Systems and methods for repairing compressor blades using hybrid manufacturing techniques

1. A method of repairing a compressor blade, the method comprising:

providing a mounting tool, said mounting tool having a plurality of support bases and a slot, said slot configured for securement of said compressor blade to said mounting tool;

securing said compressor blade to said mounting tool via said slot;

associating said mounting tool and said secured compressor blade with a hybrid manufacturing machinery;

additive manufacturing to: (a) add material to said compressor blade secured to said mounting tool; (b) add material to said plurality of support bases to form a sacrificial support on each of said plurality of support bases; and (c) build a bridge spanning from said compressor blade to each said sacrificial support; and

subtractive manufacturing to remove material from said compressor blade while said compressor blade is secured to the mounting tool;

wherein, at least a portion of one of said sacrificial supports stabilizes said compressor blade during at least a part of each of said subtractive manufacturing and said additive manufacturing.

2. The method of claim 1 , wherein said subtractive manufacturing is initiated before said additive manufacturing is completed.

3. The method of claim 1 , wherein at least one of said plurality of support bases is formed as part of at least one of said mounting tool.

4. The method of claim 1 , wherein each of said plurality of support bases is releasably attached to said mounting tool.

5. The method of claim 1 , further including dissociating each said sacrificial supports from said compressor blade.

6. The method of claim 1 , wherein said mounting tool includes a fastener for securing said compressor blade within said slot.

7. The method of claim 6 , further including tightening said fastener via an opening in said mounting tool.

8. The method of claim 1 , further including disassociating said compressor blade from said mounting tool.

9. The method of claim 8 , further including finishing said compressor blade after said compressor blade is disassociated from said mounting tool.

10. A method of repairing a compressor blade, comprising:

providing a mounting tool, said mounting tool having a plurality of support bases and a slot, said slot configured for securement of said compressor blade to said mounting tool;

securing said compressor blade to said mounting tool via said slot;

associating said mounting tool and said secured compressor blade with a hybrid manufacturing machinery;

using each of additive manufacturing and subtractive manufacturing to repair said compressor blade while said compressor blade is secured to said mounting tool; and

building a sacrificial support on each of said plurality of support bases wherein said additive manufacturing includes building a plurality of bridges, each of said

plurality of bridges connecting said compressor blade to one of said sacrificial supports.

11. The method of claim 10 , further including removing said compressor blade from said mounting tool for finishing.

12. The method of claim 10 , wherein at least a first part of said additive manufacturing is effectuated prior to at least a first part of said subtractive manufacturing and at least a second part of said additive manufacturing is effectuated after said first part of said subtractive manufacturing.

13. A method of repairing a blade using a mounting tool, the mounting tool having a slot and a plurality of support bases, the method comprising:

securing said blade to said mounting tool via said slot;

associating said mounting tool and said secured blade using a hybrid manufacturing machinery;

additive manufacturing to: (a) add material to said blade secured to said mounting tool; (b) add material to said plurality of support bases to form a sacrificial support on each of said plurality of support bases; and (c) build a bridge spanning from said blade to each said sacrificial support; and

subtractive manufacturing to remove material from said blade while said blade is secured to said mounting tool;

wherein, at least a portion of one of said sacrificial supports stabilizes said blade during at least a part of each of said subtractive manufacturing and said additive manufacturing.

14. The method of claim 13 , wherein said subtractive manufacturing is initiated before said additive manufacturing is completed.

15. The method of claim 13 , wherein each of said plurality of support bases is releasably attached to said mounting tool.

16. The method of claim 13 , wherein each of said plurality of support bases is attached to said mounting tool.