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A system and method for repairing a hollow fan blade. In one aspect the blade includes a hollow portion having a plug disposed therein, wherein the plug is smaller than the opening. During processing the blade is located under a vacuum box and the gap is sealed between the plug and the opening using

A system and method for repairing a hollow fan blade. In one aspect the blade includes a hollow portion having a plug disposed therein, wherein the plug is smaller than the opening. During processing the blade is located under a vacuum box and the gap is sealed between the plug and the opening using a fiber laser.

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1. A method, comprising: providing a blade including a hollow portion and an opening to the hollow portion;placing a plug in the opening, the plug having a cross section smaller than the opening;evacuating at least a portion of a gas in an enclosure defining the blade;sealing a gap between the plug

1. A method, comprising: providing a blade including a hollow portion and an opening to the hollow portion;placing a plug in the opening, the plug having a cross section smaller than the opening;evacuating at least a portion of a gas in an enclosure defining the blade;sealing a gap between the plug and the opening using a fibre laser; andwherein the blade comprises three material sheets, the method further comprising machining a slot in the blade wherein a bottom face of the slot intersects the opening. 2. The method of claim 1, further comprising forming the blade into a specified contour with a laser deposition operation. 3. The method of claim 1, wherein at least one side face of the slot comprises a beveled face. 4. The method of claim 3, wherein the beveled face is beveled at about 45 degrees. 5. The method of claim 1, wherein the bottom face of the slot is at least about 0.01 inches lower than a blowpipe. 6. The method of claim 5, further comprising removing the blowpipe. 7. The method of claim 1, wherein the bottom face of the slot is flat. 8. The method of claim 1, wherein the slot is formed from material removed from only two of the three material sheets. 9. The method of claim 1, wherein the material sheets comprise one of titanium and a titanium alloy. 10. The method of claim 1, further comprising removing an excess plug portion with a machine tool. 11. The method of claim 1, wherein the plug is sized to form a gap of at least 0.002 inches between the plug and at least one edge of the opening. 12. The method of claim 1, further comprising positioning a shim between the plug and the at least one edge of the opening. 13. The method of claim 12, wherein the shim comprises a width of about 0.02 inches. 14. The method of claim 1, wherein evacuating at least a portion of a gas in an enclosure defining the blade comprises introducing a substantial vacuum in the enclosure, and holding the substantial vacuum for about 10 minutes prior to the sealing a gap between the plug and the at least one edge of the opening. 15. The method of claim 1, wherein the plug is positioned in a blowpipe remainder. 16. The method of claim 1, further comprising forming the opening with a machine tool. 17. A method, comprising: providing a blade including a hollow portion and an opening to the hollow portion;placing a plug in the opening, the plug having a cross section smaller than the opening;evacuating at least a portion of a gas in an enclosure defining the blade;sealing a gap between the plug and the opening using a fibre laser; andmachining a slot in the blade wherein a bottom face of the slot intersects the opening; wherein the bottom face of the slot is lower than a blowpipe; andwhich further comprises removing the blowpipe. 18. The method of claim 1, wherein said evacuating comprises introducing a substantial vacuum in the enclosure and holding the substantial vacuum prior to said sealing. 19. The method of claim 1, wherein the blade comprises one of titanium and titanium alloy; further comprises forming the blade with a laser deposition operation; andfurther comprises removing at least a portion of said plug. 20. The method of claim 17, further comprising removing an excess plug portion with a machine tool. 21. The method of claim 17, wherein the plug is sized to form a gap of at least 0.002 inches between the plug and at least one edge of the opening. 22. The method of claim 17, further comprising positioning a shim between the plug and the at least one edge of the opening. 23. The method of claim 22, wherein the shim comprises a width of about 0.02 inches. 24. The method of claim 17, wherein evacuating at least a portion of a gas in an enclosure defining the blade comprises introducing a substantial vacuum in the enclosure, and holding the substantial vacuum for about 10 minutes prior to the sealing a gap between the plug and the at least one edge of the opening. 25. The method of claim 17, further comprising forming the opening with a machine tool. 26. The method of claim 17, wherein said evacuating comprises introducing a substantial vacuum in the enclosure and holding the substantial vacuum prior to said sealing. 27. The method of claim 17, wherein the blade comprises one of titanium and titanium alloy; further comprises forming the blade with a laser deposition operation; andfurther comprises removing at least a portion of said plug.