Turbine nozzle assemblies and methods for repairing turbine nozzle assemblies

1. A method for repairing a turbine nozzle assembly with an insert and a support structure, wherein the turbine nozzle assembly is annular with a central axis, comprising the steps of:

positioning the insert on the support structure of the turbine nozzle assembly, wherein the insert includes first mounting holes circumferentially arranged around the insert and configured to mount the nozzle assembly; and

plug welding the insert to the support structure of the turbine nozzle assembly, wherein the plug welding step includes

drilling a hole through the insert and into a surface of the support structure in an axial direction relative to the turbine nozzle assembly; and

filling the hole with a weld material,

wherein the plug welding step includes plug welding the insert to the support structure at a plurality of plug weld positions, and

wherein the plug welding step includes plug welding such that the plug weld positions are circumferentially aligned and radially clocked relative to the first mounting holes.

2. The method of claim 1 , wherein the plug welding step includes positioning each of the plug weld positions equidistant between the first mounting holes.

3. The method of claim 1 , wherein the plug welding step includes equally spacing the plug weld positions around the insert.

4. The method of claim 1 , further comprising the step of removing any deterioration in the support structure prior to the positioning step.

5. A turbine nozzle assembly for a system, comprising

a shroud configured to surround a plurality of turbine blades; and

a support structure comprising a support structure body coupled to the shroud and an insert configured to mount the turbine nozzle assembly to another portion of the system, the insert being secured to the support structure body with a plurality of plug welds,

wherein the plug welds extend through the insert and into the support structure body,

wherein the support structure is annular with a central axis and the plug welds extend in an axial direction relative to the support structure, and

wherein the insert includes a plurality of first mounting holes for mounting the turbine nozzle assembly to the another portion of the system, the plug welds being circumferentially aligned and radially clocked relative to the first mounting holes.

6. The turbine nozzle assembly of claim 5 , wherein each of the plug welds is positioned equidistant between adjacent first mounting holes.

7. The turbine nozzle assembly of claim 5 , wherein the plug welds are equally spaced around the insert.

8. An air cycle machine, comprising:

a compressor configured to receive and compress an air flow;

a turbine system configured to receive the air flow and to extract energy with a plurality of turbine blades;

a shaft coupled to the turbine blades and configured to transmit the extracted energy;

a housing configured to house the shaft; and

a turbine nozzle assembly coupling the turbine system to the housing and comprising

a shroud configured to surround the plurality of turbine blades and to at least partially form a flow path for the air flow through the turbine system, and

a support structure comprising a support structure body coupled to the shroud and an insert for coupling the turbine system to the housing, the insert being secured to the support structure body with a plurality of plug welds,

wherein the insert includes a plurality of first mounting holes for mounting the turbine nozzle assembly to the housing, the plug welds being circumferentially aligned and radially clocked relative to the first mounting holes.

9. The air cycle machine of claim 8 , wherein the turbine nozzle assembly further comprises an inlet coupled the support structure for receiving the air flow from the compressor.

10. The air cycle machine of claim 8 , wherein the plug welds extend through the insert and into the support structure body.

11. The air cycle machine of claim 8 , wherein the support structure is annular with a central axis and the plug welds extend in an axial direction relative to the support structure.

12. The air cycle machine of claim 8 , wherein each of the plug welds is positioned equidistant between adjacent first mounting holes.