Patent ID: 7811396

Claim:
A method for repairing a nickel-base superalloy article comprising the steps of providing the nickel-base superalloy article that has previously been in service in the flowpath of a gas turbine engine, the article having flowpath cooling holes therein and the article further having a flowpath surface; applying a restoration to the flowpath surface of the article by the steps of providing a restoration nickel-base superalloy different from that of the nickel-base superalloy article, thereafter applying a restoration coating of the restoration nickel-base superalloy to the flowpath surface of the article by a hyper-velocity oxyfuel metal spray process, the restoration coating overcoating the flowpath cooling holes, thereafter heating the article with the restoration coating applied to the flowpath surface thereof to a sufficiently high temperature to diffusion bond the restoration coating to the flowpath surface of the article, redrilling flowpath cooling holes in the overcoated flowpath surface of the article; and applying a diffusion aluminide environmental coating to the article and machining the diffusion aluminide environmental coating from the flowpath surface of the article, wherein the restoration nickel-base superalloy has a composition in weight percent of 0.01-0.03 percent carbon, 0.1 percent maximum manganese, 0.5-0.6 percent silicon, 0.01 percent maximum phosphorus, 0.004 percent maximum sulfur, 7.4-7.8 percent chromium, 2.9-3.3 percent cobalt, 0.01 percent maximum molybdenum, 3.7-4.0 percent tungsten, 5.3-5.6 percent tantalum, 0.02 percent maximum titanium, 7.6-8.0 percent aluminum, 1.5-1.8 percent rhenium, 0.005 percent maximum selenium, 0.3 percent maximum platinum, 0.01-0.02 percent boron, 0.03 percent maximum zirconium, 0.12-0.18 percent hafnium, 0.1 percent maximum niobium, 0.1 percent maximum vanadium, 0.1 percent maximum copper, 0.2 percent maximum iron, 0.0035 percent maximum magnesium, 0.01 percent maximum oxygen, 0.01 percent maximum nitrogen, balance nickel with other elements 0.5 percent maximum.