System and method for repairing a gas turbine engine component

Abstract

A method for repairing a defect in a component having a first major surface and a second major surface, a thickness defined between the major surfaces, and an edge adjoining both the major surfaces is characterized by forming a slot cut entirely through the thickness of the component between the first and second major surfaces, the slot extending inward from the edge of the component towards an interior of the component to a depth from the edge sufficient to remove at least a substantial part of the defect, the slot defining an open end at the edge of the component, a closed end within the component, a width, a radius formed by the closed end, and opposing chamfered edges at the open end.

1 . A method for repairing a defect in a component having a first major surface and a second major surface, a thickness defined between the major surfaces, and an edge adjoining both the major surfaces, the method characterized by forming a slot cut entirely through the thickness of the component between the first and second major surfaces, the slot extending inward from the edge of the component towards an interior of the component to a depth from the edge sufficient to remove at least a substantial part of the defect, the slot defining an open end at the edge of the component, a closed end within the component, a width, a radius formed by the closed end, and opposing chamfered edges at the open end. 
     
     
         2 . The method of  claim 1 , wherein the slot is formed using at least one device capable of removing consistent amounts of material from the component regardless of an operator that is operating the at least one device. 
     
     
         3 . The method of  claim 1 , further comprising:
 weld repairing the component after the slot is formed therein.   
     
     
         4 . The method of  claim 3  and further comprising:
 using the chamfered edges at the open end of the slot to provide a visual indicium of the depth of a weld formed in the slot. 
 
     
     
         5 . The method of  claim 1 , wherein the component comprises a gas turbine engine blade or a gas turbine engine vane. 
     
     
         6 . The method of  claim 1  and further comprising:
 utilizing a template to determine if the component is suitable for repair prior to forming the slot; and 
 fitting the template over at least a portion of the component. 
 
     
     
         7 . The method of  claim 1  and further comprising:
 utilizing a first, second, and third device to form the slot, the first device having a first cutting surface to form an initial cut through the thickness of the component and extending inward from the edge of the component towards an interior of the component at a depth sufficient to remove at least a substantial part of the defect, the second device having a second cutting surface to finish the initial cut to define the width and the radius, and the third device having a third cutting surface to chamfer the edges at the open end of the finished cut. 
 
     
     
         8 . A method for repairing a defect in a gas turbine engine component comprising at least one of a blade and a vane, the method comprising:
 utilizing a template that fits over the component to determine if the component is suitable for repair;   securing the component in a fixture;   forming a slot extending inward from an edge of the component towards an interior of the component while the component is secured in the fixture, wherein the slot is cut through a thickness between major surfaces of the component to remove at least a substantial part of the defect and has an open end at the edge of the component, a closed end within the component, a width, a radius at the closed end, and chamfered edges at the open end; and   weld repairing the component.   
     
     
         9 . The method of  claim 8 , wherein forming the slot in the component comprises:
 forming an initial cut in the component with a first cutting surface, wherein the initial cut extends from the edge of the component at least to the defect;   finishing the initial cut to a predetermined width and radius with a second cutting surface, resulting in a finished cut including an edge at an open end of the finished cut at the edge of the component; and   chamfering the edge of the finished cut with a third cutting surface.   
     
     
         10 . The method of  claim 8 , wherein forming a slot in the component comprises:
 positioning a single removal device capable of forming the slot in contact with the component.   
     
     
         11 . The method of  claim 8 , wherein the component comprises a gas turbine engine component. 
     
     
         12 . The method of  claim 8 , and further comprising:
 utilizing a set-up device to align the component in the fixture prior to securing the component in the fixture.   
     
     
         13 . A method for repairing a defect in a component, the method comprising:
 securing the component in a fixture configured to receive the component; and   forming a slot in the component, the slot cut through a thickness between major surfaces of the component and extending inward from an edge of the component towards an interior of the component at a depth sufficient to remove at least a substantial part of the defect, wherein the slot has an open end at the edge of the component, a closed end within the component, a width, a radius at the closed end, and chamfered edges at the open end.   
     
     
         14 . The method of  claim 13 , wherein the slot is formed using at least one removal device that allows consistent amounts of material to be removed from the component regardless of the operator that is utilizing the at least one removal device. 
     
     
         15 . The method of  claim 13 , wherein the method further comprises:
 determining if the component is suitable for repair before the slot is formed therein by using a template.   
     
     
         16 . The method of  claim 13 , wherein the component comprises a gas turbine engine component. 
     
     
         17 . The method of  claim 16 , wherein the gas turbine engine component comprises at least one of: a blade and a vane. 
     
     
         18 . The method of  claim 14 , wherein the at least one removal device comprises a single cutting wheel designed to cut the slot in the component. 
     
     
         19 . The method of  claim 14 , wherein the at least one removal device comprises:
 a rough cutting device capable of rough-cutting the slot in the component;   a finish routing device capable of establishing a consisting routing width and radius at the end of the slot after the slot is rough-cut; and   a chamfering device capable of chamfering the edges of the open end at the edge of the component after the slot is finish routed.   
     
     
         20 . The method of  claim 13 , and further comprising:
 positioning the component in a set up device with a predetermined orientation before the slot is formed therein.