System and method for repairing high-temperature gas turbine components

1. A method of repairing a component comprising:

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;

printing the mixture into a desired shape without melting the base material;

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;

liquid-phase sintering the replacement piece to melt a braze material applied to the replacement piece, the braze material filling space created by the removal of the binder; and

attaching the second interface surface to the first interface surface to replace the damaged portion of the component.

2. The method of claim 1 , wherein the desired shape is heated to remove the binder without melting the base material.

3. The method of claim 1 , wherein the component includes a first side wall and a second side wall spaced apart from the first side wall, and wherein the removing the damaged portion step includes forming the first interface surface on the first side wall and forming a third interface surface on the second side wall.

4. The method of claim 3 , wherein the desired shape includes the second interface surface arranged to match the first interface surface and a fourth interface surface arranged to match the third interface surface.

5. The method of claim 4 , wherein the first interface surface and the third interface surface are each defined by the same continuous curve.

6. The method of claim 1 , wherein the replacement piece is a portion of a leading edge of a turbine vane.

7. The method of claim 1 , wherein the printing step includes micro-injecting a first layer having a thickness of between 10 microns and 100 microns.

8. The method of claim 1 , further comprising repeating the micro-injecting step to form additional layers to complete the replacement piece.

9. A method of repairing a component comprising:

removing a damaged portion from the component to leave a first interface surface;

mixing a powdered base material and a binder to define a mixture;

micro-injecting a layer of the mixture having a thickness between 10 microns and 100 microns;

repeating the micro-injecting process to form additional layers and complete a replacement piece;

heating the replacement piece to remove the binder;

sintering the replacement piece;

performing a liquid-phase sintering process while adding a braze material, the braze material filling empty spaces created by the removal of the binder within the replacement piece; and

fixedly attaching the replacement piece to the component to replace the damaged portion.

10. The method of claim 9 , wherein the sintering step includes a solid-state sintering process.

11. The method of claim 9 , wherein a temperature of the heating step is selected to remove the binder without melting the base material.

12. The method of claim 9 , wherein the component includes a first side wall and a second side wall spaced apart from the first side wall, and wherein the removing the damaged portion step includes forming the first interface surface on the first side wall and forming a third interface surface on the second side wall.

13. The method of claim 12 , wherein the desired shape includes the second interface surface arranged to match the first interface surface and a fourth interface surface arranged to match the third interface surface.

14. The method of claim 13 , wherein the first interface surface and the third interface surface are each defined by a continuous curve.

15. The method of claim 9 , wherein the replacement piece is a portion of a leading edge of a turbine vane.