Abstract: A casing component is configured to form part of a flow path in a turbine. The casing component includes a base made of nodular cast iron, and a repaired region in the base. The repaired region includes a butter layer applied on the base and a fill layer applied on the butter layer.

Abstract: A casing component is configured to form part of a flow path in a turbine. The casing component includes a base made of nodular cast iron, and a repaired region in the base. The repaired region includes a butter layer applied on the base and a fill layer applied on the butter layer.

Abstract: A system for manufacturing an airfoil includes a laser beam and a first fluid column surrounding the laser beam to create a confined laser beam directed at the airfoil. A liquid flowing inside the airfoil disrupts the first fluid column inside the airfoil. A method for manufacturing an airfoil includes confining a laser beam inside a first fluid column to create a confined laser beam and directing the confined laser beam at a surface of the airfoil. The method further includes creating a hole through the surface of the airfoil with the confined laser beam, flowing a liquid inside the airfoil, and disrupting the first fluid column with the liquid flowing inside the airfoil.

Abstract: A system for manufacturing an airfoil includes a laser beam and a first fluid column surrounding the laser beam to create a confined laser beam directed at the airfoil. A liquid flowing inside the airfoil disrupts the first fluid column inside the airfoil. A method for manufacturing an airfoil includes confining a laser beam inside a first fluid column to create a confined laser beam and directing the confined laser beam at a surface of the airfoil. The method further includes creating a hole through the surface of the airfoil with the confined laser beam, flowing a liquid inside the airfoil, and disrupting the first fluid column with the liquid flowing inside the airfoil.

Abstract: A bi-layer bond coating for use on metal alloy components exposed to hostile thermal and chemical environment, such as a gas turbine engine, and the method for applying such coatings. The preferred coatings include a bi-layer bond coat applied to the metal substrate using high velocity oxy-fuel (HVOF) thermal spraying. Bi-layer bond coatings in accordance with the invention consist of a dense first inner layer (such as iron, nickel or cobalt-based alloys) that provides oxidation protection to the metal substrate, and a second outer layer having controlled porosity that tends to promote roughness, mechanical compliance, and promotes adherence of the thermal barrier coating (TBC). Preferably, the outer, less dense layer of the bi-layer bond coat is formed from a mixture of metallic powder and polyester to adjust and control the porosity, but without sacrificing mechanical compliance.

Abstract: A spray coating simulation for a robotic spray gun assembly imports a discretized model of an object geometry. Next, the simulator imports a numerically characterized spray pattern file and a robot motion file having a plurality of motion positions, dwell times and orientations defining a motion path of the spray gun. The individual motion positions within the motion file are read and a determination is made as to which portions of the object geometry are visible at each motion position. Next, a coating thickness at each visible portion of the object geometry is computed, based on the specified spray pattern data, the dwell time and the orientation of the robot motion path, for each motion position. Finally, the total coating thickness over the object geometry is calculated.