Systems and methods of blade leading edge repair using field assisted sintering technology

A method, comprising:

• removing a portion of an airfoil to form a second mating surface of the airfoil, the second mating surface defining a plane, the plane forming an acute angle with a radial plane, the radial plane being normal to a centerline extending through the airfoil, wherein the removing the portion of the airfoil comprises machining off the portion of the airfoil, the second mating surface extending from a first point of a first edge defined by a leading edge of the airfoil at a first radial position to a second point of a second edge defined by a tip of the airfoil at a second radial position, the second radial position disposed radially outward from the first radial position;
• forming a component comprising a first mating surface extending from and bounded by a third point of a component first edge defined by a component leading edge and a fourth point of a component second edge defined by a component tip, wherein the third point corresponds to the first point and the fourth point corresponds to the second point, and wherein the component leading edge and the component tip define an outer contour of the component, the outer contour within a design tolerance of the airfoil;
• coupling the component to the airfoil having the second mating surface and a Field Assisted Sintering Technology (“FAST”) system, wherein the coupling includes:
• mating the first mating surface to the second mating surface such that the first point mates to the third point and the second point mates to the fourth point;
• heating, via the FAST system, the airfoil and the component;
• and
• applying, via the FAST system, a mechanical pressure between the first mating surface and the second mating surface to join the airfoil to the component and form a blade, the component at least partially defining a blade leading edge of the blade in response to joining the airfoil to the component.