US Patent 7472478 Adaptive machining and weld repair process

An apparatus and method are provided for an adaptive machining and weld repair process for repairing airfoils, damage to an airfoil leading edge and tip. First, damaged material is machined away from a damaged airfoil edge so as to expose a weld surface. New material is laser deposited on the weld surface so as to create a weld-repaired airfoil having actual dimensions. The actual dimensions of the weld-repaired airfoil are automatically measured using a CMM system so as to generate an actual geometry. The actual geometry is deformed so as to develop a deformation geometry. The component is then machined according to the deformation geometry.