Abstract: An eddy current device for inspecting a component includes an eddy current array circuit having respective pluralities of drive and sense elements and having an active face for positioning on a surface of the component during the inspection operation. A backing is disposed on a face of the eddy current array circuit opposite to the active face for concentrating an electromagnetic flux from the eddy current array circuit into the component when each of the plurality of drive elements is being energized. A mechanical arrangement is provided for supporting and deploying the backing and the array circuit to substantially conform with the surface portion under inspection and to cause each of the pluralities of drive and sense elements to be maintained at their respective substantially constant distances from the inspection surface during scanning, preferably at a controlled rate of scan.

Abstract: The invention provides a system, method, and computer program for automatically evaluating the linear displacement and inclination of the centerline of a piece of hardware to be machined on a computer numerically controlled (CNC) machine relative to an axis of rotation of the machine about which the hardware will be rotated. The invention also provides a compensation for correcting for any hardware axis misalignment.

Abstract: A variable angle stator vane assembly for an axial flow gas turbine engine compressor. The compressor casing has a bore surrounded by a boss at the position of each assembly. A housing having a central bore and a bushing assembly is located in the casing bore and is bolted to the boss. The stator vane spindle extends through the housing bore and busing assembly. The housing and bushing assembly can be removed from the casing bore, to be rotated 180.degree. or replaced, without removing the casing from the compressor or the stator vane spindle from the casing bore.

Abstract: A composite low frequency high frequency electrical signal from a metal cutting tool in a metal cutting operation is processed through separate high frequency and low frequency systems and the resulting signals digitized and combined for analysis of a tool break event.

Abstract: A real time variable laser beam spinner, wherein a manual or programmable actuator angularly displaces a mirror or optical flat during rotation in order to follow the instantaneous spin diameter requirements associated with a workpiece, whereby a variable effective spin diameter of the beam results without interrupting the work process.

Abstract: A support assembly for a gas turbine engine combustor includes an annular frame having a plurality of circumferentially spaced apart tenons, and an annular combustor liner disposed coaxially with the frame and including a plurality of circumferentially spaced apart tenons circumferentially adjoining respective ones of the frame tenons for radially and tangentially supporting the liner to the frame while allowing unrestrained differential thermal radial movement therebetween.

Abstract: A mounting assembly includes an annular supporting flange disposed coaxially about a centerline axis which has a plurality of circumferentially spaced apart supporting holes therethrough. An annular liner is disposed coaxially with the supporting flange and includes a plurality of circumferentially spaced apart mounting holes aligned with respective ones of the supporting holes. Each of a plurality of mounting pins includes a proximal end fixedly joined to the supporting flange through a respective one of the supporting holes, and a distal end disposed through a respective one of the liner mounting holes for supporting the liner to the supporting flange while unrestrained differential thermal movement of the liner relative to the supporting flange.

Abstract: An improved method of adaptive machining is disclosed which affords automatic blending between a machined surface and a complex variable contour forged surface. An adaptive postprocessor generates an adaptive NC part program from a conventional APT file which has the capability to modify the cutter tool path in real time during the machining cycle based on limited surface measurement data. Variable measurement data taken from each workpiece generates a unique toolpath adapted specifically to the contour of that workpiece being processed, obviating the subsequent need for time consuming manual grinding and smoothing operations between machined and forged surfaces.

Abstract: A method and system for machining a contoured surface of a part, such as a vane of a vane segment of a nozzle ring in a gas turbine engine. A plurality of original data points from the original surface of the vane are sensed. The system comprises an algorithm for creating a matrix of data and for generating a revised contour profile corresponding to the cross-sectioned contour of the vane for points which lie in a common plane. The original contour may have missing sections in its profile or may have areas where brazing material has been applied to the vane. The revised contour profile is adjusted in accordance with certain predefined parameters. The revised contour profile is also adjusted so that all of its points lie on or inside the perimeter shape defined by the original data points. All of the revised contour profiles associated with each cross-section of the vane is compiled to generate one machining contour.

Abstract: An apparatus and method for monitoring material removal from a workpiece by a beam of energy during a material processing operation are disclosed. A detector is positioned for sensing optical emissions from the workpiece caused by removal of material when an energy beam pulse is incident upon the surface of the workpiece. A computing circuit, algorithm or artificial neural network is provided for determining a quantity of material removed from the sensed optical emissions in real-time during the material processing operation. Analysis of the optical emission pulses caused by the material removal provides an indication of the efficiency of the material processing system and provides feedback for manual or automatic adjustment of material processing parameters during the material processing operation.

Abstract: A blackline indictor for use in tomographic and/or radioscopic inspection of a weld joint is disclosed. The indicator includes a first elongated member having a first end and a second end and a second elongated member juxtaposed to said first member and also having a first end and a second end. The first ends of the elongated members are in contact with one another, and a spacer is disposed between the first and second members to position the second ends of the members at a selected distance from one another. The selected distance is at least equal to a thickness of the weld joint under inspection, and the first and second members and the spacer define a calibrated wedge shaped gap which is radiographically imageable to permit determination and control of the x-ray inspection parameters.

Abstract: An apparatus and method for inspecting the bonding between a cell structure having a multiplicity of cells which are open at one end and bonded at an opposite end to a substrate are disclosed. The apparatus includes a heater and nozzle arrangement for directing a fluid, such as heated air, having a selected temperature, substantially different from ambient, into the open ends of the cell structure to cause a change in the temperature of the cell structure and radiance therefrom. A sensor is provided for sensing the temperature of the cell structure along the extent thereof or a detector may be provided for detecting the radiance along the cell structure.

Abstract: In a metal cutting tool wear indicator system, a ratio of an estimated ultrasonic emission signal from a metal cutting process to a measured ultrasonic emission signal, e.g. UE/UE is utilized in place of a prior ratio of horsepower to ultrasonic emission, e.g. HP/UE, together with a continuous revision of the estimator during the cutting process.

Abstract: An apparatus for welding together a plurality of portions of a workpiece with a complex geometric surface includes a laser source for generating a laser beam; the laser source is positioned at a predetermined distance from the workpiece portions to form a weld bead of a selected width. The apparatus also includes a powder feed mechanism with a nozzle for depositing a chosen volume of powder per unit of time onto the workpiece surface. The powder feed nozzle includes a structure for preventing a reflected laser beam from the workpiece surface and the weld bead from being incident upon an orifice of the nozzle and thereby preventing the powder from melting and clogging the nozzle orifice. Either the workpiece or the laser source in combination with the powder feed mechanism may be mounted on a manipulator arrangement for moving either the workpiece portions or the combination of the laser source and powder feed mechanism relative to one another to deposit the weld bead along a predetermined weld path.

Abstract: A welding apparatus operable with a high power CO.sub.2 laser beam having a laser beam wavelength-corresponding coating on an optical window mounted in the beam path deflecting the reflected workpiece image into a viewing channel allowing a real-time observation of the welding.

Abstract: In one type of aircraft propulsion system, propeller blades are mounted on a ring which surrounds a turbine. An annular space exists between the turbine and the ring. If a propeller blade should break free, the unbalanced centrifugal load tends to deform the ring. The invention reduces the deformation, as by locating spacers between the turbine and the ring.

Abstract: A low cost, portable computer aided runout measuring system for cylindrical components comprises an electrically interconnected displacement transducer, a computer and an ancillary angle measuring device. Runout deviations are stored in the computer in a displacement vs. time mode while concurrently therewith the angle at deviation is stored in the computer.

Abstract: An improved method and apparatus for laser trepanning a passage through a workpiece, gas turbine engine component or the like includes the method steps of: providing a linearly polarized beam of laser energy; focusing the laser beam on a selected location on the component; moving one of the laser beam or the workpiece relative to one another along a first selected trepanning path and along a second selected trepanning path, which is substantially opposite in direction to the first selected path, to compensate for the linear polarization of the laser beam and to reduce the processing time. The steps of moving one of the laser beam or the workpiece along the first and second trepanning paths are repeated until a passage is cut to a desired depth into the surface of the component or the passage is cut entirely through the component.

Abstract: A method for making or repairing a gas turbine engine component includes the step of directing a pulsed ultra-violet laser beam on a location of a film cooling hole after application of a thermal barrier coating to athermally remove any coating material which may be obstructing the cooling hole without damaging the engine component or removing any of the coating from the surface of the component around the cooling hole.

Abstract: A method for making a gas turbine engine component includes the steps of: providing an unfinished gas turbine engine component; directing a laser beam on a selected surface portion of the engine component to prepare the selected surface portion before at least one of a subsequent coating and bonding step; and depositing at least one layer of an abradable material, a subassembly of the component or a thermal barrier coating on the selected surface portion.