Repair of Aircraft Fan Blade

1 . A method of repairing a hollow fan blade, the hollow fan blade including a first portion and a second portion secured together by a joint, an interior cavity of the hollow fan blade being under a vacuum, the method comprising:

obtaining a replacement portion, the replacement portion having a unitary construction;

removing a portion from a cutback region of the hollow fan blade to form a weld foundation; and

welding the replacement portion to the weld foundation;

wherein, the welding is at a temperature at the joint that does not exceed a distortion temperature of the joint.

2 . The method of claim 1 , wherein welding the replacement portion to the weld foundation includes first welding the replacement portion to the weld foundation using a first welding technique and subsequently operably welding the replacement portion to the weld foundation using a second welding technique.

3 . The method of claim 2 , wherein the first welding technique includes tungsten inert gas (TIG) welding.

4 . The method of claim 3 , wherein the second welding technique includes electron beam welding.

5 . The method of claim 1 , wherein a width of the replacement portion is greater than a width of the weld foundation.

6 . The method of claim 1 , further including arranging a thermocouple on at least one of the first portion and the second portion.

7 . The method of claim 1 , including monitoring a temperature of at least a portion of the hollow fan blade during the welding.

8 . The method of claim 1 , including securing the hollow fan blade within a purge box prior to the welding.

9 . The method of claim 1 , wherein welding the replacement portion includes situating the hollow fan blade in a purge box and situating the hollow fan blade in a vacuum chamber.

10 . The method of claim 1 , wherein a length of the replacement portion is at least 20% of a length of a leading edge of the hollow fan blade.

11 . The method of claim 1 , wherein the interior cavity further includes a honeycomb structure.

12 . The method of claim 1 , including applying a finishing process after the welding.

13 . The method of claim 1 , wherein the joint includes a braze joint.

14 . A system for repairing a leading edge of a hollow fan blade, the hollow fan blade including a first portion and a second portion secured together by a joint, an interior cavity of the hollow fan blade being under a vacuum, the system comprising:

a purge box having a mount for securing the hollow fan blade during a first welding step; and

a vacuum chamber for retaining the hollow fan blade during a second welding step under a vacuum;

wherein, the first welding step is different from the second welding step.

15 . The system of claim 14 , including an electron beam welding apparatus.

16 . The system of claim 15 , including a temperature monitoring device disposed on the hollow fan blade during at least the first welding step.

17 . A method of repairing a hollow component, the hollow component having at least two portions secured to each other by a joint and a cavity disposed between the at least two portions, the cavity being under a vacuum, the method comprising:

removing a damaged section of the hollow component;

obtaining a replacement portion, the replacement portion being of unitary construction;

initially securing the replacement portion to the hollow component; and

securing the replacement portion to the hollow component after the replacement portion is initially secured to the hollow component.

18 . The method of claim 17 , wherein the hollow component is a fan blade.

19 . The method of claim 17 , wherein securing the replacement portion to the hollow component after the replacement portion is initially secured to the hollow component includes electron beam welding the replacement portion to the hollow component.

20 . The method of claim 17 , wherein initially securing the replacement portion to the hollow component includes tungsten inert gas (TIG) welding the replacement portion to the hollow component.