Method for developing a repair process to correct a deformed gas turbine engine component

A method of developing a repair process for a gas turbine engine airfoil deformed during engine operation, the method comprising:

• determining one or more peak stress locations under an applied load in a model of the airfoil;
• applying a plurality of loads to a plurality of sample airfoils based on the model to produce a plurality of geometrical correction values in the samples;
• generating data from the samples comprising the loads applied and the geometrical correction values produced;
• destructively analyzing the samples at the peak stress locations for one or more structural imperfections;
• and
• correlating the loads applied to the geometrical correction values produced to determine a plurality of allowable loads necessary to produce a plurality of target geometrical correction values in a used airfoil substantially free of structural imperfections.

A method of developing a repair process for a gas turbine engine blade deformed during engine operation, the method comprising:

• determining one or more peak stress locations in a model of the blade;
• applying a plurality of loads to a plurality of sample blades based on the model to produce a plurality of geometrical correction values in the samples;
• generating data from the samples comprising the loads applied and the geometrical correction values produced;
• destructively analyzing the samples at the peak stress locations for one or more structural imperfections;
• and
• correlating the loads applied to the geometrical correction values produced to determine a plurality of allowable loads necessary to produce a plurality of target geometrical correction values in a used blade substantially free of structural imperfections;
• and
• modifying the plurality of allowable loads necessary to produce the target geometrical correction values to account for one or more repair process steps that change the geometric correction value after the load has been applied to the used blade.