No, no robot replaced Keiko [1977-December 12, 2003] in any of the films. The orca was the real live whale in 'Free Willy 1' [1993], 'Free Willy 2' [1995], and 'Free Willy 3' [1997]. But he won't be seen in the upcoming 'Free Willy 4: Escape from Pirate's Cove' [2010].