Abstract: A method for measurement of a film cooling effect is disclosed. Film cooling is a technique developed to protect gas turbine engine components from the extremely high temperatures created during its operation. A controlled air pressure is ducted into the hollow interior of the component and the mass rate of air flowing through the plurality of film cooling features or openings is measured. A coolant is then injected into the hollow interior of the component and allowed to flow out of a film cooling feature onto the heated outer surface of the component. The resulting infrared signature is a measure of the relative cooling effect generated by the individual film cool feature. The film cooling effect for an individual feature is quantified as the proportion of mass rate of airflow contributed by its relative individual cooling effect. The area, location and shape of the cooling effect are further classified to determine the degree of conformance to its design intent.

Abstract: A method for measurement of a film cooling effect is disclosed. Film cooling is a technique developed to protect gas turbine engine components from the extremely high temperatures created during its operation. A controlled air pressure is ducted into the hollow interior of the component and the mass rate of air flowing through the plurality of film cooling features or openings is measured. A coolant is then injected into the hollow interior of the component and allowed to flow out of a film cooling feature onto the heated outer surface of the component. The resulting infrared signature is a measure of the relative cooling effect generated by the individual film cool feature. The film cooling effect for an individual feature is quantified as the proportion of mass rate of airflow contributed by its relative individual cooling effect. The area, location and shape of the cooling effect are further classified to determine the degree of conformance to its design intent.

Abstract: A method for measurement of a film cooling effect is disclosed. Film cooling is a technique developed to protect gas turbine engine components from the extremely high temperatures created during its operation. A controlled air pressure is ducted into the hollow interior of the component and the mass rate of air flowing through the plurality of film cooling features or openings is measured. A coolant is then injected into the hollow interior of the component and allowed to flow out of a film cooling feature onto the heated outer surface of the component. The resulting infrared signature is a measure of the relative cooling effect generated by the individual film cool feature. The film cooling effect for an individual feature is quantified as the proportion of mass rate of airflow contributed by its relative individual cooling effect. The area, location and shape of the cooling effect are further classified to determine the degree of conformance to its design intent.

Abstract: Processes for removing a metal oxide product from a crack with an opening in an outer surface of a part, such as a turbine component. The process includes exposing the metal oxide product to a solution effective to remove a first portion of the metal oxide product from surfaces inside the crack. After the metal oxide product is exposed to the solution, the metal oxide product is heated to a temperature and in an atmosphere effective to remove a second portion of the thermal oxide product from the surfaces inside the crack. The cleaning process may be a substitute for fluoride ion cleaning.

Abstract: A method for measurement of a film cooling effect is disclosed. Film cooling is a technique developed to protect gas turbine engine components from the extremely high temperatures created during its operation. A controlled air pressure is ducted into the hollow interior of the component and the mass rate of air flowing through the plurality of film cooling features or openings is measured. A coolant is then injected into the hollow interior of the component and allowed to flow out of a film cooling feature onto the heated outer surface of the component. The resulting infrared signature is a measure of the relative cooling effect generated by the individual film cool feature. The film cooling effect for an individual feature is quantified as the proportion of mass rate of airflow contributed by its relative individual cooling effect. The area, location and shape of the cooling effect are further classified to determine the degree of conformance to its design intent.

Abstract: An apparatus and method for characterizing gas flow through features fabricated in a hollow part. A pressure regulated cooled gas is applied to an interior of the part to the features fabricated in the part. At the same time, a pressure regulated heated gas is applied to an exterior part skin; and the heated gas has a controlled temperature differential from the pressure regulated cooled gas applied to the part interior. An infrared signature of escaping gas and the surrounding part skin is analyzed by a classification method to identify acceptable and unacceptable fabricated features.

Abstract: An apparatus and method for characterizing gas flow through features fabricated in a hollow part. A pressure regulated cooled gas is applied to an interior of the part to the features fabricated in the part. At the same time, a pressure regulated heated gas is applied to an exterior part skin; and the heated gas has a controlled temperature differential from the pressure regulated cooled gas applied to the part interior. An infrared signature of escaping gas and the surrounding part skin is analyzed by a classification method to identify acceptable and unacceptable fabricated features.

Abstract: An apparatus and method for characterizing gas flow through features fabricated in a hollow part. A pressure regulated cooled gas is applied to an interior of the part to the features fabricated in the part. At the same time, a pressure regulated heated gas is applied to an exterior part skin; and the heated gas has a controlled temperature differential from the pressure regulated cooled gas applied to the part interior. An infrared signature of escaping gas and the surrounding part skin is analyzed by a classification method to identify acceptable and unacceptable fabricated features.

Abstract: An apparatus and method for characterizing gas flow through features fabricated in a hollow part. A pressure regulated cooled gas is applied to an interior of the part to the features fabricated in the part. At the same time, a pressure regulated heated gas is applied to an exterior part skin; and the heated gas has a controlled temperature differential from the pressure regulated cooled gas applied to the part interior. An infrared signature of escaping gas and the surrounding part skin is analyzed by a classification method to identify acceptable and unacceptable fabricated features.

Abstract: An apparatus and method for characterizing gas flow through features fabricated in a hollow part. A pressurized gas is applied to an interior of the part, and this gas pressure flows outward through features fabricated in the part. At the same time, a stabilizing pressurized gas is applied to an exterior part skin; and the stabilizing gas has a controlled temperature differential from the gas applied to the part interior. An infrared signature of escaping gas and the surrounding part skin is analyzed by a classification method. Analysis of this infrared signature classifies the relative flow rate, size and position of the feature fabricated in the part.

Abstract: An apparatus and method for characterizing gas flow through features fabricated in a hollow part. A pressurized gas is applied to an interior of the part, and this gas pressure flows outward through features fabricated in the part. At the same time, a stabilizing pressurized gas is applied to an exterior part skin; and the stabilizing gas has a controlled temperature differential from the gas applied to the part interior. An infrared signature of escaping gas and the surrounding part skin is analyzed by a classification method. Analysis of this infrared signature classifies the relative flow rate, size and position of the feature fabricated in the part.

Abstract: A method for forming a complex hole through a wall of a structure. The complex hole has a smaller cross-sectional area within the wall and an outer portion with a larger cross-sectional area adjacent a first surface of the wall. The complex hole further has an inner portion extending between the smaller cross-sectional area and an inlet opening on a second surface of the wall. The method uses an EDM process to automatically first, form an entry hole in the wall extending from the first surface to a first location inside the wall, and second, form the outer portion of the complex hole in a direction moving from the first location inside the wall toward the first surface, and third, form the inner portion of the complex hole.

Abstract: A hole inspection system having a light source emitting light over its length and a multi-axes machine having a camera mounted thereon. After the light source is inserted into a cavity intersecting the complex holes, a control commands the multi-axes machine to move the camera to an inspection position associated with one of the complex holes. The control processes substantially only light intensity values received from the camera that represent light shining through the one of the complex holes. Next, a maximum intensity value of light received by the camera from the one of the complex holes is determined. The maximum intensity value is compared to a threshold value, and error data is created that identifies the one of the complex holes in response to the maximum intensity value being less than the threshold value.

Abstract: A hole inspection system having a light source emitting light over its length and a multi-axes machine having a camera mounted thereon. After the light source is inserted into a cavity intersecting the complex holes, a control commands the multi-axes machine to move the camera to an inspection position associated with one of the complex holes. The control processes substantially only light intensity values received from the camera that represent light shining through the one of the complex holes. Next, a maximum intensity value of light received by the camera from the one of the complex holes is determined. The maximum intensity value is compared to a threshold value, and error data is created that identifies the one of the complex holes in response to the maximum intensity value being less than the threshold value.

Abstract: A method for forming a complex hole through a wall of a structure. The complex hole has a smaller cross-sectional area within the wall and an outer portion with a larger cross-sectional area adjacent a first surface of the wall. The complex hole further has an inner portion extending between the smaller cross-sectional area and an inlet opening on a second surface of the wall. The method uses an EDM process to automatically first, form an entry hole in the wall extending from the first surface to a first location inside the wall, and second, form the outer portion of the complex hole in a direction moving from the first location inside the wall toward the first surface, and third, form the inner portion of the complex hole.

Abstract: An improved joint for a turbine component including an outer wall member, an inner wall member disposed within the outer wall member, and at least one air channel formed therebetween. The improved joint preferably includes a plurality of elongated ribs extending from one of the outer and inner wall members, and a plurality of elongated grooves spaced from the other wall member and facing in registry with the plurality of ribs. The ribs are received in the grooves at joint interfaces to form a plurality of joints for interconnecting the inner and outer wall members. The formation of the elongated ribs and grooves in the improved joint provides a mechanical interlock at the joint interface to improve the strength of the joints, as well as to reduce undesirable heat transfer through the joints.

Abstract: A weld-braze process is disclosed for forming high-strength metal joints using a localized heat source in combination with braze filler material. Braze filler material is sandwiched between the metal members to be joined at predetermined weld locations and the localized heat source is directed along one of the metal members in two offset passes at the predetermined weld locations to form a pair of parallel welds. The parallel welds form a pair of weld beads extending from one of the metal members through the braze filler material and into the other metal member with the braze filler material melting and forming a braze layer region intermediate the pair of weld beads to join the metal members. In one embodiment, the localized heat source comprises a computer numerically controlled laser energy beam. A method is disclosed for joining a cover sheet to a nozzle segment base in the manufacture of a high pressure nozzle segment for aircraft engines.