Abstract: A method of imaging a turbine engine test component with a first surface and a second surface that is spaced from the first surface. The turbine engine test component includes a plurality of film holes with inlets formed in the second surface or interior that are fluidly coupled to outlets formed in the first surface or exterior. The method includes flowing airflow through the plurality of film holes of the turbine engine test component, obtaining thermographic data, determining a test dataset, and calculating a performance score.

Abstract: A method of imaging a turbine engine component with a first surface and a second surface that is spaced from the first surface. The turbine engine component includes a plurality of holes with inlets formed in the second surface or interior that are fluidly coupled to outlets formed in the first surface or exterior. The method includes determining at least one fluid frequency, determining at least one sampling frequency, and pulsing fluid through at least a portion of the interior of turbine engine component while imaging the turbine engine component.

Abstract: Methods and systems of electrochemically machining are provided. The methods may include applying a first potential to a tool electrode of an electrochemical machining system to generate a primary electric field. The electrochemical machining system may include a workpiece opposite the tool electrode, at least one bias electrode, and at least one fluid delivery channel within the at least one bias electrode. The method may further include applying at least one second potential to the at least one bias electrode. The method may further include delivering a charged electrolyte solution through the at least one fluid delivery channel into the electrolyte solution. Applying at least one second potential and the delivering the charged electrolyte solution generates at least one secondary electric field adjacent to the primary electric field and quenches at least one location of the primary electric field.

Abstract: Methods and systems of electrochemically machining a component are provided. The method may include applying two or more potentials to a tool electrode comprising an array of two or more individual electrodes to generate two or more electric fields in between the tool electrode and a workpiece opposite of the tool electrode, wherein each of the two or more electric fields is generated by one of the array of two or more individual electrodes.

Abstract: An inspection system includes a thermographic sensor configured to capture thermographic data of a component having holes as a fluid is pulsed toward the holes, and one or more processors configured to temporally process the thermographic data to calculate temporal scores and spatial scores for the corresponding holes. The scores can be used to obtain a reference dataset and a test dataset. A performance score can be assigned to the component based on the difference between the datasets.

Abstract: An electrode applied in electro-machining processes, where the electrode includes a main body portion and at least one built-in internal flushing passage for introducing a flushing liquid to a volume between the electrode and a workpiece to be machined. The electrode is made by an additive fabrication process that enables specialized flushing for enhancing waste material evacuation and incorporate special material properties like zones of high electrical conductivity and thermal resistance. The fabrication process produces materials and geometries that could not otherwise be made using conventional processing.

Abstract: Electrode for an electro-erosion process, includes a shaft, a body coupled to the shaft, a plurality of machining-inserts, an insulated layer, and a flushing cover disposed on the body and coupled to the shaft. The shaft includes a channel, a plurality of first and second openings, each opening connected to the channel. The body includes a plurality of main-flushing channels, each channel connected to a corresponding first opening. The plurality of machining-inserts is spaced apart from each other along a circumferential direction and detachably coupled to a peripheral end portion of the body. Each machining-insert includes at least one third opening connected to a corresponding main-flushing channel. The insulated layer is disposed on top and bottom surfaces of the body. The flushing cover includes a plurality of side-flushing channels and a plurality of fourth openings, each channel connected to a corresponding second opening.

Abstract: A component formed using an additive manufacturing system, the component includes an exterior surface, an interior cavity, at least one powder removal device disposed within the interior cavity and adjacent to the exterior surface, wherein the at least one powder removal device is configured to remove un-sintered and partially sintered powder from the component; and at least one exit port defined in the exterior surface to facilitate egress of the un-sintered and partially sintered powder out of the component.

Abstract: A drilling tool for use in machining a conductive work piece that includes a forward electrode tip including an outer radial portion and an inner radial portion. The outer radial portion includes a forward face, and the inner radial portion extends from the forward face of the outer radial portion. The drilling tool further includes a dielectric sheath that extends circumferentially about the outer radial portion, at least one side electrode coupled to the dielectric sheath, and a protective sheath that extends circumferentially about the dielectric sheath. An opening is defined in the protective sheath such that the at least one side electrode is at least partially exposed.

Abstract: An inspection system includes a thermographic sensor configured to capture thermographic data of a component having holes as a fluid is pulsed toward the holes, and one or more processors configured to temporally process the thermographic data to calculate temporal scores and spatial scores for the corresponding holes. The scores can be used to obtain a reference dataset and a test dataset. A performance score can be assigned to the component based on the difference between the datasets.

Abstract: A method of imaging a turbine engine component with a first surface and a second surface that is spaced from the first surface. The turbine engine component includes a plurality of holes with inlets formed in the second surface or interior that are fluidly coupled to outlets formed in the first surface or exterior. The method includes determining at least one fluid frequency, determining at least one sampling frequency, and pulsing fluid through at least a portion of the interior of turbine engine component while imaging the turbine engine component.

Abstract: An electroerosion machining system for trepanning and drilling operations is disclosed. The electroerosion machining system includes an electrode assembly configured to machine a desired configuration in a workpiece, a power supply configured to energize the electrode assembly and the workpiece to opposite electrical polarities, an electrolyte supply configured to pass an electrolyte between the electrode assembly and the workpiece, a working apparatus configured to move the electrode assembly relative to the workpiece, and a control system to control the power supply and the working apparatus. The electrode assembly further includes an electrode body in the form of a tube-shaped body, the tube-shaped body defining a hollow interior and one or more replaceable inserts affixed to the electrode body at a working end thereof positioned adjacent the workpiece, the one or more replaceable inserts constructed so as to be selectively attachable and detachable from the working end of the electrode body.

Abstract: An electrical machining method comprises machining a workpiece by an electrical machining device comprising an electrode; increasing a feedrate of the electrode at a first acceleration if a discharge current passing through the electrode and the workpiece is lower than a discharge current reference; and decreasing the feedrate of the electrode at a second acceleration if the discharge current is higher than the discharge current reference, wherein the second acceleration has an absolute value higher than that of the first acceleration.

Abstract: A method for removal of residual matter includes delivering an ultra high-pressure fluid jet to an intermediate additively manufactured three-dimensional (3D) component to dislodge and remove at least a portion of the residual matter from an internal surface of the intermediate additively manufactured 3D component, or from an external surface of the intermediate additively manufactured 3D component, or both, to form a cleansed additively manufactured 3D component.

Abstract: A method for electroerosion machining includes providing an electrode assembly comprising an electrode body having a tube-shaped body that defines a hollow interior and one or more inserts affixed to the electrode body to form a cutting surface on the electrode assembly, positioning the electrode assembly adjacent a workpiece to be machined, and providing power to the electrode assembly so as to energize the electrode assembly, with the electrode assembly and the workpiece being at opposite electrical polarities. The method also includes advancing the electrode assembly through the workpiece, with a working gap being maintained between the inserts and the workpiece across which a pulse electric current is passed to remove material from the workpiece, wherein, upon advancing the electrode assembly through the workpiece, a core is formed that is completely separated from a remainder of the workpiece and is contained within the hollow interior of the electrode body.

Abstract: An electrode for use in an electromachining system includes a base and an outer rim extending circumferentially about the base. The electrode also includes a body extending between the base and the outer rim. The body defines a concave surface. The electrode is configured to discharge electrical arcs from the concave surface when electrical current is provided to the electrode.

Abstract: The polishing system includes a power supply. The polishing system also includes a container including an interior portion. The interior portion includes a conductive material thereon. The conductive material is electrically coupled to the power supply. The polishing system also includes an electrolytic solution disposed within the container. The electrolytic solution includes a plurality of abrasive particles. The polishing system further includes a flexible media disposed within the container. The container is configured to contain an object. The power supply configured to electrically couple to the object. Each of the electrolytic solution, the flexible media, and the abrasive particles is configured to partially polish the object substantially simultaneously.

Abstract: A method of operating an electrochemical machining system includes selectively performing an electrochemical machining process by an electrochemical machine of the electrochemical machining system in a macromachining mode or a micromachining mode by controlling a purity level of a machining liquid supplied to the electrochemical machine.

Abstract: An electrode applied in electro-machining processes, where the electrode includes a main body portion and at least one built-in internal flushing passage for introducing a flushing liquid to a volume between the electrode and a workpiece to be machined. The electrode is made by an additive fabrication process that enables specialized flushing for enhancing waste material evacuation and incorporate special material properties like zones of high electrical conductivity and thermal resistance. The fabrication process produces materials and geometries that could not otherwise be made using conventional processing.

Abstract: Electrochemical machining of parts employs electric or voltage pulses in which current flows in a first direction and a second direction opposite from the first direction. The cathodic/anodic pulses switch between bulk machining and oxide removal pushing bulk material removal into a homogenous regime to obtain a smooth surface finish and appropriate form control during the electrochemical machining process compared to electrochemical machining employing an electric or voltage potential in which current flows in only one direction.