Method of repairing a stack of integrally bladed rotors

A method of repairing a stack of integrally bladed rotors (IBRs), the method comprising:

• determining a plurality of initial blend profiles for the stack of IBRs, each initial blend profile in the plurality of initial blend profiles associated with a defect on an inspected IBR in the stack of IBRs;
• generating a finite element model of the stack of IBRs with a potential repaired defect of each inspected IBR in the stack of IBRs being modeled, a plurality of vane stages disposed between adjacent inspected IBRs, and an engine case;
• performing a set of simulations of the stack of IBRs based on the finite element model;
• determining whether a first set of results of the simulations meet an experience based criteria;
• performing a structural analysis and an aerodynamic analysis on the stack of IBRs in response to determining the first set of results does not meet the experience-based criteria;
• determining whether the stack of IBRs with the potential repaired defect of each inspected IBR meets a deterministic structural criteria and a deterministic aerodynamic criteria for the stack of IBRs;
• and
• repairing each IBR in the stack of IBRs with a repair process corresponding to a respective initial blend profile for the potential repaired defect of each inspected IBR in the stack of IBRs in response to determining the stack of IBRs meets the deterministic structural criteria and the deterministic aerodynamic criteria for the stack of IBRs.