Airfoil joining apparatus and method

Abstract

A wing component for attachment to a cropped airfoil is provided. The cropped airfoil includes a cropped airfoil attachment section and a cropped first side opposite a cropped second side, each of the cropped first side and the cropped second side extending axially between a cropped first edge and a cropped second edge to define a cropped chord length. The wing component includes a body having a component first side opposite a component second side. The body defines an attachment section for attaching the wing component to the cropped airfoil at the cropped airfoil attachment section. The attachment section extends axially between a component first edge and a component second edge to define a component chord length, and the attachment section is oversized relative to the cropped airfoil attachment section such that the component chord length is longer than the cropped chord length. Systems and methods are also provided.

Description

Technical Field

[0001] This topic generally relates to gas turbine engines, and more specifically, to apparatus and methods for joining airfoil components to a portion of a gas turbine engine airfoil. Background Technology

[0002] A typical aircraft propulsion system comprises one or more gas turbine engines, each typically consisting of a turbine. The turbine comprises, in a sequential flow order, a compressor section, a combustion section, a turbine section, and an exhaust section. In operation, air is supplied to the inlet of the compressor section, where one or more axial compressors progressively compress the air until it reaches the combustion section. Fuel is mixed with the compressed air and burned within the combustion section to provide combustion gases. These combustion gases are directed from the combustion section to the turbine section. The flow of combustion gases through the turbine section drives the turbine section and is then directed through the exhaust section, for example, discharged into the atmosphere. Attached Figure Description

[0003] The complete and feasible disclosure of this disclosure, including its best mode, is set forth in the specification with reference to the accompanying drawings, for those skilled in the art, wherein:

[0004] Figure 1 A side view of an airfoil extending radially outward from the platform and a dovetail extending from the airfoil in a radially opposite direction is provided.

[0005] Figure 2 A three-dimensional diagram of the bladed disk is provided.

[0006] Figure 3A A perspective view of a portion of the airfoil repair component positioned against the cut airfoil component is provided.

[0007] Figure 3B A perspective view of a portion of the airfoil repair component positioned against the cut airfoil component is provided.

[0008] Figure 4 A perspective view of a portion of an airfoil repair component with abutment positioning against a trimmed airfoil is provided.

[0009] Figure 5 A perspective view of an airfoil repair component with protrusions on its airfoil mating surface is provided.

[0010] Figure 6 A side cross-sectional view of the electrode assembly of the airfoil repair system is provided.

[0011] Figure 7 A side cross-sectional view of the cut airfoil electrode of the electrode assembly of the airfoil repair system is provided.

[0012] Figure 8 A side cross-sectional view of the repair component electrode of the electrode assembly of the airfoil repair system is provided.

[0013] Figure 9A A top view of the repair component electrode of the electrode assembly of the airfoil repair system is provided.

[0014] Figure 9B Provided Figure 9A A three-dimensional view of a portion of the electrode of the repair component.

[0015] Figure 10A A side perspective view of the repair component electrode body is provided.

[0016] Figure 10B A side perspective view of the repair component electrode insert is provided.

[0017] Figure 10C A three-dimensional view of the end of the electrode of the repair component is provided.

[0018] Figure 11 A perspective view of the electrode assembly of an airfoil repair system with alignment components is provided.

[0019] Figure 12 A 3D view of the feedback component of the tool assembly of the airfoil repair system is provided.

[0020] Figure 13 A side perspective view of the airfoil portion of the tool assembly for an airfoil repair system for bladed disks is provided.

[0021] Figure 14 A side perspective view of the tool assembly for an airfoil repair system for bladed disks is provided.

[0022] Figure 15 A flowchart illustrating a method for repairing airfoil components is provided. Detailed Implementation

[0023] Reference will now be made in detail to the present embodiments of this disclosure, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerals and letter reference numerals to denote features in the drawings. Similar or analogous reference numerals in the drawings and description have been used to denote similar or analogous portions of this disclosure.

[0024] As used herein, the terms “first,” “second,” and “third” are used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of the individual components.

[0025] The terms "front" and "rear" refer to relative positions within a gas turbine engine or vehicle, and specifically to the normal operating posture of the gas turbine engine or vehicle. For example, in the case of a gas turbine engine, "front" refers to the position closer to the engine inlet, while "rear" refers to the position closer to the engine nozzle or exhaust port.

[0026] The terms "upstream" and "downstream" refer to the relative directions of fluid flow within a fluid path. For example, "upstream" refers to the direction from which the fluid flows, and "downstream" refers to the direction from which the fluid flows.

[0027] Unless otherwise stated herein, the terms “connection,” “fixed,” “attached to,” etc., refer to both direct connection, fixation, or attachment, and indirect connection, fixation, or attachment via one or more intermediate components or features.

[0028] Unless the context clearly indicates otherwise, the singular forms “a,” “a,” and “the” include plural references.

[0029] As used herein throughout the specification and claims, approximate language is applied to modify any quantitative expression that may allow for variation without altering its underlying function. Therefore, values ​​modified by terms such as “about,” “approximately,” and “substantially” are not limited to specified precise values. In at least some cases, approximate language may correspond to the precision of the instrument used to measure the value, or the precision of the method or machine used to construct or manufacture the component and / or system. Approximate language may refer to a margin of + / - 1%, 2%, 4%, 10%, 15%, or 20% at the endpoints of a single value, a range of values, and / or a defined range of values.

[0030] Throughout this specification and claims, scope limitations are combined and interchanged, and unless the context or language otherwise indicates otherwise, such scopes are identified and include all subscopes contained herein. For example, all scopes disclosed herein include endpoints, and endpoints may be combined independently of each other.

[0031] A typical compressor has multiple stages or rows of rotor blades and corresponding stator blades, which sequentially increase the air pressure as air flows axially downstream. In some compressors, the compressor blades include dovetail joints for removable mounting in corresponding dovetail slots around the rotor disc. The dovetail-to-dovetail construction allows for individual manufacturing of each blade and individual replacement of blades in case of damage during operation. However, completely replacing a damaged blade can be expensive, especially when the damage is near the blade tip, leaving most of the blade and dovetail joint intact.

[0032] In other compressors, compressor blades can be provided as bladed disks, also known as impellers. An impeller includes a row of rotor airfoils, which are integrally formed with the periphery of the rotor disk as a one-piece or integral construction. Therefore, unlike the removable blades described above, in the event of damage to the impeller airfoils, the entire impeller must be replaced, or the damaged airfoils must be removed and replaced without damaging adjacent airfoils, which can be expensive and / or complex. Other airfoils within the turbine (e.g., in the fan and turbine sections) may also have a dovetail configuration or be part of the impeller, and face similar disadvantages or limitations as described above.

[0033] Therefore, there is a need for improved airfoil repair and airfoil treatment methods and equipment.

[0034] Generally, this subject matter provides methods and apparatus for airfoil repair. For example, it provides methods and apparatus for removing damaged portions of an airfoil to form a cut airfoil and for attaching airfoil repair components to the cut airfoil to repair it. Such airfoil repairs can be time-consuming and / or expensive, and often have low productivity; however, the methods and apparatus described herein can improve success rates and productivity while reducing repair time and costs for individual airfoils (e.g., airfoils fixed to a disk via dovetail joints) and / or integral airfoils (e.g., bladed disk airfoils integrally formed with a disk). For example, the airfoil repair component includes a repair attachment section for attaching the airfoil repair component to the cut airfoil at the attachment section. In at least some embodiments, the repair attachment segment is excessively large relative to the cut airfoil attachment segment, such that the repair attachment segment has a repair chord length longer than the cut chord length of the cut airfoil attachment segment and a repair width wider than the cut width of the cut airfoil attachment segment. The partially or globally oversized airfoil repair component can increase the chance of proper alignment between the airfoil repair component and the cut airfoil (i.e., the airfoil with the damaged portion removed) and increase the material margin or stock for post-joining processing to achieve the net shape of the original airfoil. Furthermore, this subject matter provides an electrode assembly including a repair component electrode and a cut airfoil electrode, which surround the airfoil repair component and the cut airfoil, respectively, and are positioned to align the airfoil repair component with the cut airfoil such that when current flows through it under applied force, the airfoil repair component is attached to the cut airfoil. For example, this subject matter provides methods and apparatus for securing airfoil repair components and / or trimmed airfoils within electrodes to eliminate excessive constraint and allow for more accurate positioning of the airfoil repair components and / or trimmed airfoils, while also reducing or eliminating manual tooling for loading and unloading components from their respective electrodes, for example, by using spring-loaded design features and other design features that facilitate manual manipulation. Furthermore, this subject matter provides features for process feedback, environmental shielding, and / or stabilization, which can produce higher quality welds or joints between the airfoil repair components and trimmed airfoils, better and / or faster alignment of the airfoil repair components with the trimmed airfoils, and / or easier extraction of the repaired airfoil after joining.

[0035] Referring now to the accompanying drawings, where the same numbers indicate the same elements throughout all the drawings. Figure 1 This is a schematic diagram of an airfoil 100 (e.g., an airfoil for a gas turbine engine). Figure 2This is a schematic diagram of a bladed disk 122 (also called a bladed disk) having a plurality of airfoils 100 integrally formed with, for example, a rotor disk that can be used in a gas turbine engine. In at least some embodiments, the gas turbine engine may be a turbofan jet engine comprising a fan section and a core turbine engine disposed downstream of the fan section. The core turbine engine typically comprises a substantially tubular casing that surrounds, in a series flow relationship: a compressor section comprising a boost or low-pressure (LP) compressor and a high-pressure (HP) compressor; a combustion section; a turbine section comprising a high-pressure (HP) turbine and a low-pressure (LP) turbine; and an exhaust nozzle section. A high-pressure (HP) shaft or spool drives the HP turbine to the HP compressor. A low-pressure (LP) shaft or spool drives the LP turbine to the LP compressor. During operation of the turbofan jet engine, a certain amount of air passes through the fan blades of a fan disposed in the fan section. A first portion of the air is directed or directed into a bypass airflow passage, and a second portion of the air is directed or directed into the LP compressor. The ratio between the first portion of air and the second portion of air is generally referred to as the bypass ratio.

[0036] As the second portion of air is directed through the high-pressure (HP) compressor and into the combustion section, its pressure increases. In the combustion section, the second portion of air mixes with fuel and burns to provide combustion gases. The combustion gases are then directed through the HP turbine, where a portion of the thermal and / or kinetic energy from the combustion gases is extracted via a series of stages of HP turbine stator blades connected to the housing of the core turbine engine and HP turbine rotor blades connected to the HP shaft or spool, thus rotating the HP shaft or spool to support the operation of the HP compressor. The combustion gases are then directed through the LP turbine, where a second portion of the thermal and kinetic energy is extracted from the combustion gases via a series of stages of LP turbine stator blades connected to the housing of the core turbine engine and LP turbine rotor blades connected to the LP shaft or spool, thus rotating the LP shaft or spool to support the operation of the LP compressor and / or the rotation of the fan. The combustion gases are subsequently directed through the injection exhaust nozzle section of the core turbine engine to provide propulsive thrust.

[0037] Simultaneously, as the first portion of air is directed through the bypass airflow passage before exiting the fan nozzle exhaust section, the pressure of the first portion of air increases significantly, also providing propulsive thrust. The HP turbine, LP turbine, and injection exhaust nozzle section at least partially define the hot gas path used to guide combustion gases through the core turbine engine.

[0038] In some embodiments, Figure 1 and Figure 2 The airfoil 100 depicted may be a compressor blade, such as the rotor blade of the LP compressor or HP compressor of the aforementioned turbofan jet engine. In other embodiments, Figure 1and Figure 2 The airfoil 100 depicted may be a turbine blade, such as the rotor blade of an LP turbine or HP turbine of a turbofan jet engine. In yet another embodiment, the airfoil 100 may be another airfoil of the aforementioned turbofan jet engine, another airfoil of another gas turbine engine, or another airfoil of another component or system having one or more airfoils.

[0039] like Figure 1 and Figure 2 As depicted in the embodiment, the airfoil 100 includes a concave pressure side 102 opposite to the convex suction side 104. The opposing pressure side 102 and suction side 104 of the airfoil 100 extend radially along a span S from a root 106 to a tip 108 at the radially outermost portion of the airfoil 100. That is, the root 106 defines a first radial end of the airfoil 100, and the tip 108 defines a second radial end of the airfoil 100, wherein the root 106 and the tip 108 are spaced apart in the radial direction R. The pressure side 102 and suction side 104 of the airfoil 100 extend axially along a chord length c between a leading edge 110 and an opposing trailing edge 112. The leading edge 110 defines the front end of the airfoil 100, and the trailing edge 112 defines the rear end of the airfoil 100, wherein the leading edge 110 and the trailing edge 112 are spaced apart in the axial direction A. Furthermore, the pressure side 102 defines the outer pressure surface 114 of the airfoil 100, and the suction side 104 defines the outer suction surface 116 of the airfoil 100.

[0040] More generally, the airfoil 100 can be described as having a first side opposite to the second side, wherein either the first side or the second side is a pressure side 102 or a suction side 104, and the other of the first side and the second side is the other of pressure side 102 and suction side 104. Each of the first side and the second side extends axially between a first edge and an opposite second edge, wherein either the first edge or the second edge is a leading edge 110 or a trailing edge 112, and the other of the first edge and the second edge is the other of leading edge 110 and trailing edge 112. Furthermore, the first side defines a first outer surface of the airfoil 100, and the second side defines a second outer surface of the airfoil 100, wherein either the first outer surface or the second outer surface is an outer pressure surface 114 or an outer suction surface 116, and the other of the first outer surface and the second outer surface is the other of outer pressure surface 114 and outer suction surface 116.

[0041] exist Figure 1In the embodiments described, the airfoil 100 extends radially outward from the platform 118. A dovetail tenon 120 extends from the platform 118 in a direction radially opposite to the airfoil 100. The dovetail tenon 120 is configured to receive within a complementary dovetail groove in a rotor disk (not shown). In the depicted embodiments, the airfoil 100, platform 118, and dovetail tenon 120 are fixed to each other, or integrally formed as a single piece or component, such that the airfoil 100, platform 118, and dovetail tenon 120 are removably received together in the rotor disk. It should be understood that a plurality of airfoils 100 are fixed to the rotor disk via a corresponding number of dovetail tenons 120 to form a first-stage rotor blade, such as a first-stage compressor blade of a gas turbine engine compressor. The plurality of airfoils 100 are circumferentially spaced from each other, or spaced along a circumferential direction C, to define a ring of airfoils 100, similar to... Figure 2 The airfoil 100 of the bladed disk 122 shown.

[0042] like Figure 1 As further shown, fillet 105 defines the transition between pressure side 102 and platform 118, and suction side 104 and platform 118. Furthermore, airfoil 100 defines a section line SL, for example, at half the distance between the tip 108 at the leading edge 110 and the tangent of the leading edge fillet, which is intercepted at fillet 105 between the leading edge 110 and platform 118.

[0043] As mentioned above, Figure 2 A bladed disk or bladed disk 122 is depicted having multiple airfoils 100 extending from a rotor disk 124 at an integral platform 126. It should be understood that the airfoils 100 of the bladed disk 122 are configured as shown regarding... Figure 1 As described. However, with Figure 1 Unlike the separate platform 118 and dovetail 120 for each airfoil 100 in the embodiments, the bladed disk 122 includes a single platform 126 serving as a platform for each of the plurality of airfoils 100. Furthermore, in Figure 2 In this embodiment, the dovetail tenon 120 is not required because the airfoil 100 is integrally formed with the rotor disk 124. Therefore, although Figure 1 The airfoil 100 can be removed from the rotor disk, but Figure 2 The airfoil 100 is not removable relative to the rotor disk 124, but is integrally formed with the platform 126 and the rotor disk 124 to form the bladed disk 122.

[0044] Sometimes, the airfoil 100 may be damaged during use. For example, the airfoil 100 may experience localized damage during use, such as through unintentional sharp-point friction against the shield or housing, impact from a foreign object, and / or other contact between the airfoil 100 and another component, object, or substance. The airfoil 100 may develop a damaged area 128, for example, in... Figure 2As shown on the airfoil 100 of the bladed disk 122, it can be, for example, a cavity. As used herein, the term "cavity" refers to any hollow space within the airfoil 100, such as an opening, crack, gap, orifice, hole, etc. Such a cavity or damaged area 128 can be formed on or within the airfoil 100 by normal use and generally refers to an area where fragments, chunks, flakes, etc., of the original airfoil material have broken off or been released from the airfoil 100.

[0045] In at least some cases, the damaged area 128 impairs the function of the airfoil 100, necessitating repair of the airfoil 100. Typically, the airfoil 100 can be repaired by replacing the entire airfoil 100 or by removing and replacing a portion 130 of the airfoil 100 containing the damaged area 128, referred to herein as the damaged portion 130. In some embodiments, the damaged portion 130 may be along the section line SL (… Figure 1 Below or relative to the section line SL ( Figure 1 The radially inward plane is removed, resulting in more than half of the airfoil 100 being removed. In other embodiments, the damaged portion 130 may be removed along a plane above or radially outward relative to the section line SL, resulting in less than half of the airfoil 100 being removed.

[0046] It should be understood that replacing the entire airfoil 100 is generally more expensive than replacing only the damaged portion 130 of the airfoil 100. Furthermore, at least for the bladed disk 122, replacing the entire airfoil 100 typically involves complex manufacturing processes and may carry the risk of damaging the platform 126 and / or rotor disk 124 of the bladed disk 122, as well as adjacent undamaged airfoils 100. Other complex situations may also require replacing the entire airfoil 100.

[0047] Therefore, to minimize replacement costs and management complexity, this topic provides methods, components, systems, and equipment for replacing only the damaged part 130. For example, steering... Figure 3A , Figure 3B and Figure 4 An airfoil component or airfoil repair component 200 is provided to replace the damaged portion 130. As described in more detail herein, from the airfoil 100 (e.g., in...) Figure 1 Above, below, or at the section line SL shown, remove the damaged portion 130 to form a trimmed airfoil 140, such that the trimmed airfoil 140 has a span S smaller than that of the airfoil 100. Figure 1 The radial height of the airfoil 140. The cut airfoil 140 includes the airfoil root 106, and thus remains fixed (or can be refixed) to about Figure 1 The platform 118 and dovetail tenon 120 of the described individual airfoil 100, or retaining with Figure 2The rotor disk 124 and platform 126 of the bladed disk 122 are integrated. Furthermore, the trimmed airfoil 140 includes the pressure side 102, suction side 104, leading edge 110, and the remaining portion of trailing edge 112, which are referred to herein as trimmed pressure side 102c, trimmed suction side 104c, etc. Figure 3A ,3B), trim the leading edge 110c ( Figure 7 ) and cut the back edge 112c ( Figure 7 ).

[0048] Similar to airfoil 100, cut airfoil 140 may have features more generally described as a first cut side and an opposing second cut side, which are either a cut pressure side 102c or a cut suction side 104c. Each of the first and second cut sides extends axially between a first cut edge and an opposing second cut edge, which are either a leading edge 110c or a trailing edge 112c.

[0049] refer to Figure 4 Because the airfoil repair component 200 is attached to the cut airfoil 140 to produce the repaired airfoil 100, the airfoil repair component 200 is constructed similar to the one described above. Figure 1 and Figure 2 The airfoil 100 is described. More specifically, refer to... Figure 3A , Figure 3B and Figure 4 The airfoil repair component 200 includes a body 205 having a repair pressure side 202 opposite to a repair suction side 204 and a repair leading edge 210 opposite to a repair trailing edge 212. Furthermore, the repair pressure side 202 and the repair suction side 204 extend axially between the repair leading edge 210 and the repair trailing edge 212. More generally, the airfoil repair component 200 includes a body 205 having a first side opposite to a second side, wherein the first side and the second side are either the repair pressure side 202 or the repair suction side 204, and the first side and the second side extend axially between a first edge and a second edge, wherein the first edge and the second edge are either the repair leading edge 210 or the repair trailing edge 212. Similar to the trimmed airfoil 140, the airfoil repair component 200 has a span S smaller than that of the airfoil 100. Figure 1 The radial height of ).

[0050] The body 205 of the airfoil repair component 200 is defined for attaching the airfoil repair component 200 to the repair attachment section 242 of the cut airfoil 140. For example... Figure 3A , Figure 3B and Figure 4As shown, the trimmed airfoil 140 includes a trimmed airfoil attachment section 142, which is the outermost radial section of the trimmed airfoil 140. Similarly, as... Figure 3A , Figure 3B and Figure 4 As shown, the repair attachment section 242 is the innermost radial section of the airfoil repair component 200.

[0051] To attach the airfoil repair component 200 to the cut airfoil 140, the repair attachment section 242 is aligned with the cut airfoil attachment section 142, and the airfoil repair component 200 is secured to the cut airfoil 140, for example, by welding the airfoil repair component 200 to the cut airfoil 140, as described in more detail below. For example, the repair attachment section 242 defines a repair mating surface 244 ( Figure 3A , 3B 5, 8, 9A, 9B), and the trimmed airfoil attachment section 142 defines the trimmed joint surface 144 ( Figure 7 When the airfoil repair component 200 is aligned with the cut airfoil 140, the repair mating surface 244 intersects with the cut mating surface 144. The airfoil repair component 200 can then be joined to the cut airfoil 140 by welding or other suitable joining processes, for example, along the interface between the repair mating surface 244 and the cut mating surface 144. It should be understood that the repair mating surface 244 defines the inner end of the airfoil repair component 200, and the opposing tip 208 ( Figure 4 , 8 The outer end of the airfoil repair component 200 is defined, while the cutting joint surface 144 defines the outer end of the cut airfoil 140, and the opposing root 106 defines the inner end of the cut airfoil 140.

[0052] like Figure 3A and 3B As shown, at least the repair attachment section 242 is too large relative to the cut airfoil attachment section 142. For example, the repair attachment section 242 has a cut chord length c greater than that of the cut airfoil attachment section 142. c Longer repair chord length c r That is, to repair the chord length c r The cutting chord length c of the 142th section of the cut airfoil attachment is greater than that of the cut airfoil attachment section. c Longer. As another example, the repair attachment section 242 is too large relative to the trimmed airfoil attachment section 142, causing the repair width w of the body 205 at the repair attachment section 242 to be longer. r The cutting width w of the cut airfoil 140 at the attachment section 142 of the cut airfoil c Wider. In some embodiments, the repair attachment section 242 may be too large relative to the trimmed airfoil attachment section 142, such that the repair chord length c rthan the length of the cut chord c c Longer or repaired width w r Compare to the cutting width w c Wider. In other embodiments, for example Figure 3A and 3B As shown, the repaired chord length c r and repair width w r Each is greater than the length of the cut chord c c and the cutting width w c That is, to repair the chord length c r than the length of the cut chord c c Longer, and the width w is fixed. r Compare to the cutting width w c Wider.

[0053] Similar to the chord length c mentioned above, the chord length c is repaired. r The repair extends along the axial direction A from the leading edge 210 to the trailing edge 212 (or from the first edge of the component to the second edge of the component), and the chord length c is trimmed. c The axial direction A extends from the leading edge 110c to the trailing edge 112c (or from the first cutting edge to the second cutting edge). The width of each airfoil segment is measured along the circumferential direction C from the pressure side to the suction side. Therefore, the repair width w r Extending from the repair pressure side 202 to the repair suction side 204 (or extending between the first and second sides of the airfoil repair component 200), and with a cutting width w c The circumferential direction C extends from the cutting pressure side 102c to the cutting suction side 104c (or extends between the first and second cutting sides of the cut airfoil 140). At least the repair attachment section 242 of the airfoil repair component 200 is too large relative to the cut airfoil attachment section 142 of the cut airfoil 140, such that the repair attachment section 242 extends beyond the cut airfoil attachment section 142 in the axial or chordal and circumferential or lateral directions.

[0054] Still referencing Figure 3A and 3B In at least some embodiments, the oversized repair attachment section 242 defines a flared extension of the body 205. For example... Figure 3A and 3B As shown, the repair attachment section 242 extends outward from the main body 205, wherein the repair width w of the repair attachment section 242 is... r The body width w is greater than the body width of body 205. bWider. The flared or oversized repair attachment section 242 provides a larger repair engagement surface 244 than the rest of the body 205, providing a larger surface for alignment with the cut engagement surface 144, which can aid in the alignment or positioning of the airfoil repair component 200 with the cut airfoil 140. For example, the larger repair engagement surface 244 of the oversized repair attachment section 242 can be more easily aligned with the cut engagement surface 144 compared to an engagement surface of approximately the same size and shape as the cut engagement surface 144 of the cut airfoil 140. That is, the flared, oversized repair attachment section 242 provides a larger platform on the airfoil repair component 200 to increase the initial part assembly allowance. The remainder of the body 205 may be a net shape, for example, the flared extension defined by the repair attachment section 242 may be the only dimension of the airfoil repair component 200 that exceeds the size of the rest of the airfoil repair component 200, wherein the remainder of the airfoil repair component 200 has the same shape and size as the portion of the original airfoil 100 that the airfoil repair component 200 is replacing.

[0055] Turning Figure 4 In some embodiments, the entire airfoil repair component 200 is excessively large relative to the trimmed airfoil 140. For example, the body 205 of the airfoil repair component is excessively large relative to the trimmed airfoil attachment section 142, such that the body 205 located away from or outside the repair attachment section 242 has a length greater than the trimming chord c. c Longer body chord length c b And the cutting width w c Wider body width w b Besides the main body 205, the repair attachment section 242 is too large relative to the aforementioned trimmed airfoil attachment section 142, that is, the repair chord length c r than the length of the cut chord c c Longer, and the width w is fixed. r It is wider than the cutting width wc. Therefore, the airfoil repair component 200 can generally be larger than the cut airfoil 140.

[0056] like Figure 4 As shown, the oversized or larger airfoil repair component 200 therefore has "extra" or additional material that can be machined away after the airfoil repair component 200 is attached to the cut airfoil 140 to restore the desired net shape of the original undamaged airfoil 100. That is, as Figure 4As shown, the net shape of airfoil 100 is contained within an oversized airfoil repair component 200, and the net shape is revealed through processing (e.g., machining, deformation, etc.) after attaching the airfoil repair component 200 to the trimmed airfoil 140. In at least some embodiments, for example, an oversized airfoil repair component 200 provides a greater margin of error when aligning the airfoil repair component 200 with the trimmed airfoil 140 compared to a partially enlarged or oversized airfoil repair component 200 (e.g., only in the area of ​​the repair attachment section 242). For example, an overall enlarged or oversized airfoil repair component 200 (rather than a partially enlarged / oversized airfoil repair component 200) can be used to repair the damaged airfoil 100 of the bladed disk 122 because the space for observing / inspecting and ensuring the alignment of the airfoil repair component 200 with the trimmed airfoil 140 on the bladed disk 122 is smaller because other airfoils 100 are adjacent to the trimmed airfoil 140. The overall enlarged / oversized airfoil repair component 200 allows for less precise placement of the airfoil attachment section 242 relative to the trimmed airfoil attachment section 142 (e.g., the airfoil repair component 200 can be used with the removable airfoil 100 compared to a partially enlarged or oversized airfoil repair component 200), because the additional material can be machined away after attachment to define the shape of the airfoil 100.

[0057] on the contrary, Figure 3A and 3B The airfoil repair component 200 shown is partially enlarged or oversized, with the chord length c increased only in the repair attachment section 242 as described above. r And the width w was increased. r . Figure 3A and 3B The airfoil repair component 200 shown has a body 205 that has the final shape of the airfoil 100, i.e., the shape of the body 205 is similar to the original, undamaged airfoil 100. In at least some embodiments, the repair attachment section 242 is consumed when the airfoil repair component 200 is attached to the trimmed airfoil 140, so that it is compatible with the airfoil 100. Figure 4 Unlike the overall enlarged / oversized airfoil repair component 200, once the airfoil repair component 200 is attached to the trimmed airfoil 140, almost no processing is required because the body 205 of the airfoil repair component 200 has already defined the final shape of the airfoil 100.

[0058] like Figure 3A , Figure 3B and Figure 4As shown, the repair joint surface 244 and the trimmed joint surface 144 intersect in a plane-to-plane interaction manner. In other words, there is a plane-to-plane contact between the airfoil repair component 200 and the trimmed airfoil 140. This interaction is designed to minimize the effects of alignment errors and counteract the stresses caused by the joint. When the airfoil repair component 200 is joined to the trimmed airfoil 140 in a welding process, the repair joint surface 244 and the trimmed joint surface 144 are consumed during the welding process because the two components are joined together. The planar interaction between the airfoil repair component 200 and the trimmed airfoil 140 helps ensure that the airfoil repair component 200 is properly aligned relative to the trimmed airfoil 140 so as to define the overall shape of the airfoil 100 once the joint process is completed (and if necessary, any post-joining processing, such as machining, deformation processing (e.g., cold working or hot working, etc.)).

[0059] refer to Figure 5 When the airfoil repair component 200 is positioned relative to the cut airfoil 140 to engage the airfoil repair component 200 with the cut airfoil 140 (e.g.) Figure 6 As shown), the repair joint surface 244 may include surfaces away from the repair joint surface 244, for example, toward the trimming joint surface 144. Figure 7 One or more protrusions 246 extending from it. Additionally or alternatively, although not in Figure 5 As shown, however, when the airfoil repair component 200 is positioned relative to the cut airfoil 140 to engage the airfoil repair component 200 to the cut airfoil 140, the cut engagement surface 144 may include one or more protrusions 246 extending away from the cut engagement surface 144, for example, toward the repair engagement surface 244. One or more protrusions 246 alter the repair engagement surface 244 (and / or the cut engagement surface 144), wherein the cut engagement surface 144 includes one or more protrusions 246, for example... Figure 5 The protrusion 246 (as shown relative to the repair joint surface 244) is designed to help guide current during the jointing process, and each protrusion 246 can have any suitable shape and size. Figure 5 As shown, the depicted protrusions 246 narrow the repair mating surface 244 from the body 205 toward the cut airfoil 140, such that when the airfoil repair component 200 and the cut airfoil 140 are placed together for mating, for example, the smaller surface area of ​​the airfoil repair component 200 contacts the cut airfoil 140 compared to the surface area of ​​the airfoil mating surface 244 without the protrusions 246. Therefore, one or more protrusions 246 consumed during the mating process help to position the current at the start of the mating process, which can help concentrate heat in the desired area early in the mating process.

[0060] In some embodiments, the airfoil 100 includes a twist along the span S. For example, in Figure 2 In this configuration, the root 106 of the airfoil 100 may be offset from the tip 108 of the airfoil 100 in the circumferential direction C, such that, for example, the leading edge 100 does not extend from the root 106 to the tip 108 in a generally straight line. Twist, offset, or deviation from linearity does not need to exist over the entire span S; for example, the airfoil 100 may not have a twist along the length of the span S. For example, in situations such as... Figure 4 In some of the depicted embodiments, the airfoil 100 may extend substantially linearly in the radial direction R from approximately the middle of the span to the tip 108; that is, the twist may be located between the root 106 and the middle of the span. Nevertheless, regardless of the location or degree of the twist, when repaired with the airfoil repair component 200, the repaired airfoil 100 should also include the twist, such that the repaired airfoil 100 has the same final shape as the original, undamaged airfoil 100.

[0061] like Figure 3A As shown, in at least some embodiments, the airfoil repair component 200 can be shaped to eliminate distortion in the repair attachment section 242. For example, the repair attachment section 242 extends substantially straight or linearly in the radial direction R, while the airfoil repair component 200 radially above the repair attachment section 242 extends along a span S ( Figure 1 This includes distortion. In some embodiments, the cut airfoil attachment segment 142 of the cut airfoil 140 may also be substantially straight or linear in the radial direction R. For example, as Figure 3A As shown at position 145, local coining or similar processes can be used to remove distortion in the area of ​​the trimmed airfoil attachment segment 142, or to straighten the trimmed airfoil 140. Having straight or linear trimmed airfoil attachment segments 142 and / or repair attachment segments 242 can help define planar interactions between the trimmed airfoil 140 and the airfoil repair component 200 along the trimmed joint surface 144 and the repair joint surface 244, which can help improve alignment between the trimmed airfoil 140 and the airfoil repair component 200. Furthermore, during the joining process, for example, when the airfoil repair component 200 is welded to the cut airfoil 140, the straight or linear cut airfoil attachment section 142 and / or repair attachment section 242 are consumed, causing the airfoil geometry modified to remove distortion or to be undistorted to disappear during the joining process, leaving only the repair airfoil 100 with the distortion of the original airfoil 100.

[0062] Although regarding individual airfoil components 100 ( Figure 3A and 3B ) describes the repair component 200 for an airfoil that is open or partially oversized, and regarding the bladed disk 122 ( Figure 4 The description refers to the oversized repair component 200, but it should be understood that regarding... Figure 3A and 3B The described features and about Figure 4 The described features apply to individual airfoil 100 or airfoil repair components 200 of airfoil 100 integrated into bladed disk 122. That is, the description provided herein is not intended to limit the application of the features shown. Furthermore, protrusion 246 can also be used for individual airfoil 100 or airfoil repair components 200 of airfoil 100 integrated into bladed disk 122 and / or trimmed airfoil 140. Similarly, other features described herein, although shown or described with respect to individual airfoil 100 or bladed disk airfoil 100, can be used for individual airfoil 100 or airfoil repair components 200 of airfoil 100 integrated into bladed disk 122 and / or trimmed airfoil 140.

[0063] Turn now Figures 6 to 14 In at least some embodiments, the airfoil repair component 200 is an airfoil repair system 300. Figure 12 , 14 The airfoil repair system 300 includes components for placing, positioning, and holding the airfoil repair component 200 relative to the cut airfoil 140. The airfoil repair system 300 also includes components that facilitate the engagement of the airfoil repair component 200 to the cut airfoil 140.

[0064] Special Reference Figure 6 The airfoil repair system 300 includes an electrode assembly 302. The electrode assembly 302 includes a repair component electrode 304 and a trimmed airfoil electrode 306. The repair component electrode 304 receives an airfoil repair component 200, while the trimmed airfoil electrode 306 receives a trimmed airfoil 140. As described herein, current is passed through the repair component electrode 304, in which the airfoil repair component 200 is positioned, and the trimmed airfoil electrode 306, in which the trimmed airfoil 140 is positioned, to bond the airfoil repair component 200 to the trimmed airfoil 140. For example, solid-state resistance welding (SSRW) technology can be used to weld the airfoil repair component 200 to the cut airfoil 140 by flowing current through the airfoil repair component 200 and the cut airfoil 140 when the repair joint surface 244 is in contact with (or at the boundary of) the cut joint surface 144; the repair component electrode 304 and the cut airfoil electrode 306 can also provide, for example, a compressive axial force toward the end of the current pulse to aid in welding the airfoil repair component 200 and the cut airfoil 140. Other welding or joining techniques or processes may also be used.

[0065] Turning Figure 7 In some embodiments, the trimmed airfoil electrode 306 includes a dovetail block 308, an electrode body 310, and a retaining assembly 312. As previously described, Figure 1As shown, the cut airfoil 140, formed by individual or removable airfoil 100, includes dovetail tenons 120 that facilitate securing the airfoil 100 to the rotor disk. Figure 7 As depicted, the dovetail tenon 120 can be received within the dovetail block 308 of the cut airfoil electrode 306. For example, the dovetail block 308 defines a dovetail opening 314 having a shape complementary to that of the dovetail tenon 120, and the dovetail tenon 120 is received in the dovetail opening 314 that is complementary to the shape of the dovetail block 308. Therefore, the dovetail block 308 helps to secure and / or stabilize the cut airfoil 140 within the cut airfoil electrode 306, along the stacking axis A. S ( Figure 6 The cut airfoil 140 may be constrained along any longitudinal orientation that facilitates the joining process. The dovetail block 308 may or may not be constrained relative to the cut airfoil electrode 306. For example, the dovetail block 308 may be locked in place using a locating screw or the like, or it may not be subject to hard constraints, allowing it to move freely relative to the cut airfoil electrode 306. It should be understood that in other embodiments, such as where the cut airfoil 140 does not include the dovetail tenon 120, for example in the bladed disk 122 embodiment, the dovetail block 308 of the cut airfoil electrode 306 may be omitted.

[0066] In addition, such as Figure 7 As shown, the cut airfoil 140 is removably secured to the electrode body 310 by single-handed operation of the retaining assembly 312. For example, the retaining assembly 312 includes a thrust element 316 (e.g., a lever or button) and a stop 318 (which may be a pin, etc.). The thrust element 316 and the stop 318 extend along the cut chord c. c The elements are arranged relative to each other; for example, when the cut airfoil 140 is loaded in the cut airfoil electrode 306, one of the thrust element 316 and the stop 318 is positioned against the cutting leading edge 110c, and the other of the thrust element 316 and the stop 318 is positioned against the cutting trailing edge 112c. The thrust element 316 can be manipulated by a user, for example, using a single finger (e.g., thumb) or one hand, to load and unload the cut airfoil 140 from the cut airfoil electrode 306. For example, each of the thrust element 316 and the stop 318 provides a point constraint on the cut airfoil 140, and the thrust element 316 is manipulated or movable to relax the point constraint provided by the thrust element 316, thereby loading and / or unloading the cut airfoil 140 relative to the cut airfoil electrode 306. More specifically, the thrust element 316 can be moved away from the area where the cut airfoil 140 is located when it is loaded into the electrode body 310, in order to load and / or unload the cut airfoil 140 from the cut airfoil electrode 306.

[0067] Now for reference Figure 8In at least some embodiments, the airfoil repair component 200 is similarly removably attached to the repair component electrode 304. For example, similar to the trimmed airfoil electrode 306, Figure 8 The repair component electrode 304 shown includes an electrode body 320 and a retaining assembly 322. To more easily distinguish between the electrode body 310 and the electrode body 320, in at least some instances herein, the electrode body 310 of the cut airfoil electrode 306 may be referred to as the cut airfoil electrode body 310, and the electrode body 320 of the repair component electrode 320 may be referred to as the repair component electrode body 320.

[0068] The airfoil repair component 200 is removably secured to the electrode body 320 via one-handed operation of the retaining assembly 322. Figure 8 In one embodiment, the retaining assembly 322 includes a thrust element 326 (e.g., a lever or button) and a stop 328 (which may be a pin, etc.). The thrust element 326 and the stop 328 extend along the repair chord length c. r They are arranged opposite to each other. For example, when the airfoil repair component 200 is loaded in the repair component electrode 304, one of the thrust element 326 and the stop 328 is set to abut against the repair leading edge 210, and the other of the thrust element 326 and the stop 328 is set to abut against the repair trailing edge 212.

[0069] The thrust element 326 can be manipulated by a user, for example, using a single finger (e.g., thumb) or one hand, to load and unload the airfoil repair component 200 from the repair component electrode 304. For example, each of the thrust element 326 and the stop 328 provides a point constraint on the airfoil repair component 200. The thrust element 326 is manipulateable or movable to relax the point constraint provided by the thrust element 326, thereby loading and / or unloading the airfoil repair component 200 relative to the repair component electrode 304. That is, the thrust element 326 can be moved away from the airfoil repair component 200 or the area where the airfoil repair component 200 is located when loaded into the electrode body 320, to load and / or unload the airfoil repair component 200 from the repair component electrode 304.

[0070] Figure 9A and 9B Another embodiment of the repair component electrode 304 is shown. Figure 9A and 9BIn one embodiment, the retaining assembly 322 includes a stabilizing element 324 defining an opening 325 for receiving the airfoil repair component 200, wherein a periphery 323 extends around the opening 325. Furthermore, the stabilizing element 324 includes a stabilizing arm 327 that contacts the repair suction side 204 to push the airfoil repair component 200 into contact with the repair pressure side 202, and a second stop 328b that provides at least point constraint on the repair leading edge 210. (See also: [Specific Reference]) Figure 9B The stabilizing arm 327 includes a locating screw 329 for tightening the stabilizing arm 327 against the airfoil repair component 200, wherein one or more springs are used for retracting the stabilizing arm 327. In this way, the airfoil repair component 200 can be held in place with minimal force, preventing excessive restraint on the airfoil repair component 200. In other embodiments, other methods can be used to advance and retract the stabilizing arm 327 relative to the airfoil repair component 200.

[0071] In various embodiments, depending on the construction of, for example, the stabilizing element components and the airfoil repair component 200, components of the stabilizing element 324 (i.e., periphery 323, stabilizing arm 327, first stop 328a, and second stop 328b) can provide point, line, and / or planar constraints on the airfoil repair component 200. It should be understood that the stabilizing arm 327 can be manipulated to constrain or release the airfoil repair component 200, wherein the periphery 323, stabilizing arm 327, first stop 328a, and second stop 328b of the stabilizing element 324 provide sufficient constraint to stabilize the airfoil repair component 200 for engagement processing without over-constraining it.

[0072] Turn now Figure 10A and 10B In some embodiments, the repair component electrode 304 includes a repair component electrode insert 330 that surrounds at least a portion of the airfoil repair component 200 and is removable relative to the repair component electrode body 320. For example... Figure 10A As shown, the repair component electrode insert 330 is received in the repair component electrode body 320. Figure 10B In the image, the repair component electrode insert 330 is shown as being removed from the repair component electrode body 320.

[0073] like Figure 10BAs shown, the repair component electrode insert 330 defines an inert gas manifold 332 for receiving inert gas. Furthermore, the repair component electrode insert 330 defines a first plurality of grooves 334a extending from the inert gas manifold 332 along a first outer surface 336a of the repair component electrode insert 330 and a second plurality of grooves 334b ​​extending from the inert gas manifold 332 along a second outer surface 336b of the repair component electrode insert 330. The first plurality of grooves 334a and the second plurality of grooves 334b ​​guide inert gas IG from the inert gas manifold 332 along a first side 338a and a second side 338b of the repair component electrode insert 330, respectively, to define an inert gas shield around the airfoil repair component 200.

[0074] For example, an inert gas shield is useful when the airfoil 100 and the airfoil repair component 200 are formed of reactive materials such as titanium alloys. For instance, reactive materials may exhibit undesirable reactions during some joining processes (such as solid-state resistance welding (SSRW)), which could contaminate the weld interface between the cut airfoil 140 and the airfoil repair component 200. By providing a shield or barrier to inert gases, undesirable atmospheric reactions can be reduced or eliminated.

[0075] exist Figure 9A and 9B In the illustrated embodiment, the repair component electrode insert 330 engages the leading and trailing edge profiles of the airfoil repair component 200. Specifically, the repair component electrode insert 330 is shaped such that its inner surface 340 engages the repair leading edge 210 and the repair trailing edge 212. Furthermore, the repair component electrode insert 330 includes a leading edge guide 331a and a trailing edge guide 331b. For example, in titanium airfoil repair applications, the leading edge guide 331a and trailing edge guide 331b are minimal conductivity, high temperature resistance, and wear resistance guides that help stabilize the relatively thin edges of the airfoil repair component 200. For example, the leading edge guide 331a and trailing edge guide 331b hold the leading edge 210 and trailing edge 212 respectively to stabilize the airfoil repair component 200. Leading edge guide 331a and trailing edge guide 331b can also control heat, as well as leading edge 210 and trailing edge 212, respectively, to help prevent overheating of leading edge 210 and trailing edge 212 during the bonding process. Leading edge guide 331a and trailing edge guide 331b can be made of materials selected for minimizing thermal conductivity, withstanding high temperatures, and being wear-resistant.

[0076] In the depicted embodiments, the repair component electrode insert 330 defines a cavity 342 for receiving the airfoil repair component 200. In some embodiments, only one of the repair leading edge 210 and the repair trailing edge 212, or only one or a portion of both of the repair leading edge 210 and the repair trailing edge 212, is engaged via the repair component electrode insert 330. The engagement between the repair component electrode insert 330 and the airfoil repair component 200 can help stabilize the airfoil repair component 200 within the repair component electrode 304 by preventing warping or overlapping of the thinner leading and trailing edges of the cut airfoil 140 and / or the airfoil repair component 200.

[0077] like Figure 10A and 10B As further shown, in some embodiments, the repair component electrode insert 330 includes a first half 330a and a second half 330b. In the depicted embodiment, the repair component electrode insert 330 is divided chordally or axially relative to the airfoil repair component 200 to define the first half 330a and the second half 330b. Each of the first half 330a and the second half 330b defines a portion of the inert gas manifold 332, such that the two halves 330a, 330b together define the inert gas manifold 332.

[0078] Furthermore, each of the first half 330a and the second half 330b of the illustrated repair component electrode insert 330 defines a portion of a plurality of recesses 334. More specifically, the first half 330a defines a first plurality of recesses 334a, and the second half 330b defines a second plurality of recesses 334b. Each of the first plurality of recesses 334a and the second plurality of recesses 334b ​​extends from the inert gas manifold 332 along the respective first half 330a and second half 330b of the repair component electrode insert 330.

[0079] like Figure 10A and 10B As shown in the embodiments, each of the plurality of grooves 334 extends parallel to the remaining grooves 334. In other embodiments, the plurality of grooves 334 may not all be parallel to each other, but at least one of the plurality of grooves 334 may extend in different directions relative to one or more of the plurality of grooves 334. Furthermore, the plurality of grooves 334 may be substantially symmetrical with respect to the repair component electrode insert 330. For example, for Figure 10A and 10BThe electrode insert 330 of the halved repair component shown has a first plurality of recesses 334a with an equal number of second plurality of recesses 334b, and each corresponding recess 334a of the first plurality of recesses 334a is defined opposite to a corresponding recess 334b ​​of the second plurality of recesses 334b ​​along the lateral dimension of the airfoil repair component 200. However, in other embodiments, the plurality of recesses 334 may not be symmetrical; for example, the number of recesses 334a defined in the first half 330a may be different from the number of recesses 334b ​​defined in the second half 330b.

[0080] refer to Figure 10C In at least some embodiments, the repair component electrode 304 includes serrations 343 defined in the repair component electrode body 320. The serrations 343 are openings or areas in the repair component electrode body 320 where no material is present. Figure 10C As shown, each serration 343 includes a change in orientation; for example, the serration 343 includes a first portion inclined from a first side of the repair component electrode body 320 toward a relatively second side of the repair component electrode body 320 and a second portion inclined from a second side of the repair component electrode body 320 toward a relatively first side of the repair component electrode body 320. The serration 343 can function as a spring or other biasing member to achieve better or improved contact between the repair component electrode 304 and the airfoil repair component 200. Furthermore, during the bonding process, the serration 343 can provide cooling, particularly at the leading edge 210 and / or trailing edge 212 of the airfoil repair component 200, for example, to protect the relatively thin leading edge 210 and trailing edge 212. For example, the serration 343 can throttle or choke the current through the repair component electrode 304 to the airfoil repair component 200 at the leading edge 210 and / or trailing edge 212 to help prevent overheating of the leading edge 210 and / or trailing edge 212 when the airfoil repair component 200 is engaged to the cut airfoil 140.

[0081] Turn now Figure 11 , 12 And 13, the airfoil repair system 300 includes a tool assembly 344 for positioning the airfoil repair component 200 relative to the cut airfoil 140. (See also: Special Reference) Figure 11 In at least some embodiments, tool component 344 includes alignment component 346. Figure 11 In one embodiment, the alignment assembly 346 is an independent-axis three-degree-of-freedom manipulator configured to adjust the airfoil repair component 200 (enclosed within) along three separate axes defined by the trimmed airfoil 140. Figure 11 The repair component electrode 304 is located within the trimmed airfoil 140 (surrounding the electrode 304). Figure 11The position of the airfoil repair component 200 is within the trimmed airfoil electrode 306. As shown in the figure, the alignment assembly 346 includes: a first rotatable knob 348a, which adjusts the position of the airfoil repair component 200 along the first degree of freedom, axial direction A, or along the chord of the trimmed airfoil 140; a second rotatable knob 348b, which adjusts the position of the airfoil repair component 200 along the second degree of freedom, circumferential direction C, or laterally along the trimmed airfoil 140; and a third rotatable knob 348c, which adjusts the position of the airfoil repair component 200 relative to the third degree of freedom, stacking axis A. S The position of the airfoil repair component 200 can be adjusted using rotatable knobs 348a, 348b, 348c, allowing for more precise alignment of the airfoil repair component 200 relative to the trimmed airfoil 140 compared to other alignment modes. However, it should be understood that in other embodiments, besides or instead of rotatable knobs, the alignment assembly 346 may utilize other means to adjust the position or alignment of the airfoil repair component 200 along various degrees of freedom. It should be understood that the alignment assembly 346 shown is merely an example. In other embodiments, the alignment assembly 346 may manipulate or adjust the position of the airfoil repair component 200 and / or the trimmed airfoil 140 with any number of degrees of freedom (e.g., fewer or more than three degrees of freedom).

[0082] Furthermore, using the alignment assembly 346, the airfoil repair component 200 can be tilted or offset relative to the cut airfoil 140, for example, to help ensure the desired geometry of the joined airfoil repair component 200 and the cut airfoil 140. For example, the position of the airfoil repair component 200 can be manipulated along one or more degrees of freedom to control the post-joining (e.g., post-weld) geometry, which can minimize or eliminate post-joining cold working. Thus, the alignment assembly 346 can help position the airfoil repair component 200 relative to the cut airfoil 140 (e.g., with a few degrees of tilt, such as within the range of 0°-10° relative to the axial direction A, radial direction R, and / or circumferential direction C, etc.) to very similar to or approximate the post-joining geometry of the airfoil 100.

[0083] Now for reference Figure 12 In at least some embodiments, tool assembly 344 includes a feedback system 350, which includes at least one feedback device 352 positioned to determine the position of airfoil repair component 200 relative to the cut airfoil 140, and / or determine the dimensions (e.g., height, width, and / or thickness) of airfoil repair component 200, repair component electrode 304, etc. Determining the dimensions of a corresponding component can be referred to as on-machine probing, where the dimensions of the component are determined, and then it is decided where to place the component for the desired treatment.

[0084] exist Figure 12In one embodiment, the feedback system 350 includes a first feedback device 352a and a second feedback device 352b positioned radially outward from the electrode assembly 302. The first feedback device 352a and the second feedback device 352b can provide feedback regarding the position of the repair component electrode 304 (in which the airfoil repair component 200 is disposed) relative to the cut airfoil electrode 306 (in which the cut airfoil 140 is disposed), or relative to another reference point or component within the airfoil repair system 300, and / or regarding the dimensions of the airfoil repair component 200 and / or the repair component electrode 304. This feedback can be used to determine whether the airfoil repair component 200 is correctly aligned with the cut airfoil 140 prior to the bonding process, and if not, can help reposition the airfoil repair component 200 until it is adequately aligned with the cut airfoil 140 to initiate the bonding process. It should be understood that one or more feedback devices (e.g., first feedback device 352a and second feedback device 352b) may be cameras, non-contact or contact gauges, non-contact or contact measuring devices, or combinations thereof, that provide image, position data, and / or other data to a user interface, controller, etc., to allow the user or operator, controller, etc., to manually or automatically initiate the repositioning or engagement process of the airfoil repair component 200. Furthermore, although not in Figure 12 As shown, however, the feedback system 350 may be supported by a frame or other support system that allows the electrode assembly 302 to be removed from and replaced in the field of view or sensing field of at least one feedback device 352, for example, after one airfoil repair component 200 is engaged to a cut airfoil 140 and another airfoil repair component 200 is ready to be engaged to another cut airfoil 140.

[0085] Turning Figure 13 The cutting airfoil portion 344C of the tool assembly 344 for stabilizing the bladed disk 122 and cutting the airfoil 140 is shown. Figure 13 As shown, in at least some embodiments, the cutting airfoil portion 344C of the tool assembly 344 includes a frame 354 supporting a clamp 356, a hydraulic clamp assembly 358 including an electrode element 360 and a hydraulic cylinder 362, and a strip electrode 364. The clamp 356 and the hydraulic clamp assembly 358 stabilize the cutting airfoil 140, for example, allowing the airfoil repair component 200 to be aligned with the cutting airfoil 140 for engagement operations. The clamp 356 is not directly coupled to the frame 354, but rather engaged to the frame 354 in a manner that avoids introducing any significant stress and / or deformation into the frame 354, which helps ensure the highest level of accuracy while using the least amount of total material. Figure 13As depicted, the electrode element 360 of the hydraulic clamp assembly 358 extends from the hydraulic cylinder 362 and presses the cut airfoil 140 into the strip electrode 364 supported by the clamp 356, such that the cut airfoil 140 is pressed into the clamp 356.

[0086] Furthermore, the clamp 356 extends around the hydraulic clamp assembly 358 and slides freely within the frame 354, and the hydraulic cylinder 362 is supported by the frame 354. For example, in Figure 13 In the arrangement shown, the clamp 356 applies compressive force to the closed structural ring to reduce or eliminate bending stress from the frame 354 and other associated tool components. Therefore, the tool assembly 344 will keep the elements separated from the electrodes to help eliminate bending moments on the trim airfoil 140 and the airfoil repair component 200.

[0087] Furthermore, one or more openings 366 may be formed in the clamping fixture 356 and other components of the cutting airfoil portion 344C of the tool assembly 344 to accommodate the airfoil 100 of the impeller 122 adjacent to the cutting airfoil 140. It should be understood that the cutting airfoil portion 344C of the machining assembly can be made as compact as possible, for example, to facilitate post-engagement extraction of the impeller 122, and the cutting airfoil portion 344C captures the cutting airfoil 140 to position the impeller 122 and the cutting airfoil 140 relative to the airfoil repair component 200. Additionally, the cutting airfoil portion 344C of the tool assembly 344 can help stabilize the cutting airfoil electrode 306 and help ensure contact between the cutting airfoil 140 and the cutting airfoil electrode 306. Furthermore, the trimmed airfoil portion 344C of the tool assembly 344 facilitates the alignment of the airfoil repair component 200 with the bladed disk 122 and its trimmed airfoil 140, for example, Figure 14 As shown.

[0088] Figure 14 A side perspective view of tool assembly 344 is provided, including an airfoil-side tool (i.e., the airfoil trimming portion 344C) and an airfoil repair component-side tool (i.e., the airfoil repair component portion 344R). For example, as Figure 14 The tool assembly 344 shown can be used to stabilize the bladed disk 122 and the airfoil repair component 200 with the corresponding repair component electrode 304 and the airfoil trimming electrode 306, while simultaneously attaching the airfoil repair component 200 to the airfoil trimming component 140 of the bladed disk 122. Therefore, as Figure 14 As shown, the trimming airfoil portion 344C of the tool assembly 344 (or its segment) can be mounted onto the slide rail 368 or other similar support element to assist in moving the impeller 122 relative to the airfoil repair component portion 344R of the tool assembly 344. Figure 14As further described, the feedback system 350 can be vertically mounted in the tool assembly 344 below the trimmed airfoil 140 and the airfoil repair component 200. It should be understood that in other embodiments, the feedback system 350 can be mounted or supported at any suitable location on the airfoil repair system 300, for example, above, below, to the side, at an angle relative to the airfoil repair system 300, or one or more components of the feedback system 350 can be mounted in one location while one or more components of the feedback system 350 are mounted in one or more different locations.

[0089] Now for reference Figure 15 This topic also provides methods for repairing airfoil components. For example... Figure 15 As shown, the method 1500 for repairing airfoil 100 includes (1502) removing a damaged portion 130 of the airfoil 100 to form a trimmed airfoil 140. As described herein, the damaged portion 130 may include a damaged area 128, which is a hollow region or cavity, such as an opening, crack, gap, orifice, hole, etc., in the airfoil 100. For example, as per [reference to...] Figure 1 As described, the airfoil 100 may include a section line SL, which may be, for example, half the distance between the tip 108 at the leading edge and the tangent T of the leading edge fillet. The damaged portion 130 (including the damaged area 128) may be removed above, below, or at the section line SL (or radially outward, radially inward, or at the section line SL).

[0090] Furthermore, method 1500 may include (1504) partially removing spanwise twist from the cut airfoil 140, which may also be referred to as die-casting the cut airfoil 140 to remove at least a portion of the twist along the airfoil span S. As described herein, for example regarding Figure 3AIn at least some embodiments, the trimmed airfoil 140 may be shaped to eliminate twist in the trimmed airfoil attachment segment 142, and the airfoil repair component 200 may be shaped to eliminate twist in the repair attachment segment 242. For example, each of the trimmed airfoil attachment segment 142 and the repair attachment segment 242 extends substantially straight or linearly in the radial direction R, while the remainder of the trimmed airfoil 140 and the airfoil repair component 200 are twisted along the span S. Having straight or linear trimmed airfoil attachment segments 142 and / or repair attachment segments 242 can help define planar interactions or surface or region contacts between the trimmed airfoil 140 and the airfoil repair component 200 along the trimmed joint surface 144 and the repair joint surface 244, which can help improve the alignment between the trimmed airfoil 140 and the airfoil repair component 200. Furthermore, for example, when the airfoil repair component 200 is welded to the trimmed airfoil 140, the straight or linear segment trimmed airfoil attachment segment 142 and / or repair attachment segment 242 are consumed during the joining process, such that during the joining process, the modified airfoil geometry, which is either removed or free of distortion, is discharged from the weld interface as weld burrs, and the repaired airfoil 100 retains the distortion of the original airfoil 100. It should be understood that in other embodiments, the original airfoil 100 may not include spanwise distortion, such that (1504) partial removal of spanwise distortion can be omitted from method 1500.

[0091] Still referencing Figure 15 Method 1500 may further include (1506) disposing the cut airfoil 140 in the cut airfoil electrode 306, and (1508) disposing the airfoil repair component 200 in the repair component electrode 304. The cut airfoil 140, the airfoil repair component 200, the repair component electrode 304, and the cut airfoil electrode 306 may be as described herein (e.g., regarding...). Figure 1-14 Construction. For example, the repair component electrode 304 and the trimmed airfoil electrode 306 may be part of the electrode assembly 302, and in at least some embodiments, the repair component electrode 304 includes a repair component electrode insert 330 removably received within the repair component electrode body 320. The repair component electrode insert 330 may include an inert gas manifold 332 and a plurality of recesses 334 for forming an inert gas shield around the airfoil repair component 200.

[0092] Method 1500 may further include (1510) positioning the airfoil repair component 200 relative to the trimmed airfoil 140. As described herein, in at least some embodiments, positioning the airfoil repair component 200 relative to the trimmed airfoil 140 includes using a feedback system to position the repair component electrode 304 to determine the position of the airfoil repair component 200 relative to the trimmed airfoil 140. For example, the feedback system 350 may include one or more feedback devices 352, such as a camera, measuring instrument, etc., positioned around the electrode assembly 302 to provide feedback on the position of the repair component electrode 304 relative to the trimmed airfoil electrode 306.

[0093] Furthermore, in at least some embodiments, positioning the airfoil repair component 200 relative to the trimmed airfoil 140 includes manipulating an alignment assembly 346 (e.g., an independent axis degree of freedom manipulator) to reposition the airfoil repair component 200 and / or the trimmed airfoil 140 along, for example, an axis defined by the trimmed airfoil 140. For example, the alignment assembly 346 may include three rotatable knobs (e.g., a first knob 348a, a second knob 348b, and a third knob 348c), wherein each knob 348a, 348b, 348c adjusts or manipulates the position of the repair component electrode 304 relative to the trimmed airfoil electrode 306 along one degree of freedom.

[0094] like Figure 15 As further shown, method 1500 may include (1512) performing a bonding process to bond the airfoil repair component 200 to the cut airfoil 140, thereby replacing the damaged portion 130 removed from the airfoil 100 with the airfoil repair component 200. In at least some embodiments, the bonding process includes passing current through the cut airfoil electrode 306 and the repair component electrode 304 to attach the airfoil repair component 200 to the cut airfoil 140 and form a repair airfoil. For example, passing current through the cut airfoil electrode 306 and the repair component electrode 304 includes welding the airfoil repair component 200 to the cut airfoil 140 by solid-state resistance welding. In other embodiments, other suitable methods for bonding the airfoil repair component 200 to the cut airfoil 140 may be used.

[0095] Furthermore, in embodiments where the airfoil repair component 200 is joined to the cut airfoil 140 using current, the airfoil repair system 300 can incorporate adaptive current control to improve throughput. For example, the airfoil repair system 300 can utilize welding illumination and / or thermal imaging, as well as controllers, to analyze and adjust the supplied current, for example, to match the welding uniformity to a predetermined welding uniformity. The current can be adjusted, for example, by manipulating a pulse sequence. By adjusting the welding during the joining process, throughput or repair success rate can be increased.

[0096] Additionally or alternatively, the airfoil repair system 300 can utilize multiple power sources. For example, for resistance welding joining processes (e.g., solid-state resistance welding), the airfoil repair system 300 can utilize single-phase alternating current (AC), primary and secondary rectified direct current (DC), capacitor discharge (CD), or intermediate frequency DC (MFDC). For example, MFDC can allow for finer current control, faster rise time, and a smaller footprint than AC and DC power sources. However, for some applications of the airfoil repair system 300, AC, DC, and CD power can provide advantages over MFDC.

[0097] Still referencing Figure 15 Method 1500 may further include (1514) obtaining a net-shape finished product from the repaired airfoil 100. For example, method 1500 may include post-joining processing to obtain the net shape of the original airfoil 100 from the repaired airfoil 100. For example, after the airfoil repair component 200 is joined to the trimmed airfoil 140, the repaired airfoil 100, including the airfoil repair component 200, may be machined (e.g., milled, etc.) to obtain the net shape of the original airfoil 100. As described herein, the airfoil repair component 200 may be locally or entirely oversized (i.e., the entire airfoil repair component 200 is oversized) in the region of the repair attachment section 242, such that at least a portion of the airfoil repair component 200 does not have the net shape of the airfoil 100. It should be understood that the term "oversized" refers to the additional material of the airfoil repair component 200, which can provide an increased margin or tolerance for the alignment between the trimmed airfoil 140 and the airfoil repair component 200, so that the two components do not have to be precisely aligned. For example, the additional material of the oversized airfoil repair component 200 allows misalignment between the airfoil repair component 200 and the trimmed airfoil 140 to be corrected by finishing, for example, repairing the pressure side 202 or repairing the suction side 204 can be machined more or less than the other of repairing the pressure side 202 and repairing the suction side 204 to compensate for lateral misalignment. As another example, the repair airfoil 100 can undergo additional post-joining treatments (e.g., cold working or other deformation treatments) after joining to transform the defective airfoil into a net-shape part, rather than undergoing machining after joining. In such embodiments, the repair airfoil 100 can be largely in the desired shape after joining, but some cold working may be required to shape the airfoil 100 within the desired limits.

[0098] The airfoil repair component 200 may be dimensionally oversized at least near the location where it engages with the trimmed airfoil 140, such that at least a portion of the oversized section of the airfoil repair component 200 can be consumed during the engagement process. After engaging the airfoil repair component 200 and trimming the airfoil 140, the remaining dimensionally oversized portion of the airfoil repair component 200 can be machined to define the desired shape of the airfoil 100. As described herein, for individual airfoils 100 (having a platform and dovetail joint, for example as...) Figure 1 The airfoil repair component 200 (shown) may be partially oversized, while the airfoil repair component 200 for the airfoil 100 of the bladed disk 122 may be entirely oversized, for example, to minimize the risk of damaging the entire bladed disk 122 during the repair of one bladed disk airfoil. Of course, in some embodiments, the airfoil repair component 200 for an individual airfoil 100 may be entirely oversized, while the airfoil repair component 200 for the airfoil 100 of the bladed disk 122 may be partially oversized.

[0099] Various features of the airfoil repair component 200 and / or airfoil repair system 300 may be described or illustrated herein with respect to an individual airfoil or bladed disk airfoil. However, it should be understood that at least some features of the airfoil repair component 200 and / or airfoil repair system 300 may be applied to both configurations, although only one configuration is shown and / or described herein. Furthermore, it should be understood that various features of the airfoil repair component 200 and / or airfoil repair system 300 may be used in additional and / or alternative combinations beyond those shown and described herein.

[0100] Furthermore, it should be understood that although the above description pertains to airfoil repair, this subject matter can also be applied to initial or newly constructed parts. For example, airfoil repair component 200 may alternatively be referred to as airfoil component 200, which is joined to a trimmed or base airfoil 140 to form a complete or whole airfoil 100. Airfoil component 200 may be formed as airfoil repair component 200 as described herein, for example, airfoil component 200 may have a flared attachment section 242 or an oversized body 205, and airfoil component 200 has a component pressure side 202 (or a first component side and a second component side) opposite the component suction side 204, each side extending axially between the component leading edge 210 and the component trailing edge 212 (or the component first edge and the component second edge). For example, attachment section 242 attaches airfoil component 200 to cut or base airfoil 140, and is too large relative to the cut airfoil attachment section 142, such that attachment section 242 has a cut chord length c greater than that of the cut airfoil attachment section 142. c The longer component chord length c r The cutting width w of the wing-shaped attachment section 142 is compared with the cutting width of the wing-shaped component.c Wider component width w r Furthermore, the airfoil component 200 can be received in an electrode similar to the repair component electrode 304 (which may be referred to as the airfoil component electrode 304) and positioned in its cut or base airfoil 140 in its cut airfoil electrode 306 using a tool assembly 344 as described herein. For example, for some configurations of the bladed disk 122, it may be useful to join the airfoil component 200 to the cut or base airfoil 140, where airfoils 100 of certain sizes can be more easily manufactured into the bladed disk 122 using the joining techniques and features described herein.

[0101] Therefore, as described herein, this subject matter provides methods and apparatus for repairing airfoil components. For example, this subject matter provides airfoil repair parts for replacing damaged portions of airfoils, wherein the airfoil repair parts may be oversized, deformed, and / or have extended sacrificial tips. For example, airfoil repair parts that are partially or entirely oversized increase the chance of proper alignment between the airfoil repair part and the trimmed airfoil (i.e., the airfoil with the damaged portion removed), and provide additional cleanup of inventory for post-joining processing to achieve a net shape. Furthermore, this subject matter provides methods and apparatus for securing airfoil repair parts and / or trimmed airfoils within electrodes to eliminate excessive constraints and allow for more accurate positioning of the airfoil repair parts and / or trimmed airfoils. For example, this subject matter eliminates the need for manual tools for loading and unloading components from their respective electrodes by using spring-loaded design features and other design features that facilitate manual manipulation. Furthermore, this subject matter provides, for example, adaptive current control using welding light emission or thermal imaging feedback; integral bi-alloy inserts and inert gas shields for solid-state resistance welding of reactive materials such as titanium alloys; alignment tools, such as cameras, for better and / or faster alignment of airfoil repair components with trimmed airfoils; and compact stabilizing tools for easier extraction of repaired airfoils after joining. Other advantages of the subject matter described herein can also be realized by those skilled in the art.

[0102] Further aspects of this disclosure are provided by the subject matter of the following clauses:

[0103] An airfoil component for attachment to a cut airfoil, the cut airfoil including a cut airfoil attachment section and a cut first side opposite a second cut side, the first cut side and the second cut side each extending axially between a first cut edge and a second cut edge to define a cut chord length, the airfoil component including a body having a first component side opposite a second component side, the body defining the attachment section for attaching the airfoil component to the cut airfoil at the cut airfoil attachment section, the attachment section extending axially between a first component edge and a second component edge to define a component chord length, wherein the attachment section is larger than the cut airfoil attachment section in size, such that the component chord length is longer than the cut chord length.

[0104] According to any of the foregoing clauses, the cut width is defined between the first cut side and the second cut side, the component width is defined between the first component side and the second component side, and the component width at the attachment section is wider than the cut width at the cut airfoil attachment section.

[0105] According to any of the foregoing clauses, the body outside the attachment section has a body chord length longer than the cut chord length of the cut airfoil attachment section, and a body width wider than the cut width of the cut airfoil attachment section.

[0106] According to any of the foregoing clauses, the airfoil component, wherein the repair attachment section defines a repair joint surface, and the cut airfoil attachment section defines a cut joint surface, and wherein the repair joint surface intersects with the cut joint surface.

[0107] According to any of the foregoing clauses, the airfoil component, wherein the repair joint surface and the cut joint surface intersect in a planar interaction manner.

[0108] An airfoil repair system includes: a cut airfoil, the cut airfoil including a cut airfoil attachment section and a cut first side opposite to a second cut side, the first cut side and the second cut side each extending axially between a first cut edge and a second cut edge to define a cut chord length; and an airfoil repair component including a body having a repair first side opposite to a repair second side, the body defining a repair attachment section for attaching the airfoil repair component to the cut airfoil at the cut airfoil attachment section, the repair attachment section being... The repair chord extends axially between a first edge and a second edge to define a repair chord length, wherein the repair attachment section is too large relative to the size of the cut airfoil attachment section, such that the repair chord length is longer than the cut chord length; a repair component electrode for receiving the airfoil repair component, the repair component electrode including a repair component electrode insert removable relative to the repair component electrode body, the repair component electrode insert surrounding at least a portion of the airfoil repair component; and a tool assembly for positioning the airfoil repair component relative to the cut airfoil.

[0109] According to any of the foregoing clauses, the airfoil repair system includes a repair component electrode insert defining an inert gas manifold for receiving inert gas and a plurality of grooves extending from the inert gas manifold along the repair component electrode insert.

[0110] According to any of the foregoing clauses, the airfoil repair system wherein the repair component electrode insert includes a first half and a second half, each of the first half and the second half defining a portion of an inert gas manifold for receiving inert gas, and each of the first half and the second half defining a plurality of grooves extending from the inert gas manifold along the respective half of the repair component electrode insert.

[0111] The airfoil repair system according to any of the foregoing clauses further includes a cut airfoil electrode for receiving the cut airfoil, wherein the cut airfoil electrode includes a dovetail block, a cut airfoil electrode body, and a retaining assembly, wherein the cut airfoil includes a dovetail tenon that can be received within the dovetail block, and wherein the dovetail block is removably secured to the cut airfoil electrode body by a one-handed operation of the retaining assembly.

[0112] According to any of the foregoing clauses, the airfoil repair system wherein the repair component electrode body defines a plurality of serrations, each serration having a directional variation.

[0113] According to any of the foregoing clauses, the airfoil repair system includes the trimmed airfoil, and the tool assembly includes a trimmed airfoil portion for positioning the airfoil repair component relative to the airfoil.

[0114] According to any of the foregoing clauses, the airfoil repair system, wherein the tool assembly includes a feedback system, the feedback system including at least one feedback device, the at least one feedback device being positioned to determine at least one of the size and position of the airfoil repair component relative to the cut airfoil.

[0115] According to any of the foregoing clauses, in the airfoil repair system, the tool assembly includes an alignment component, wherein the alignment component is configured to adjust the position of the airfoil repair component relative to the cut airfoil along one or more independent axes defined by the cut airfoil.

[0116] According to any of the foregoing clauses, the airfoil repair system includes point constraints, line constraints, and planar constraints relative to the airfoil repair component, and wherein the point constraints are configured to be manipulated to release the airfoil repair component for removal from the repair component electrodes.

[0117] A method for repairing an airfoil includes: removing a damaged portion of an original airfoil to form a trimmed airfoil, wherein the trimmed airfoil includes a trimmed airfoil attachment section and a trimmed first side opposite to a second trimmed side, the first trimmed side and the second trimmed side each extending axially between a first trimmed edge and a second trimmed edge to define a trimmed chord length; disposing the trimmed airfoil in a trimmed airfoil electrode; and disposing an airfoil repair component within a repair component electrode, the repair component electrode including a repair component electrode insert removably received within a repair component electrode body, wherein the airfoil repair component includes a repair first side opposite to a repaired second side. The body defines a repair attachment section for attaching the airfoil repair component to the cut airfoil at the cut airfoil attachment section. The repair attachment section extends axially between a first repair edge and a second repair edge to define a repair chord length. The repair attachment section is larger than the cut airfoil attachment section in size, such that the repair chord length is longer than the cut chord length. The airfoil repair component is positioned relative to the cut airfoil. Current is passed through the cut airfoil electrode and the repair component electrode to attach the airfoil repair component to the cut airfoil and form a repair airfoil.

[0118] The method according to any of the foregoing clauses further includes die casting the cut airfoil to remove the twist from the cut airfoil.

[0119] According to any of the preceding clauses, positioning the airfoil repair component relative to the cut airfoil includes positioning the repair component electrodes via a feedback system to determine at least one of the size and position of the airfoil repair component relative to the cut airfoil.

[0120] According to any of the foregoing clauses, positioning the airfoil repair component relative to the cut airfoil includes manipulating an alignment assembly to reposition the airfoil repair component along at least one independent axis defined by the cut airfoil.

[0121] According to any of the foregoing clauses, the method of passing current through the cut airfoil electrode and the repair component electrode includes welding the airfoil repair component to the cut airfoil by solid-state resistance welding.

[0122] The method according to any of the foregoing clauses further includes post-joining processing of the repaired airfoil to obtain the net shape of the original airfoil.

[0123] According to any of the foregoing clauses, the post-joining processing includes machining the repair airfoil.

[0124] According to any of the foregoing provisions, the post-joining processing includes deforming the repair airfoil.

[0125] According to any of the foregoing provisions, the deformation treatment of the repair airfoil includes cold working the repair airfoil.

[0126] An airfoil repair system includes: a repair component electrode for receiving an airfoil repair component, the repair component electrode including a repair component electrode insert removable relative to a repair component electrode body, the repair component electrode insert surrounding at least a portion of the airfoil repair component; and a tool assembly for positioning the airfoil repair component relative to a trimmed airfoil.

[0127] According to any of the foregoing clauses, the airfoil repair system is an airfoil from which the damaged portion has been removed.

[0128] According to any of the foregoing clauses, the airfoil repair system includes a dovetail tenon configured to be received in a complementary dovetail groove in the rotor disk.

[0129] According to any of the foregoing clauses, the airfoil repair system wherein the trimmed airfoil is integrally formed with the rotor disk, which is part of the bladed disk.

[0130] The airfoil repair system according to any of the foregoing clauses further includes a cut airfoil electrode for receiving the cut airfoil.

[0131] According to any of the foregoing clauses, in the airfoil repair system, the tool assembly is configured to position the airfoil repair component received in the repair component electrode adjacent to the cut airfoil received in the cut airfoil electrode for a joining process, thereby attaching the airfoil repair component to the cut airfoil.

[0132] The airfoil repair system according to any of the foregoing clauses, wherein the tool assembly includes a feedback system, the feedback system including at least one feedback device.

[0133] The airfoil repair system according to any of the foregoing clauses, wherein the feedback device includes at least one camera.

[0134] According to any of the foregoing clauses, the airfoil repair system, wherein the feedback device includes at least one measuring instrument.

[0135] A method for repairing an airfoil includes: disposing a cut airfoil in a cut airfoil electrode; disposing an airfoil repair component in a repair component electrode, the repair component electrode including a repair component electrode insert removably received within a repair component electrode body; positioning the airfoil repair component relative to the cut airfoil; and performing a bonding process to attach the airfoil repair component to the cut airfoil and form an airfoil.

[0136] The method according to any of the foregoing clauses further includes removing the damaged portion of the airfoil to form the cut airfoil.

[0137] According to any of the foregoing clauses, the bonding process includes passing current through the cut airfoil electrode and the repair component electrode.

[0138] According to any of the foregoing clauses, the method of passing the current through the cut airfoil electrode and the repair component electrode includes solid-state resistive welding of the airfoil repair component received in the repair component electrode to the cut airfoil received in the cut airfoil electrode.

[0139] The method according to any of the foregoing clauses further includes obtaining the net shape of the airfoil.

[0140] According to any of the foregoing clauses, obtaining the net shape of the airfoil includes machining the airfoil.

[0141] According to any of the foregoing clauses, obtaining the net shape of the airfoil includes deforming the airfoil.

[0142] This written description uses examples to disclose the subject matter, including best practices, and also enables any person skilled in the art to practice this disclosure, including making and using any device or system and methods of making any combination. The patent scope of this disclosure is defined by the claims and may include other examples that would occur to a person skilled in the art. Such other examples are intended to fall within the scope of the claims if they include structural elements that are not indistinguishable from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. An airfoil component repair system, characterized in that, include: A cut airfoil, the cut airfoil including a cut airfoil attachment section and a cut first side opposite to a cut second side, the cut first side and the cut second side each extending axially between a cut first edge and a cut second edge to define a cut chord length; An airfoil repair component includes a body having a first repair side opposite to a second repair side, the body defining a repair attachment section for attaching the airfoil repair component to the cut airfoil at the cut airfoil attachment section, the repair attachment section extending axially between a first repair edge and a second repair edge to define a repair chord length, the repair attachment section being too large relative to the cut airfoil attachment section, such that the repair chord length is longer than the cut chord length; Repair component electrode for receiving the airfoil repair component, the repair component electrode including a repair component electrode insert removable relative to the repair component electrode body, the repair component electrode insert surrounding at least a portion of the airfoil repair component; as well as A retaining component is used to position the airfoil repair component relative to the cut airfoil. The repair component electrode insert defines an inert gas manifold for receiving inert gas, and a plurality of grooves extending from the inert gas manifold along the repair component electrode insert, wherein the plurality of grooves guide inert gas from the inert gas manifold to define an inert gas shield around the airfoil repair component. The repair component electrode insert defines a cavity for receiving the airfoil repair component, and the inner surface of the repair component electrode insert defining the cavity is capable of engaging the first repair edge and the second repair edge.

2. The airfoil component repair system according to claim 1, characterized in that, in, The repair component electrode insert includes a first half and a second half, each of the first half and the second half defining a portion of the inert gas manifold for receiving the inert gas, and each of the first half and the second half defining the plurality of grooves extending from the inert gas manifold along the respective half of the repair component electrode insert.

3. The airfoil component repair system according to claim 1, characterized in that, The device further includes a cut airfoil electrode for receiving the cut airfoil, wherein the cut airfoil electrode includes a dovetail block, a cut airfoil electrode body, and the retaining assembly, wherein the cut airfoil includes a dovetail tenon that can be received within the dovetail block, and wherein the dovetail block is removably secured to the cut airfoil electrode body by a one-handed operation of the retaining assembly.

4. The airfoil component repair system according to claim 1, characterized in that, in, The electrode body of the repair component defines multiple serrations, each serration having a directional change.

5. The airfoil component repair system according to claim 1, characterized in that, in, The bladed disk includes the trimmed airfoil, and wherein the retaining assembly includes a trimmed airfoil portion for positioning the airfoil repair component relative to the bladed disk.

6. The airfoil component repair system according to claim 1, characterized in that, in, The retaining component includes a feedback system, the feedback system including at least one feedback device, the at least one feedback device being positioned to determine at least one of the size and position of the airfoil repair component relative to the cut airfoil.

7. The airfoil component repair system according to claim 1, characterized in that, in, The retaining assembly includes an alignment assembly, wherein the alignment assembly is configured to adjust the position of the airfoil repair component relative to the cut airfoil along one or more independent axes defined by the cut airfoil.

8. The airfoil component repair system according to claim 1, characterized in that, in, The repair component electrode includes point constraints, line constraints, and planar constraints relative to the airfoil repair component, wherein the point constraints are configured to be manipulated to release the airfoil repair component for removal from the repair component electrode.

9. A method for repairing an airfoil component, characterized in that, include: The damaged portion of the original airfoil is removed to form a trimmed airfoil, wherein the trimmed airfoil includes a trimmed airfoil attachment section and a trimmed first side opposite to a trimmed second side, the trimmed first side and the trimmed second side each extending axially between a trimmed first edge and a trimmed second edge to define a trimmed chord length; The cut airfoil is placed in the cut airfoil electrode; An airfoil repair component is disposed within a repair component electrode, the repair component electrode including a repair component electrode insert removably received within a repair component electrode body, wherein the airfoil repair component includes a body having a repair first side opposite a repair second side, the body defining a repair attachment section for attaching the airfoil repair component to the cut airfoil at the cut airfoil attachment section, the repair attachment section extending axially between a repair first edge and a repair second edge to define a repair chord length, the repair attachment section being oversized relative to the cut airfoil attachment section such that the repair chord length is longer than the cut chord length, wherein the repair component electrode insert defines a cavity for receiving the airfoil repair component, the inner surface of the repair component electrode insert defining the cavity being capable of engaging the repair first edge and the repair second edge; Position the airfoil repair component relative to the cut airfoil component; An inert gas manifold for receiving inert gas is defined in the repair component electrode insert, and a plurality of grooves extending from the inert gas manifold along the repair component electrode insert are provided, wherein the inert gas from the inert gas manifold is guided by the plurality of grooves to define an inert gas shield around the airfoil repair component. as well as Current is passed through the cut airfoil electrode and the repair component electrode to attach the airfoil repair component to the cut airfoil and form a repair airfoil.

10. The method according to claim 9, characterized in that, It further includes die-casting the cut airfoil to remove the twist from the cut airfoil.

11. The method according to claim 9, characterized in that, in, Positioning the airfoil repair component relative to the cut airfoil includes positioning the repair component electrodes via a feedback system to determine at least one of the size and position of the airfoil repair component relative to the cut airfoil.

12. The method according to claim 9, characterized in that, in, Positioning the airfoil repair component relative to the cut airfoil includes manipulating an alignment assembly to reposition the airfoil repair component along at least one independent axis defined by the cut airfoil.

13. The method according to claim 9, characterized in that, in, Passing current through the cut airfoil electrode and the repair component electrode includes welding the airfoil repair component to the cut airfoil by solid-state resistance welding.

14. The method according to claim 9, characterized in that, The process further includes post-joining treatment of the repaired airfoil to obtain the net shape of the original airfoil.

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