US Patent 8640942 Repair of superalloy component

A method of repairing a superalloy component (22) wherein a section (24) of the component containing a plurality of service-induced cracks (18, 20) is removed, then a replacement section (26) of superalloy material is installed with a structural braze joint (28) containing no boron or silicon. The replacement section may have a textured surface ((38) to enhance bonding with an overlying thermal barrier coating (42). The replacement section may be pre-formed to standardized dimensions in expectation of a typical service-induced crack pattern, and the removed section excavated accordingly. The interface between the replacement section and the component may be shaped to provide a mechanical interlock there between.