Abstract: Methods for preparing a hybrid article include disposing an additive structure comprising a plurality of layers on a build surface of a part, the build surface being defined based on x, and y coordinates, and the additive structure being defined by a three dimensional model defined by a series of planes based on x, y and z coordinates that define a plurality of layers, one layer comprising an interface surface having a contour being defined by x, and y coordinates. When the build surface and the interface surface are both oriented in space according to corresponding x, y and z coordinates, a cladding system is directed to deposit each of the sequential layers of the additive structure according to toolpaths that correspond with each of the plurality of layers of the three dimensional model.

Abstract: A process for providing a manufacturing modality for a hybrid article includes defining a model for a build surface on a part in a three dimensional space, and defining a model for an additive structure, the model including an interface surface of the additive structure that corresponds with the build surface in the three dimensional space. The process further includes orienting the x, y and z coordinates of each of the build surface of the part and the interface surface of the model in relation to a three dimensional work space, aligning contours of each of the build surface and the interface surface relative to the work space, and directing a cladding system to define toolpaths for two or more cladding layers that are defined by vertical planar segments or slices of the additive structure model.

Abstract: A process for providing a manufacturing modality for a hybrid article includes defining a model for a build surface on a part in a three dimensional space, and defining a model for an additive structure, the model including an interface surface of the additive structure that corresponds with the build surface in the three dimensional space. The process further includes orienting the x, y and z coordinates of each of the build surface of the part and the interface surface of the model in relation to a three dimensional work space, aligning contours of each of the build surface and the interface surface relative to the work space, and directing a cladding system to define toolpaths for two or more cladding layers that are defined by vertical planar segments or slices of the additive structure model.

Abstract: Methods for preparing a hybrid article include disposing an additive structure comprising a plurality of layers on a build surface of a part, the build surface being defined based on x, and y coordinates, and the additive structure being defined by a three dimensional model defined by a series of planes based on x, y and z coordinates that define a plurality of layers, one layer comprising an interface surface having a contour being defined by x, and y coordinates. When the build surface and the interface surface are both oriented in space according to corresponding x, y and z coordinates, a cladding system is directed to deposit each of the sequential layers of the additive structure according to toolpaths that correspond with each of the plurality of layers of the three dimensional model.

Abstract: A coating process for applying a bifurcated coating to an article is disclosed including applying an aluminizing slurry to a first portion of the article, applying a chromizing slurry to a second portion of the article, and simultaneously heat treating the article, the aluminizing slurry, and the chromizing slurry. Heat treating the aluminizing slurry forms an aluminide coating on the first portion of the article and an aluminide diffusion zone between the article and the aluminide coating. Heat treating the chromizing slurry forms a chromide coating on the second portion of the article and a chromide diffusion zone between the article and the chromide coating. The first portion and the second portion are both maintained in an unmasked state while applying the aluminizing slurry and the chromizing slurry and during the heat treating.

Abstract: A coating process for applying a bifurcated coating to an article is disclosed including applying an aluminizing slurry to a first portion of the article, applying a chromizing slurry to a second portion of the article, and simultaneously heat treating the article, the aluminizing slurry, and the chromizing slurry. Heat treating the aluminizing slurry forms an aluminide coating on the first portion of the article and an aluminide diffusion zone between the article and the aluminide coating. Heat treating the chromizing slurry forms a chromide coating on the second portion of the article and a chromide diffusion zone between the article and the chromide coating. The first portion and the second portion are both maintained in an unmasked state while applying the aluminizing slurry and the chromizing slurry and during the heat treating.

Abstract: An unmanned aircraft system (UAS) to inspect equipment and a method of inspecting equipment with the UAS are described. The UAS includes a scanner to obtain images of the equipment and a memory device to store information for the UAS. The UAS also includes a processor to determine a real-time flight path based on the images and the stored information, and a camera mounted on the UAS to obtain camera images of the equipment as the UAS traverses the real-time flight path.

Abstract: A method of treatment includes laser-hardening a portion of a component and texturing a treated surface of the portion with a hydrophobic surface texture. In some embodiments, the method includes polishing the treated surface after laser-hardening the portion and prior to texturing the treated surface. A component includes a component body having a portion that is laser-hardened. The treated surface is hydrophobic with a hydrophobic surface texture. In some embodiments, the component is a turbine component. In some embodiments, the portion is a leading edge. A turbine system includes a turbine shaft and a turbine component attached to the turbine shaft. The turbine component includes a component body having a leading edge. The leading edge is laser-hardened and the treated surface of the leading edge is hydrophobic with a hydrophobic surface texture.

Abstract: An article treatment method is disclosed including removing an affected area from an article, the article including the affected area and a substrate composed of a substrate material, forming an unaffected surface. A structural material is applied to the unaffected surface by cold spraying a plurality of particles of the structural material from a cold spray apparatus. The structural material and the article are finished, forming a treated article including an unused article conformation. A turbine component treatment method is disclosed for a turbine component including a hard-to-weld (HTW) alloy, wherein applying the structural material includes impacting the plurality of particles, and plastically deforming the plurality of particles to form a mechanical bond between the structural material and the HTW alloy. An airfoil treatment method is disclosed further including the cold spraying forming a near net shape of an unused airfoil composition.

Abstract: A process for forming a thermal barrier coating system on a substrate is disclosed including preparing a slurry including a donor powder, an activator powder, and a binder. The donor powder includes a metallic aluminum alloy having a melting temperature higher than aluminum, and the binder includes at least one organic polymer gel. The process further includes applying the slurry to the substrate, heating the slurry to form an aluminide bond coating including an additive aluminide layer and an aluminide interdiffusion zone disposed between the substrate and the additive aluminide layer, and applying a thermal barrier coating to the aluminide bond coating. The thermal barrier coating may be a dense vertically-cracked thermal barrier coating, and the substrate may be a gas turbine component. Thermal barrier coating systems formed by the process are also disclosed.

Abstract: A modification process and modified article are disclosed. The modification process includes locating an area in an article, removing the area by machining to form a machined region, inserting a modification material into the machined region, securing the modification material to the article, machining the modification material flush with a geometry of the article, and applying a coating over at least a portion of the article. Another modification process includes locating an area under a suction side leading edge tip shroud fillet of an airfoil, removing the area by machining to form a hole, inserting a modification material having improved material properties as compared to an original base material into the hole, securing the modification material in place, machining the modification material and the airfoil to form a new fillet contour, and applying a coating over at least a portion of the airfoil. Also disclosed is the modified article.

Abstract: Methods for manufacturing strain sensors on turbine components include providing a turbine component comprising an exterior surface, depositing a ceramic material onto a portion of the exterior surface, and ablating at least a portion of the ceramic material to form a strain sensor comprising at least two reference points.

Abstract: The invention relates generally to the measurement and dimensional analysis of an object and, more particularly, to the correction of distortion in volumetric data of the object using dimensional data of the object. In one embodiment, the invention provides a method of analyzing an object, the method comprising: acquiring volumetric data of an object using an X-ray computed tomography (CT) imaging system; acquiring dimensional data of the object using a vision-based system; determining whether the volumetric data include a distortion; and in the case that the volumetric data are determined to include a distortion, correcting the distortion in the volumetric data using the dimensional data.

Abstract: An unmanned aircraft system (UAS) to inspect equipment and a method of inspecting equipment with the UAS are described. The UAS includes a scanner to obtain images of the equipment and a memory device to store information for the UAS. The UAS also includes a processor to determine a real-time flight path based on the images and the stored information, and a camera mounted on the UAS to obtain camera images of the equipment as the UAS traverses the real-time flight path.

Abstract: Methods for manufacturing strain sensors on turbine components include providing a turbine component comprising an exterior surface, depositing a ceramic material onto a portion of the exterior surface, and ablating at least a portion of the ceramic material to form a strain sensor comprising at least two reference points.

Abstract: The invention relates generally to the measurement and dimensional analysis of an object and, more particularly, to the correction of distortion in volumetric data of the object using dimensional data of the object. In one embodiment, the invention provides a method of analyzing an object, the method comprising: acquiring volumetric data of an object using an X-ray computed tomography (CT) imaging system; acquiring dimensional data of the object using a vision-based system; determining whether the volumetric data include a distortion; and in the case that the volumetric data are determined to include a distortion, correcting the distortion in the volumetric data using the dimensional data.

Abstract: A gas turbine engine component includes a substrate formed of a high temperature resistant material and a corrosion resistant layer. The corrosion resistant layer is inert to the molten salt impurities and includes a refractory metal vanadate of formula MxVyOz, wherein M is selected from the group consisting of alkaline earth metals, group IV and V transition metals, rare-earth metals and their combinations, and wherein z=x+2.5y, or z=1.5x+2.5y, or z=2x+2.5y.

Abstract: A modification process and modified article are disclosed. The modification process includes locating an area in an article, removing the area by machining to form a machined region, inserting a modification material into the machined region, securing the modification material to the article, machining the modification material flush with a geometry of the article, and applying a coating over at least a portion of the article. Another modification process includes locating an area under a suction side leading edge tip shroud fillet of an airfoil, removing the area by machining to form a hole, inserting a modification material having improved material properties as compared to an original base material into the hole, securing the modification material in place, machining the modification material and the airfoil to form a new fillet contour, and applying a coating over at least a portion of the airfoil. Also disclosed is the modified article.

Abstract: Various embodiments include approaches for monitoring turbomachine components. In various particular embodiments, a system for monitoring a component within a turbomachine includes: a borescope probe sized to pass through an opening in the turbomachine, the borescope probe for detecting a symbolic data array on the component within the turbomachine; and at least one computing device operably coupled to the borescope probe, the at least one computing device configured to: obtain image data about the symbolic data array from the borescope probe; evaluate the image data to determine whether the image data is compatible with a symbolic data array analysis program; and analyze the image data using the symbolic data array analysis program in response to determining the image data is compatible with the symbolic data array analysis program.

Abstract: A visual inspection device for inspecting interior passages of a system is disclosed herein. In an embodiment, the visual inspection device includes a visual inspection tool and a tube having a lumen disposed therein, the visual inspection tool being disposed at a distal end of the tube. A plurality of actuators are disposed along an axial extent of an exterior of the tube, and a locomotor is disposed on an exterior of the tube. A locator for tracking a location of the visual inspection tool is also provided as part of the visual inspection device.