one brazing material between approximately 10% by weight and approximately 40% by weight.

8. A method of fabricating a machine component in accordance with claim 1 , wherein said forming a pre-sintered preform hybrid hardface mixture further comprises combining a portion of at least one hardfacing material between approximately 80% by weight and approximately 85% by weight with a portion of at least one brazing material between approximately 20% by weight and approximately 15% by weight.

9. A method of fabricating a machine component in accordance with claim 1 , wherein said fixedly coupling the sintered preform further comprises:

heating the machine component and the sintered preform from approximately 1200° F. to approximately 1800° F. at a rate of heat addition of approximately 25° F. per minute; and

heating the machine component and the sintered preform at a holding temperature of approximately 1800° F. for a holding period of approximately 30 minutes.

10. A method of fabricating a machine component in accordance with claim 9 , wherein said fixedly coupling the sintered preform further comprises:

heating the machine component and the sintered preform from approximately 1800° F. to between approximately 2200° F. and approximately 2255° F. at a rate of heat addition of approximately 35° F. per minute; and

heating the machine component and the sintered preform at a holding temperature of between approximately 2200° F. and approximately 2255° F. for a holding period of approximately 20 minutes.

11. A method of fabricating a machine component in accordance with claim 10 , wherein said fixedly coupling the sintered preform further comprises:

reducing the heat of the machine component to approximately 2050° F.; and

maintaining a holding temperature of approximately 2050° F. for a holding period of approximately 60 minutes.