Repair method for sealing liquid-cooled stator bar end fittings for a generator

The method includes repairing the stator bar end fittings used for the electrical and hydraulic connections at the stator bar ends of a generator with suitable integrity to be as good as new or better than an in-kind replacement with new components for the stator bar. The method addresses the need to repair leaks in liquid cooled generator end windings and the respective end fittings. In particular, the method repairs leaks that develop between the joints of interior adjacent strands and between the outermost strands and the end fitting. The method employs the replacement of the original end fitting with another end fitting similar in geometry. A majority of the original end fitting along with the original window (if any) is preserved and utilized as a ring to surround and compress the strand bundle, with the original braze intact, thus preserving the original geometry of the strand bundle. After repairing the strands, the machined ring is inserted into the replacement end fitting and brazed with an alloy with a lower temperature melting point than the original alloy in order to keep intact the prior brazing. The replacement end fitting of the repaired stator bar end may now be connected to the generator winding, insulated and returned to service in the same manner as that of a new stator bar.