Turbine blade tip repair using dual fusion welding

A method for repairing a blade tip of a turbine blade, the method comprising:

• removing a damaged portion of blade, wherein the damaged portion is removed at an initial cut level, wherein an undamaged portion of the turbine blade exists as a base below the initial cut level;
• laser cladding build up a replacement section to the base;
• machining the replacement section to form a tip pocket;
• placing a tip plate in the tip pocket, wherein the tip plate comprises a first portion and a second portion, wherein each of the first portion and the second portion interface vertically with one or more ribs of the turbine blade;
• welding the tip plate using a dual fusion weld process comprising a first weld process and a second weld process, wherein the second weld process comprises the tip plate being welded at the one or more ribs interfacing with the first portion and the second portion;
• and
• building a squealer tip using a welding process that forms a mechanical locking bead over the tip plate.

A method for repairing a blade tip of a turbine blade, the method comprising:

• removing a damaged portion of blade, wherein the damaged portion is removed at an initial cut level using a machining process, wherein an undamaged portion of the turbine blade exists as a base is below the initial cut level;
• welding a replacement section to the base, wherein welding a replacement section includes laser cladding build up;
• machining an excess laser cladding build up forming a tip pocket;
• placing a tip plate in the tip pocket, wherein the tip plate comprises a first portion and a second portion, wherein the first portion and the second portion interface at the third rib of the blade tip;
• welding the tip plate using a dual fusion weld process comprising a first welded process and a second weld process, wherein the first weld process comprises the tip plate being welded circumferentially to the blade tip, and the second weld process comprises the tip plate being welded at a first rib, a second rib, a third rib, and a fourth rib of the turbine blade, and each end of the first portion and the second portion of the tip plate being welded to a corresponding portion of the tip plate and the blade tip;
• and
• building a squealer tip using a welding process that forms a mechanical locking bead over the tip plate, wherein the welding process comprises welding circumferentially over the plate, and wherein the welding process is a laser cladding process.