United Technologies Corporation

William M Rose

David A Rutz

Monika D Kinstler

James J Moor

John P Arrigoni

Darren M Smith

Robert A Charbonneau

David R Malley

Timothy P Hasselberg

John F Mullooly

Edward Mierzejewski

Stephen P Sullivan

A method for low heat welding includes providing short circuit pulse Metal Inert Gas (MIG) welding at less than a rate of about a twenty (20) inch a minute travel speed.

Method of short circuit pulse metal inert gas welding

A repair tool and repair method for restoring gas turbine engine blade tips to a predetermined configuration is provided. The repair tool is an electrode that includes a tool body and a number of pins. The repair tool can be used to repair turbine blade tips through an electrical discharge machining process, such as a ram- or sink-type electrical discharge machining process.

Methods and tools for use in repairing gas engine turbine blades

A component blending tool for forming a pre-determined blended area into a component utilizes a belt having a material removing surface that is contoured to mimic a predetermined depth ratio of the blended area. The tool has an interchangeable shoe that contours the belt and forces the belt upon the component until the pre-determined blended area is substantially the same as said blend ratio.

Component blending tool

A variable vane having an airfoil, an inner trunnion shaft and an outer trunnion shaft, with the outer trunnion shaft having a threaded hole and a groove extending around a circumference of the outer trunnion shaft is repaired by removing a portion of the outer trunnion shaft leaving a shaft stub. A repair detail is prepared having an outer peripheral shaft portion with a nominal outer diameter. The repair detail further has a pilot portion extending forwardly and having a smaller outer diameter than an outer diameter of the nominal outer diameter. The shaft stub has a remaining bore portion, which is a portion of the threaded hole. The pilot portion is sized to be received within the remaining bore portion. The pilot is inserted into the remaining bore portion. The repair detail is welded to the shaft stub. A repaired variable vane is also disclosed.

Method to repair variable vanes

A fuel nozzle guide for a combustor of a turbine engine includes an annular base with a hub section, the hub section at least partially formed of a Cold Metal Transfer (CMT) weld and a method and system therefor.

Method for repairing fuel nozzle guides for gas turbine engine combustors using cold metal transfer weld technology

A cold metal transfer (CMT) contact tip has a substantially copper-free contact surface defining a wire passage. The CMT contact tip is used with a CMT welding apparatus having a weld wire and a wire feeder for feeding and oscillating the weld wire forward and backward through the wire passage where the weld wire shares a concentric axis with the wire passage.

Cold metal transfer gas metal arc welding apparatus and method of operation

A knife edge seal assembly includes at least one knife edge and at least one honeycomb ring seal. The at least one knife edge has material removed to a first knife edge radial height and the least one honeycomb ring seal has material removed to a finished radial thickness for sealable engagement with the at least one knife edge. The finished radial thickness of the replacement honeycomb ring seal establishes a first radial gap between an inner annular surface of the replacement honeycomb ring seal and the knife edge before the knife edge seal assembly begins rotating in the gas turbine.

Method of repairing knife edge seals

A method of repairing a stator assembly of a gas turbine engine includes removing a worn surface of the stator assembly to provide a revealed area, and securing additional material to the stator assembly utilizing gas metal arc welding.

Method for repairing a gas turbine engine component

A blade processing fixture has first and second jaws. The second jaw is movable relative to the first jaw from a disengaged position for accepting a root of the blade. The blade is accepted in a receiving area between the first and second jaws. The second jaw is movable to an engaged position clamping the blade between the first and second jaws. A gas flow path extends from an inlet port to an outlet port. The outlet port is positioned to introduce gas to a blade inlet port when the blade is installed.

Turbine element repair fixture

An example method of repairing an airfoil includes securing a cap to an end portion of a worn airfoil and securing additional material to the cap. The method includes altering some of the cap to form a desired airfoil contour.

Method for repairing an airfoil

A method of repairing an engine case for a gas turbine engine includes the steps of identifying a damaged flange on an engine case, removing the damaged flange down to a surface of the engine case to receive a replacement flange. The replacement flange is placed on the surface, and welded to the surface utilizing cold metal transfer.

Gas turbine engine case with replaced flange and method of repairing the same using cold metal transfer

A method of repairing a gas turbine knife edge seal assembly in which assembly is included a used honeycomb ring seal and a knife edge. The method includes removing the used honeycomb ring seal, removing material from the knife edge to a first knife edge radial height, installing a replacement honeycomb ring seal with a stock radial thickness, and removing material from the replacement honeycomb ring seal to a finished radial thickness for sealable engagement with the knife edge. The finished radial thickness of the replacement honeycomb ring seal establishes a first radial gap between an inner annular surface of the replacement honeycomb ring seal and the knife edge before the knife edge seal assembly begins rotating in the gas turbine.

A method of repairing an airfoil blade involves the steps of providing an airfoil blade have a leading edge, a trailing edge, a tip and a base. A length of the airfoil blade is defined by the tip and the base and a width of the airfoil blade is defined by the leading edge and the trailing edge. A weld is made along a first direction of the length of the airfoil blade and then made in a second direction along the width of the airfoil blade to form a first weld layer. The first weld layer has a first portion extending across the length of the airfoil blade and a second portion extending across its width. A second weld layer is welded onto the first layer such that an end wall of the second weld layer abuts the second portion of the first weld layer.

Method of restoring an airfoil blade

A method for repairing a turbine engine component is provided. The method broadly comprises the steps of providing a turbine engine component having an airfoil portion, applying a coating to the airfoil portion, and restoring a tip portion, a chord, and surfaces of the airfoil portion to original dimensions in a single operation. A system for repairing the turbine engine component is also described.

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Warren, MA, United States of America

William M Rose