Methods for the repair of gas turbine engine components using additive manufacturing techniques

1. A method for repairing a damaged metallic component using additive manufacturing techniques, the method comprising the steps of:

separating a damaged portion of the damaged metallic component from an undamaged portion of the damaged metallic component;

further separating areas of the metallic component in the undamaged portion that are adjacent to the damaged portion to form recesses in the undamaged portion of the metallic component adjacent to the damaged portion;

measuring the undamaged portion to determine the dimensions of the removed damaged portion and the removed recesses from the undamaged portion;

fabricating a replacement portion using additive manufacturing techniques in accordance with the determined dimensions of the removed damaged portion and the removed recesses from the undamaged portion, wherein the replacement portion includes a locking feature that comprises flanges that correspond in shape with the recesses, and further wherein the replacement portion is fabricated using a first material at a first end thereof and a second material at a second end thereof that is opposite the first end, wherein the first end comprises the locking feature and the first material comprises a joining material that differs from a material of the metallic component, and wherein the second end comprises the material of the metallic component; and

joining the replacement portion with the undamaged portion of the damaged metallic component to form a repaired metallic component, wherein the joining further comprises joining the flanges of the locking feature with the recesses in the undamaged portion.

2. The method of claim 1 , further comprising evaluating the damaged metallic component prior to separating the damaged portion from the undamaged portion to determine an extent of damage to the metallic component.

3. The method of claim 2 , wherein evaluating the damaged metallic component comprises visually inspecting the damaged metallic component or non-destructively evaluating the damaged metallic component.

4. The method of claim 1 , further comprising subjecting the replacement portion to a post-processing operation.

5. The method of claim 4 , wherein subjecting the replacement portion to the post-processing operation comprises subjecting the replacement portion to a process selected from the group consisting of: aging, annealing, quenching, peening, polishing, hot isostatic pressing (HIP), or coating.

6. The method of claim 1 , further comprising performing a finishing operation on the repaired metallic component.

7. The method of claim 6 , wherein performing the finishing operating on the repaired metallic component comprises one or more of aging, annealing, quenching, peening, polishing, hot isostatic pressing (HIP), or coatings.

8. The method of claim 1 , further comprising performing a final inspection on the repaired metallic component.

9. The method of claim 8 , wherein performing the final inspection on the repaired metallic component comprises visually inspecting the damaged metallic component or non-destructively evaluating the damaged metallic component.

10. The method of claim 1 , wherein separating the damaged portion of the damaged metallic component comprises one or more of Electro-Discharge Machining (EDM), electro-chemical machining, milling, and laser cutting.

11. The method of claim 1 , wherein measuring the undamaged portion comprises measuring the undamaged portion using a coordinate measuring machine (CMM) or white light measuring.

12. The method of claim 1 , wherein fabricating the replacement portion using additive manufacturing techniques comprises fabricating the replacement portion using DMLS, EBM, or SLS.

13. The method of claim 1 , wherein joining the replacement portion with the undamaged portion of the damaged metallic component comprises diffusion bonding or brazing the replacement portion with the undamaged portion, and wherein the joining material of the first end of the replacement portion comprises a braze metal or a weld metal.

14. The method of claim 1 , wherein the damaged metallic component comprises a gas turbine engine component.

15. The method of claim 1 , wherein the damaged gas turbine engine component is a component selected from the group consisting of: a turbine nozzle, a turbine vane segment, a heat exchanger, and a fuel control manifold.

16. A method for repairing a damaged gas turbine engine component using additive manufacturing techniques, the method comprising the steps of:

evaluating a damaged gas turbine engine component to determine an extent of damage to the gas turbine engine component;

separating a damaged portion of the gas turbine engine component from an undamaged portion of the damaged gas turbine engine component;

further separating areas of the metallic component in the undamaged portion that are adjacent to the damaged portion to form recesses in the undamaged portion of the metallic component adjacent to the damaged portion;

measuring the undamaged portion to determine the dimensions of the removed damaged portion and the removed recesses from the undamaged portion;

fabricating a replacement portion using additive manufacturing techniques in accordance with the determined dimensions of the removed damaged portion and the removed recesses from the undamaged portion, wherein the replacement portion includes a locking feature that comprises flanges that correspond in shape with the recesses, and further wherein the replacement portion is fabricated using a first material at a first end thereof and a second material at a second end thereof that is opposite the first end, wherein the first end comprises the locking feature and the first material comprises a joining material that differs from a material of the metallic component, and wherein the second end comprises the material of the metallic component;

subjecting the replacement portion to a post-processing operation; and

joining the replacement portion with the undamaged portion of the damaged gas turbine engine component to form a repaired gas turbine engine component, wherein the joining further comprises joining the flanges of the locking feature with the recesses in the undamaged portion.

17. The method of claim 16 , wherein joining the replacement portion with the undamaged portion of the damaged gas turbine engine component comprises diffusion bonding or brazing the replacement portion with the undamaged portion, and wherein the joining material of the first end of the replacement portion comprises a braze metal or a weld metal.

18. The method of claim 16 , wherein the damaged gas turbine engine component is a component selected from the group consisting of: a turbine nozzle, a turbine vane segment, a heat exchanger, and a fuel control manifold.

19. The method of claim 16 , wherein fabricating the replacement portion using additive manufacturing techniques comprises fabricating the replacement portion using DMLS, EBM, or SLS.

20. A method for repairing a damaged metallic component using additive manufacturing techniques, the method comprising the steps of:

separating a damaged portion of the damaged metallic component from an undamaged portion of the damaged metallic component;

further separating areas of the metallic component in the undamaged portion that are adjacent to the damaged portion to form recesses in the undamaged portion of the metallic component adjacent to the damaged portion;

measuring the undamaged portion to determine the dimensions of the removed damaged portion and the removed recesses from the undamaged portion;

fabricating a replacement portion using additive manufacturing techniques in accordance with the determined dimensions of the removed damaged portion and the removed recesses from the undamaged portion, wherein the replacement portion includes a locking feature that comprises flanges that correspond in shape with the recesses, and further wherein the replacement portion is fabricated using a first material at a first end thereof and a second material at a second end thereof that is opposite the first end, wherein the first material differs from the second material; and

joining the replacement portion with the undamaged portion of the damaged metallic component to form a repaired metallic component, wherein the joining further comprises joining the flanges of the locking feature with the recesses in the undamaged portion.