Method of repair for cantilevered stators

Abstract

A method for repairing a cantilevered stator vane includes removing a damaged portion leaving a remaining vane portion. A supplemental airfoil portion is then selected and is attached to the remaining vane portion to provide a repaired cantilevered stator vane.

1 . A method for repairing a cantilevered stator vane comprising:
 (a) providing a cantilevered stator vane including an airfoil supported by a platform that is to be supported by a non-rotating engine structure;   (b) removing a damaged portion of the airfoil leaving a remaining vane portion;   (c) selecting a supplemental airfoil portion; and   (d) attaching the supplemental airfoil portion to the remaining vane portion.   
   
   
       2 . The method according to  claim 1  wherein step (d) includes welding the supplemental airfoil portion to the remaining vane portion. 
   
   
       3 . The method according to  claim 1  including smoothing surfaces of the remaining vane portion prior to step (d). 
   
   
       4 . The method according to  claim 3  including cleaning the surfaces of the remaining vane portion prior to step (d). 
   
   
       5 . The method according to  claim 1  including blending and smoothing an attachment interface formed between the remaining vane portion and the supplemental airfoil portion subsequent to step (d) to form a repaired cantilevered stator vane. 
   
   
       6 . The method according to  claim 5  including heat treating the repaired cantilevered stator vane subsequent to step (d). 
   
   
       7 . The method according to  claim 1  wherein the cantilevered stator vane is to be positioned between a pair of compressor blades that rotate about an engine axis, and wherein step (b) includes cutting the airfoil at a location radially inward of the platform relative to the engine axis and radially outward of the damaged portion relative to the engine axis. 
   
   
       8 . The method according to  claim 7  including cutting across an entire width of the airfoil at the location. 
   
   
       9 . A cantilevered stator vane comprising:
 a first vane structure to be supported by a non-rotating engine structure, said first vane structure comprising a non-damaged portion that remains after removal of a damaged portion; and   a second vane structure secured to said first vane structure at an attachment interface, said second vane structure comprising a supplemental portion that is selected for attachment to said non-damaged portion, said first and said second vane structures cooperating to comprise a repaired cantilevered stator vane.   
   
   
       10 . The cantilevered stator vane according to  claim 9  including a platform to be supported by the non-rotating engine structure, and wherein said first vane structure comprises a first airfoil portion that extends away from said platform, said first airfoil portion comprising said non-damaged portion that remains after removal of a damaged airfoil portion, and wherein said supplemental portion comprises a supplemental airfoil portion that is secured to said first airfoil portion at said attachment interface. 
   
   
       11 . The cantilevered stator vane according to  claim 9  wherein said attachment interface comprises a weld interface. 
   
   
       12 . The cantilevered stator vane according to  claim 9  wherein said non-rotating engine structure comprises an outer shroud portion. 
   
   
       13 . A gas turbine engine comprising:
 at least one of a fan and a low pressure compressor;   a combustion section;   a turbine section;   a main shaft; and   a high pressure compressor with a plurality of disks and blades that are mounted to rotate with said main shaft about an axis, said compressor including at least one cantilevered stator vane that is mounted to a non-rotating engine structure, said at least one cantilevered stator vane including
 a platform supported by the non-rotating engine structure, 
 a first airfoil portion extending inwardly from said platform, said first airfoil portion comprising a non-damaged portion that remains after removal of a damaged airfoil portion, and 
 a second airfoil portion secured to said first airfoil portion at an attachment interface, said second airfoil portion comprising a supplemental airfoil portion that is selected for attachment to said non-damaged portion, said first and said second airfoil portions cooperating to comprise a repaired cantilevered stator vane. 
   
   
   
       14 . The gas turbine engine according to  claim 13  wherein said non-rotating engine structure comprises an outer shroud. 
   
   
       15 . The gas turbine engine according to  claim 13  wherein said compressor includes a support structure extending in a direction generally parallel to said axis with said disks extending radially inward from said support structure toward said axis and said blades extending radially outward from said support structure toward said axis, and wherein a distal tip of said repaired cantilevered stator vane is spaced radially inward from said support structure in a space between two adjacent blades. 
   
   
       16 . The gas turbine engine according to  claim 13  wherein said attachment interface comprises a weld interface.