Airfoils with improved strength and manufacture and repair thereof

A method of repairing an airfoil, comprising:

• a. providing an airfoil having specified nominal dimensions, said airfoil comprising a nickel-based superalloy and further comprising a leading edge section and a trailing edge section;
• b. removing at least one portion of at least one section of said airfoil to create at least one deficit of material for said airfoil relative to said specified nominal dimensions, said at least one section selected from the group consisting of said leading edge section and said trailing edge section;
• c. providing at least one insert comprising a material having at least one of (1) a creep life that is at least about three times greater than a creep life of said nickel-based superalloy, and (2) a fatigue life that is at least three times greater than a fatigue life of said nickel-based superalloy;
• and
• d. disposing said at least one insert onto said airfoil such that said at least one deficit of material is substantially eliminated.

A method for manufacturing a gas turbine airfoil having specified nominal dimensions, a leading edge section, and a trailing edge section, said method comprising:

• a. providing an airfoil having at least one deficit of material relative to at least one specified nominal dimension, said airfoil comprising a first material having a creep life and a fatigue life, said at least one deficit located in at least one section of said airfoil selected from the group consisting of said leading edge section and said trailing edge section;
• b. providing at least one insert comprising a second material, said second material having at least one of (1) a creep life that is at least about three times greater than said creep life of said first material, and (2) a fatigue life that is at least three times greater than said fatigue life of said first material;
• and
• c. disposing said at least one insert onto said airfoil such that said at least one deficit of material is substantially eliminated.

A method for manufacturing a gas turbine airfoil having specified nominal dimensions, said airfoil comprising a leading edge section and a trailing edge section, said method comprising:

• a. providing an airfoil having at least one deficit of material relative to at least one specified nominal dimension, said at least one deficit located in at least section of said airfoil selected from the group consisting of the leading edge section and the trailing edge section, said airfoil comprising a nickel-based superalloy;
• b. providing at least one insert comprising a material having at least one of (1) a creep life that is at least about three times greater than a creep life of said nickel-based superalloy, and (2) a fatigue life that is at least three times greater than a fatigue life of said nickel-based superalloy;
• and
• c. disposing said at least one insert onto said airfoil such that said at least one deficit of material is substantially eliminated.

A gas turbine airfoil, comprising:

• a main body comprising a first material, said first material having a creep life and a fatigue life;
• and
• at least one insert comprising a second material, said second material having at least one of (1) a creep life that is at least about three times greater than said creep life of said first material, and (2) a fatigue life that is at least three times greater than said fatigue life of said first material, said at least one insert joined to said main body;
• said airfoil comprising a leading edge section and a trailing edge section, wherein said at least one insert comprises at least one portion of at least one section of said airfoil selected from the group consisting of the leading edge section and the trailing edge section.

A gas turbine airfoil, comprising:

• a main body comprising a nickel-based superalloy;
• and
• at least one insert, said at least one insert comprising a material having at least one of (1) a creep life that is at least about three times greater than a creep life of said nickel-based superalloy, and (2) a fatigue life that is at least three times greater than a fatigue life of said nickel-based superalloy;
• said airfoil comprising a leading edge section and a trailing edge section, wherein said at least one insert comprises at least one portion of at least one section of said airfoil selected from the group consisting of the leading edge section and the trailing edge section.