Laser powder deposition weld rework for gas turbine engine non-fusion weldable nickel castings

A method, comprising:

• removing a casting defect from a component manufactured of a base alloy to form a cavity in the component;
• and
• depositing a plurality of layers of laser powder deposition spots within the cavity, each of the laser powder deposition spots comprising a filler alloy, and the laser powder deposition spots comprising a first spot, a second spot, a third spot and a fourth spot;
• wherein the first spot contacts and partially overlaps the second spot and the third spot in a lateral direction;
• wherein the first spot contacts and partially overlaps the fourth spot in a transverse direction that is perpendicular to the lateral direction.

A method, comprising:

• removing a casting defect from a component manufactured of a base alloy to form a cavity that extends into the component from a surface of the component;
• and
• depositing a plurality of layers of laser powder deposition spots within the cavity, each of the laser powder deposition spots comprising a filler alloy, and each of the laser powder deposition spots in a first of the plurality of layers at least partially overlapping another one of the laser powder deposition spots in the first of the plurality of layers;
• wherein a width of a first of the laser powder deposition spots along a first axis is equal to a width of the first of the laser powder deposition spots along a second axis that is perpendicular to the first axis;
• and
• wherein the first axis and the second axis define a plane that is parallel to a plane of the surface.