Turbine nozzle segment and method of repairing same

Abstract

A method for repairing a turbine nozzle segment having at least two vanes disposed between outer and inner bands includes the steps of separating the nozzle segment into a first singlet containing a repairable vane and a second singlet containing a non-repairable vane, and joining the first singlet to a newly manufactured singlet having a configuration that is similar to the second singlet.

What is claimed is:  
     
         1 . A method of repairing a turbine nozzle segment having at least two vanes disposed between outer and inner bands, said method comprising the steps of: 
 separating said nozzle segment into a first singlet containing one of said vanes and a second singlet containing another one of said vanes; and    joining said first singlet to a newly manufactured singlet having a configuration that is similar to said second singlet.    
     
     
         2 . The method of  claim 1  wherein said step of separating said nozzle segment into first and second singlets comprises cutting said outer band and said inner band in two between said two vanes.  
     
     
         3 . The method of  claim 1  further comprising the step of repairing damage in said first singlet.  
     
     
         4 . The method of  claim 3  wherein some damage in said first singlet is repaired prior to joining said first singlet to said newly manufactured singlet and some damage in said first singlet is repaired subsequently to joining said first singlet to said newly manufactured singlet.  
     
     
         5 . The method of  claim 1  wherein said newly manufactured singlet has an in-process shape that is larger than said second singlet.  
     
     
         6 . The method of  claim 1  further comprising the step of applying an alloy build up to said nozzle segment, subsequently to joining said first singlet to said newly manufactured singlet.  
     
     
         7 . The method of  claim 6  further comprising the step of machining said nozzle segment to its design shape subsequently to applying said alloy build up.  
     
     
         8 . The method of  claim 1  wherein said newly manufactured singlet is fabricated from the same material as said first singlet.  
     
     
         9 . The method of  claim 1  wherein said newly manufactured singlet is fabricated from a material that has enhanced material properties with respect to the material that said first singlet is fabricated from.  
     
     
         10 . The method of  claim 1  further comprising the steps of separating said first singlet from said newly manufactured singlet; and 
 joining said newly manufactured singlet to another newly manufactured singlet having a configuration that is similar to said first singlet.  
 
     
     
         11 . A method of repairing a turbine nozzle segment having a repairable vane and a non-repairable vane disposed between a first outer band and a first inner band, said method comprising the steps of: 
 providing a newly manufactured singlet including a vane disposed between a second outer band having a first joining surface and a second inner band having a second joining surface;    cutting said first outer band and said first inner band of said nozzle segment in two between said two vanes so as to separate said nozzle segment into a first singlet containing said repairable vane and a second singlet containing said non-repairable vane, wherein said first singlet includes a third joining surface on said first outer band and a fourth joining surface on said first inner band;    repairing damage in said first singlet; and    joining said first singlet to said newly manufactured singlet by bonding said first and third joining surfaces together and said second and fourth joining surfaces together.    
     
     
         12 . The method of  claim 11  wherein said newly manufactured singlet has an in-process shape that is larger than said second singlet.  
     
     
         13 . The method of  claim 11  further comprising the step of applying an alloy build up to said nozzle segment, subsequently to joining said first singlet to said newly manufactured singlet.  
     
     
         14 . The method of  claim 13  further comprising the step of machining said nozzle segment to its design shape subsequently to applying said alloy build up.  
     
     
         15 . The method of  claim 11  wherein said newly manufactured singlet is fabricated from the same material as said first singlet  
     
     
         16 . The method of  claim 11  wherein said newly manufactured singlet is fabricated from a material that has enhanced material properties with respect to the material that said first singlet is fabricated from.  
     
     
         17 . The method of  claim 11  further comprising the step of machining said third and fourth joining surfaces prior to joining said first singlet to said newly manufactured singlet.  
     
     
         18 . The method of  claim 11  further comprising the steps of separating said first singlet from said newly manufactured singlet; and 
 joining said newly manufactured singlet to another newly manufactured singlet having a configuration that is similar to said first singlet.  
 
     
     
         19 . A turbine nozzle segment comprising: 
 an outer band;    an inner band; and    first and second vanes disposed between said outer and inner bands, wherein said first vane and contiguous portions of said outer and inner bands define a first section of said nozzle segment and said second vane and respectively contiguous portions of said outer and inner bands define a second section of said nozzle segment, said first section being previously used and said second section being newly manufactured.    
     
     
         20 . The nozzle segment of  claim 19  wherein said first and second sections are fabricated from the same material.  
     
     
         21 . The nozzle segment of  claim 19  wherein said second section is fabricated from a material that has enhanced material properties with respect to the material that said first section is fabricated from.