Repaired vane assemblies and methods of repairing vane assemblies

Methods are provided for repairing a vane assembly, where the vane assembly includes an inner annular housing, an outer annular housing, and a vane extending therebetween. In one embodiment, the method includes removing an identified section of the vane to thereby form a pocket in an inner surface of the outer annular housing, a slot through the inner annular housing, and an edge on the vane, inserting a replacement vane portion with an advanced coating through the formed slot such that a first edge of the replacement vane portion is disposed in the pocket and at least a portion of the first edge is spaced apart from at least a portion of the outer annular housing inner surface, and welding a section of the replacement vane portion to the annular inner annular housing. The repaired vane assembly is also provided.