Patent ID: 7591057

Claim:
A method of reconditioning a splined component to yield a reconditioned splined component having slightly reclocked splines, the method comprising: providing a splined component having a plurality of radially spaced splines, each of the splines comprising a nickel-based superalloy and having a surface comprising a pressure face and a non-pressure face opposite the pressure face, the pressure face being substantially worn, the non-pressure face being substantially unworn; identifying a desired weld area on each of the non-pressure faces; providing a tubular overlay comprising a nickel-based superalloy, the tubular overlay having an outer surface and a substantially cylindrical inner surface, the substantially cylindrical inner surface having a plurality of radially-spaced spline-receiving grooves substantially conforming to a plurality of radially spaced splines of an aircraft turbine engine shaft, each of the radially-spaced spline-receiving grooves being substantially parallel to the major axis of the substantially cylindrical inner surface, the inner surface being configured to substantially contact essentially each of the desired weld areas upon insertion of the plurality of radially spaced splines into the tubular overlay; inserting the plurality of radially spaced splines into the tubular overlay such that the inner surface substantially contacts essentially each of the desired weld areas; welding selected portions of the tubular overlay corresponding to the desired weld areas to bond a layer of nickel-based superalloy derived from the tubular overlay to essentially each of the desired weld areas, yielding modified non-pressure faces, the welding temperature being selected to limit grain growth in a heat affected zone; and machining at least a portion of essentially each of the pressure faces to yield remachined pressure faces, thereby yielding a reconditioned splined component having slightly reclocked splines.