Localized rework using directed energy deposition

A method of repairing a stator stage for use with a turbine engine, comprising:

• analyzing the stator stage for defects, wherein the analysis is conducted using at least one of x-ray, blue light scanner, or microwave;
• determining, based on the analysis, that there is a first defect on an edge of a first stator vane of a plurality of stator vanes of the stator stage;
• responsive to the determining that there is the first defect on the edge, automatically removing a portion of the edge of the first stator vane that includes the first defect to form a first scallop;
• responsive to the removing the portion of the edge of the first stator vane, automatically repairing the edge of the first stator vane using an additive manufacturing process, including filling the first scallop to rebuild the edge of the first stator vane to form a repaired portion;
• and
• responsive to the repairing the edge of the first stator vane, automatically performing a blending process on the stator stage to smooth and shape the plurality of stator vanes, including the first stator vane, wherein the blending process uses a material removal process, the material removal process including at least one of milling or computer numerical control (CNC) machining.

A method of repairing a stator stage for use with a turbine engine, comprising:

• analyzing the stator stage for defects, wherein the analysis is conducted using at least one of x-ray, blue light scanner, microwave, or thermal examinations;
• determining, based on the analysis, that there is a first defect on a first edge of a first stator vane of a plurality of stator vanes of the stator stage;
• determining based on the analysis that there is a second defect on a second edge of the first stator vane of the plurality of stator vanes;
• responsive to the determining that there is the first defect on the first edge and the second edge,
• automatically removing a first portion of the first edge including the first defect to form a first scallop, and
• automatically removing a second portion of the second edge including the second defect to form a second scallop, and
• responsive to the removing the first portion of the first edge and the second portion of the second edge, automatically repairing the first stator vane including filling the first scallop and the second scallop using an additive manufacturing process.