Abstract: A method for modeling a refurbishing geometry of a component comprises removing a portion to be refurbished from the component, thereby obtaining a truncated component, with a cut surface and a boundary line of the cut surface. Image data of the truncated component are obtained and a representation of the image data is imported into a CAD system. A CAD model of the component, for instance in an unused and nominal new condition, is provided and aligning with the imported representation of the truncated component. Points are defined on the surface of the CAD model and arranged on rows. For each row, a point on the representation of the boundary line of the cut surface closest to the row is determined, and the points in each row are displaced in a translational displacement until the row intersects the representation of the boundary line, thereby obtaining a morphed CAD model representative of the refurbishing geometry of the component.

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: Described is a nozzle assembly that includes a body component defining a center axis. The nozzle assembly also includes an energy beam channel and substantially collinear with the center axis. The energy beam channel has an inlet portion and an outlet portion oriented to pass an energy beam therethrough. At least one side-feeding powder tube extends through the body component at an angle with respect to the center axis. The side-feeding powder tube discharges a powdered material into a focus point of the energy beam. The angle is selected to generate a powder concentration spot diameter that is about twice a beam focus point diameter of the energy beam focus point.

Abstract: A method for modeling a refurbishing geometry of a component comprises removing a portion to be refurbished from the component, thereby obtaining a truncated component, with a cut surface and a boundary line of the cut surface. Image data of the truncated component are obtained and a representation of the image data is imported into a CAD system. A CAD model of the component, for instance in an unused and nominal new condition, is provided and aligning with the imported representation of the truncated component. Points are defined on the surface of the CAD model and arranged on rows. For each row, a point on the representation of the boundary line of the cut surface closest to the row is determined, and the points in each row are displaced in a translational displacement until the row intersects the representation of the boundary line, thereby obtaining a morphed CAD model representative of the refurbishing geometry of the component.

Abstract: A method for masking cooling passages of a turbine component having an external surface, an internal cavity for receiving cooling air, and cooling passages extending therebetween. The location and angle of cooling passages are determined using a robotic arm and a location system. A masking device is placed in the cooling passages located during the locating step. The masking device includes a head portion having a gripping feature for gripping by a robotic arm, and a locating feature for orientation of the masking device by the robotic arm. A retaining portion extending from the head portion is arranged and disposed to retain the masking device in a cooling passage. The retaining portion is narrower proximate a distal end than proximate the head portion. The component and head portion of the masking devices are coated. The masking devices may be removed using the robotic arm and locating system.

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 method for masking cooling passages of a turbine component having an external surface, an internal cavity for receiving cooling air, and cooling passages extending therebetween. The location and angle of cooling passages are determined using a robotic arm and a location system. A masking device is placed in the cooling passages located during the locating step. The masking device includes a head portion having a gripping feature for gripping by a robotic arm, and a locating feature for orientation of the masking device by the robotic arm. A retaining portion extending from the head portion is arranged and disposed to retain the masking device in a cooling passage. The retaining portion is narrower proximate a distal end than proximate the head portion. The component and head portion of the masking devices are coated. The masking devices may be removed using the robotic arm and locating system.

Abstract: Described is a nozzle assembly that includes a body component defining a center axis. The nozzle assembly also includes an energy beam channel and substantially collinear with the center axis. The energy beam channel has an inlet portion and an outlet portion oriented to pass an energy beam therethrough. At least one side-feeding powder tube extends through the body component at an angle with respect to the center axis. The side-feeding powder tube discharges a powdered material into a focus point of the energy beam. The angle is selected to generate a powder concentration spot diameter that is about twice a beam focus point diameter of the energy beam focus point.