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The Solution

• The damaged areas on the blade tips or leading edges are rebuilt by applying a welding bead to the effected area.
• Each blade is located in a precision fixture.
• The blade is then inspected on a CMM or by using On Machine Verification (OMV) right on the machine tool.
• If no CAD data exists then the blade can be reverse engineered from point cloud inspection data. Alternatively a morphing process can be applied to the original CAD data, aligning the nominal data with the actual shape of the blade.
• New CNC toolpath data is then created to machine away any excess weld.
• A finish buffing operation is used to blend the remaining weld bead into the airfoil shape.