Abstract: The present method for machining a part includes wire electro-discharge machining the part to create a recast layer, and then removing a zinc content of the recast layer without substantially altering the remainder of the initial composition make-up of the recast layer. The final composition make-up of the recast layer is substantially identical to the initial composition make-up except for the removed zinc content.

Abstract: A process for joining two or more powder injection molded parts by preparing at least two green parts from a feedstock including a binder and an injection powder. Placing the two or more green part into intimate contact, and maintaining the two green parts in intimate contact at a position with a linkage between the at least two green parts to produce an interconnected green assembly. Placing the assembly under shape retaining conditions, melting the binder of the interconnected green assembly under shape retaining conditions to produce a seamless body.

Abstract: A process for joining two or more powder injection molded parts by preparing at least two green parts from a feedstock including a binder and an injection powder. Placing the two or more green part into intimate contact, and maintaining the two green parts in intimate contact at a position with a linkage between the at least two green parts to produce an interconnected green assembly. Placing the assembly under shape retaining conditions, melting the binder of the interconnected green assembly under shape retaining conditions to produce a seamless body.

Abstract: The present method for machining a part includes wire electro-discharge machining the part to create a recast layer, and then removing a zinc content of the recast layer without substantially altering the remainder of the initial composition make-up of the recast layer. The final composition make-up of the recast layer is substantially identical to the initial composition make-up except for the removed zinc content.

Abstract: A process for joining two or more powder injection molded parts by preparing at least two green parts from a feedstock including a binder and an injection powder. Placing the two or more green part into intimate contact, and maintaining the two green parts in intimate contact at a position with a linkage between the at least two green parts to produce an interconnected green assembly. Placing the assembly under shape retaining conditions, melting the binder of the interconnected green assembly under shape retaining conditions to produce a seamless body.

Abstract: A system and method for joining components together by projection welding and brazing are disclosed. In one embodiment, the method makes use of one or more weld projections extending from a first component and one or more spacer projections extending from either or both of the components. The one or more weld projections are taller than the one or more spacer projections by a meltdown distance that permits projection welding of the first and second components and permits the one or more spacer projections to define a brazing gap between the first and second components after projection welding.

Abstract: A method for machining a part includes wire electro-discharge machining the part, and then selectively reducing a zinc content of the residual recast layer left on a surface of the part, while otherwise leaving the recast layer substantially intact.

Abstract: A cooled wall segment for a gas turbine engine, including a body defining a contact surface configured to be in contact with circulating hot gas and an outer surface configured to be in contact with cooling air, the body including at least one retention element complementary to a retention element of the engine. The body has a first portion including the at least one retention element, and a porous second portion made of a porous material permeable to air and containing a plurality of interconnected pores, the porous material having a porosity greater than that of the first portion, the second portion being engaged to the first portion and defining at least part of the contact surface, the second portion defining at least part of a fluid communication between the outer surface and the contact surface through the interconnected pores. Methods of forming components are also discussed.

Abstract: A method of manufacturing a shroud segment, including separately molding at least first and second parts by powder injection molding. The first part has an inner surface and at least one fluid passage in communication with the inner surface. The second part has an outer surface complementary to the inner surface of the first part. At least one of the inner and outer surfaces is formed to define a plurality of grooves. A plurality of cooling passages in fluid communication with the at least one fluid passage are defined with the plurality of grooves by interconnecting the inner and outer surfaces while the first and second parts remain in a green state. The interconnected parts are debound and sintered to fuse the parts to define at least a portion of the shroud segment including the cooling passages.

Abstract: A rotor for a gas turbine engine is described and includes a disc and a plurality of blades. The disc has opposite first and second end surfaces spaced apart by a peripheral surface circumferentially extending about the rotor, and a plurality of slots defined in the peripheral surface and each having a length extending between a first slot opening in the first end surface and a second slot opening in the second end surface. Each of the slots has a tapered shape with at least one dimension of a cross-sectional shape of the slot reducing along at least a portion of the length of the slot. The at least one dimension at the first slot opening is greater than the at least one dimension at the second slot opening. The blades having a complimentary root are received in the slots of the rotor.

Abstract: A component including a porous portion which may be permeable or impermeable to air, and a method for making. In one example, the component is a cooled wall segment for a gas turbine engine, including a body defining a contact surface configured to be in contact with circulating hot gas and an outer surface configured to be in contact with cooling air. The body includes a first portion with at least one retention element, and a porous second portion made of a porous material permeable to air, containing a plurality of interconnected pores, and having a porosity greater than that of the first portion. The second portion is engaged to the first portion, defines at least part of the contact surface, and defines at least part of a fluid communication between the outer surface and the contact surface through the interconnected pores. The wall segment may be for example a heat shield or shroud segment. Methods of forming components are also discussed.

Abstract: A system and method of making a part, including capturing an actual tridimensional surface of each part to obtain a corresponding digitized actual surface, performing a tridimensional comparison between the digitized actual surface of each part and a nominal tridimensional surface, generating an actual location and orientation of an operation to be performed based on the tridimensional comparison, and performing the operation on the part based on the generated actual location and orientation of the element.

Abstract: A method of manufacturing a shroud segment, including separately molding at least first and second parts by powder injection molding. The first part has an inner surface and at least one fluid passage in communication with the inner surface. The second part has an outer surface complementary to the inner surface of the first part. At least one of the inner and outer surfaces is formed to define a plurality of grooves. A plurality of cooling passages in fluid communication with the at least one fluid passage are defined with the plurality of grooves by interconnecting the inner and outer surfaces while the first and second parts remain in a green state. The interconnected parts are debound and sintered to fuse the parts to define at least a portion of the shroud segment including the cooling passages.

Abstract: A component including a porous portion which may be permeable or impermeable to air, and a method for making. In one example, the component is a cooled wall segment for a gas turbine engine, including a body defining a contact surface configured to be in contact with circulating hot gas and an outer surface configured to be in contact with cooling air. The body includes a first portion with at least one retention element, and a porous second portion made of a porous material permeable to air, containing a plurality of interconnected pores, and having a porosity greater than that of the first portion. The second portion is engaged to the first portion, defines at least part of the contact surface, and defines at least part of a fluid communication between the outer surface and the contact surface through the interconnected pores. The wall segment may be for example a heat shield or shroud segment. Methods of forming components are also discussed.

Abstract: A system and method of making a part, including capturing an actual tridimensional surface of each part to obtain a corresponding digitized actual surface, performing a tridimensional comparison between the digitized actual surface of each part and a nominal tridimensional surface, generating an actual location and orientation of an operation to be performed based on the tridimensional comparison, and performing the operation on the part based on the generated actual location and orientation of the element.

Abstract: A system and method of making a part, including capturing an actual tridimensional surface of each part to obtain a corresponding digitized actual surface, performing a tridimensional comparison between the digitized actual surface of each part and a nominal tridimensional surface, generating an actual location and orientation of an operation to be performed based on the tridimensional comparison, and performing the operation on the part based on the generated actual location and orientation of the element.

Abstract: A process for joining two or more powder injection molded parts by preparing at least two green parts from a feedstock including a binder and an injection powder. Placing the two or more green part into intimate contact, and maintaining the two green parts in intimate contact at a position with a linkage between the at least two green parts to produce an interconnected green assembly. Placing the assembly under shape retaining conditions, melting the binder of the interconnected green assembly under shape retaining conditions to produce a seamless body.

Abstract: A method for machining a part includes wire electro-discharge machining the part, and then selectively reducing a zinc content of the residual recast layer left on a surface of the part, while otherwise leaving the recast layer substantially intact.

Abstract: A system and method of making a part, including capturing an actual tridimensional surface of each part to obtain a corresponding digitized actual surface, performing a tridimensional comparison between the digitized actual surface of each part and a nominal tridimensional surface, generating an actual location and orientation of an operation to be performed based on the tridimensional comparison, and performing the operation on the part based on the generated actual location and orientation of the element.