Method of repairing a non-line of sight feature via a multi-layer coating

Abstract

Aspects of the disclosure are directed to a method of repairing a non-line of sight feature on a surface, the method comprising machining a worn irregular non-line of sight surface to provide a substantially planar repair surface, depositing a nickel plate base layer having a base layer thickness on the substantially planar repair surface, and depositing a protective layer having a protective layer thickness on the nickel plate base layer.

1 . A method of repairing a non-line of sight feature on a surface, the method comprising:
 machining a worn irregular non-line of sight surface to provide a substantially planar repair surface;   depositing a nickel plate base layer having a base layer thickness on the substantially planar repair surface; and   depositing a protective layer having a protective layer thickness on the nickel plate base layer.   
     
     
         2 . The method of  claim 1 , where the depositing the protective layer comprises depositing using vapor deposition. 
     
     
         3 . The method of  claim 2 , where the depositing using vapor deposition comprises one of physical vapor deposition (PVD), electron-beam physical vapor deposition (EBPVD), or chemical vapor deposition (CVD). 
     
     
         4 . The method of  claim 2 , where the depositing the protective layer comprises depositing MCrAlY. 
     
     
         5 . The method of  claim 2 , where the depositing the protective layer comprises depositing a cobalt alloy. 
     
     
         6 . The method of  claim 1 , where the depositing the protective layer comprises depositing of depositing the protective layer using at least one of a powder pack process, or locally applying at least one of paint, paste, slurry or thermal spray. 
     
     
         7 . The method of  claim 6 , where protective layer comprises an aluminide. 
     
     
         8 . The method of  claim 6 , where protective layer comprises a chromide. 
     
     
         9 . The method of  claim 3 , where the protective layer thickness is about 0.001 to 0.002 inches and the base layer thickness is about 0.0005 to 0.002 inches. 
     
     
         10 . The method of  claim 3 , where the depositing the nickel plate base layer comprises depositing an electrolytic nickel plate base layer. 
     
     
         11 . The method of  claim 3 , where the depositing the nickel plate base layer comprises depositing an electroless nickel plate base layer 
     
     
         12 . A method of repairing a non-line of sight feature on a surface of a gas turbine engine component, the method comprising:
 machining a worn irregular non-line of sight surface of the gas turbine engine component to provide a substantially planar repair surface, wherein a groove extends partially longitudinally into the gas turbine engine component to a groove end surface, the groove extends laterally within the gas turbine engine component between opposing groove side surfaces, and one of the opposing groove side surfaces comprises the worn irregular non-line of sight surface;   depositing a nickel plate base layer having a base layer thickness on the substantially planar repair surface; and   depositing a protective layer having a protective layer thickness on the nickel plate base layer.   
     
     
         13 . The method of  claim 12 , where the depositing a protective layer comprises one of physical vapor deposition (PVD), electron-beam physical vapor deposition (EBPVD), or chemical vapor deposition (CVD). 
     
     
         14 . The method of  claim 13 , where the depositing the protective layer comprises depositing at least one of MCrAlY and cobalt alloy. 
     
     
         15 . The method of  claim 12 , where the depositing the protective layer comprises applying at least one of a diffused aluminide and a diffused chromide. 
     
     
         16 . The method of  claim 15 , where the depositing the nickel plate base layer comprises depositing an electrolytic nickel plate base layer. 
     
     
         17 . A method of repairing a feature on a surface, the method comprising:
 machining a worn irregular sight surface to provide a substantially planar repair surface;   depositing a nickel plate base layer using an electroless nickel plating technique, the nickel plate base layer having a base layer thickness on the substantially planar repair surface; and   depositing a protective layer having a protective layer thickness on the nickel plate base layer.   
     
     
         18 . The method of  claim 17 , where the depositing using vapor deposition comprises one of physical vapor deposition (PVD), electron-beam physical vapor deposition (EBPVD), or chemical vapor deposition (CVD). 
     
     
         19 . The method of  claim 17 , where the protective layer comprises at least one of MCrAlY, cobalt alloy, diffused aluminide and diffused chromide. 
     
     
         20 . (canceled)