Abstract: A compensation field indicating an amount of distortion compensation to be applied across at least a portion of a component is determined, and a nominal computer-aided design (CAD) model of a component is modified based on the compensation field. The amount of distortion compensation corresponds to a multiplication product of: (i) a deviation between the nominal CAD model and a physical representation of the component having been produced based on the nominal CAD model, and (ii) a nonlinear scale factor map that includes a map associating a plurality of locations of the nominal CAD model to corresponding ones of a plurality of scale factors respectively representing an increase or a decrease in the amount of distortion compensation to be applied based on a simulated effect upon the component in response to an iterative simulation process.

Abstract: A method and system, the method including receiving a nominal computer-aided design (CAD) model of a component; producing a physical representation of the component based on the CAD model using an additive manufacturing (AM) process; measuring the produced physical representation of the component to obtain measurement data of the physical representation of the component; determining a deviation between a geometry of the CAD model and the measurement data of the physical representation of the component; calculating a nonlinear scale factor using an iterative simulation process; determining a compensation field based on the determined deviation between the geometry of the CAD model and the measurement data of the physical representation of the component and the calculated nonlinear scale factor; modifying the nominal CAD model by the determined compensation field; and producing a physical representation of the component based on the modified nominal CAD model.

Abstract: A method and system, the method including receiving a nominal computer-aided design (CAD) model of a component; producing a physical representation of the component based on the CAD model using an additive manufacturing (AM) process; measuring the produced physical representation of the component to obtain measurement data of the physical representation of the component; determining a deviation between a geometry of the CAD model and the measurement data of the physical representation of the component; calculating a nonlinear scale factor using an iterative simulation process; determining a compensation field based on the determined deviation between the geometry of the CAD model and the measurement data of the physical representation of the component and the calculated nonlinear scale factor; modifying the nominal CAD model by the determined compensation field; and producing a physical representation of the component based on the modified nominal CAD model.

Abstract: A method for mechanically attaching a composite or polymeric material to a bucket in a radial airfoil includes creating at least one dovetail shape pocket in the bucket having inclined interfaces with respect to the radial airfoil, and filling the pocket with the composite or polymeric material.

Abstract: A method facilitates reducing stress in a turbine bucket including a metallic base metal. The method comprises providing a turbine bucket including at least one pocket formed therein, and filling at least one pocket defined in the bucket with a polymer composite having continuous fibers oriented in a resin matrix, such that the fibers have an orientation determined in accordance with a pre-selected frequency tuning of the bucket.

Abstract: A method for making a turbine blade includes providing a bucket in the turbine blade with a plurality of window pockets passing all the way through a wall of the bucket, positioning the window pockets in regions minimizing or at least reducing stress concentrations on the window pockets, and casting a composite comprising a resin matrix and layers of a fabric material in the bucket.

Abstract: To address certain deficiencies of carbon fiber material as a filler in a hybrid blade, a glass composite layer is provided as a barrier layer between a carbon fiber resin filler and the metallic main body of the blade. The glass composite layer also advantageously provides a gradient in thermal expansion between the carbon fiber composite and the body of the blade (steel) to reduce interfacial residual stress.

Abstract: To address certain deficiencies of carbon fiber material as a filler in a hybrid blade, a glass composite layer is provided as a barrier layer between a carbon fiber resin filler and the metallic main body of the blade. The glass composite layer also advantageously provides a gradient in thermal expansion between the carbon fiber composite and the body of the blade (steel) to reduce interfacial residual stress.

Abstract: A method facilitates reducing stress in a turbine bucket including a metallic base metal. The method comprises providing a turbine bucket including at least one pocket formed therein, and filling at least one pocket defined in the bucket with a polymer composite having continuous fibers oriented in a resin matrix, such that the fibers have an orientation determined in accordance with a pre-selected frequency tuning of the bucket.

Abstract: A method for mechanically attaching a composite or polymeric material to a bucket in a radial airfoil includes creating at least one dovetail shape pocket in the bucket having inclined interfaces with respect to the radial airfoil, and filling the pocket with the composite or polymeric material.

Abstract: A method for making a turbine blade includes providing a bucket in the turbine blade with a plurality of window pockets passing all the way through a wall of the bucket, positioning the window pockets in regions minimizing or at least reducing stress concentrations on the window pockets, and casting a composite comprising a resin matrix and layers of a fabric material in the bucket.