Abstract: A method for repairing a recess in an article surface comprises providing first and second metallic powders. The first powder has a first melting temperature and the second powder has a second melting temperature less than the first melting temperature. The first powder is disposed in the recess substantially to fill the recess at least to the article surface. The second powder is disposed over the first powder in an amount that will fill the recess at least to the article surface after melting and flowing the second powder into the recess. The powders are heated to a treatment temperature at least at the second melting temperature and less than the first melting temperature for a time sufficient to melt the second powder, to flow the second powder into the recess about the first powder, and to bond the second powder to a recess surface.

Abstract: A laser shock peening system includes an apparatus and method that senses a thickness of laser transparent confinement media flow, such as water. In one embodiment, the apparatus indicates a proper thickness, in another embodiment, the apparatus controls the flow rate of the confinement media using signals from probes of the apparatus. A first probe is used to sense a predetermined minimum thickness and another embodiment further includes a second probe to indicate a predetermined maximum thickness of the confinement media.

Abstract: A tip cap hole is loaded with a first composition comprising particles of a first alloy having a solidus temperature above the brazing temperature. The first composition is covered with a second composition comprising particles of a second alloy having a liquidus temperature below the brazing temperature. The second composition is heated to the brazing temperature to cause particles of the second alloy to melt to form a liquid of the second alloy which is carried into spaces between the particles of the first alloy by capillarity. The liquid of the second alloy is cooled to form a solid securely bonding the particles of the first alloy. By weight, the second alloy has no more than 1% B and from 3% to 11% Si. The first alloy has Cr and at least about 5% Al, at least about 0.5% Hf, no more than 0.5% Ti.

Abstract: The surface of a workpiece is treated by discharging a stream of pliant shot in a carrier fluid at a shallow angle of incidence thereagainst. The shot is then scrubbed laterally along the surface for selectively removing target material therefrom.

Abstract: A method for restoring a protective coating including a metallic environmental resistant coating of a coating total thickness within a coating design thickness range on a metal substrate of an article includes the application of a replacement material to at least one discrete local surface area on which an undesirable amount of degradation has occurred. Such degradation can extend through the protective coating into the metal substrate. The degradation product can include at least one of oxidation, coating rumpling, and coating voiding, for example, rumpling or voiding of a bond coat under a ceramic thermal barrier coating (TBC). The degradation product first is conditioned at the discrete local area to expose an underlying portion while retaining at least a portion of the metallic environmental coating on surface areas adjacent the discrete surface area. Then a replacement metallic environmental resistant material is applied, retaining the coating total thickness within the coating design thickness range.

Abstract: A turbine airfoil includes pressure and suction sides extending longitudinally from root to tip, and chordally between leading and trailing edges. A striated discharge hole terminates outside the airfoil for discharging coolant therefrom.

Abstract: An ultrasonic inspection element and method are provided for improved ultrasonic inspection of curved entry surface parts. The transducer element may be spherically focused, or have a flat surface. The transducer/mirror element combination is used to inspect through a concave or convex surface. A mirror element shapes the sound beam relative to the shape of the curved surface of the part being inspected. Curvature of the mirror is adjusted with a screw, rod, voltage modulator, or other suitable adjustment mechanism. An alternative mechanism includes multiple “quick disconnect” interchangeable curved mirror elements.

Abstract: An article comprising a substrate and an outer metallic layer, such as a coating, is provided with augmented heat transfer from the substrate through the combination of a layer thickness of about 0.003″ to about 0.017″, a layer surface roughness of at least about 500 micro inches Ra, a layer tensile bond strength of at least about 5 ksi, and a heat transfer augmentation of at least about 1.1. A method of making the article uses an electric arc wire thermal spray process in which the atomizing gas pressure is maintained within the range of about 20-80 psi.

Abstract: A dovetail of a rotor blade is mounted in a complementary slot in a rotor disk. Life of the dovetail is simulated by providing a specimen dovetail mounted in a complementary slot in a fixture. Relative stiffness of the specimen dovetail and fixture are tailored to simulate the loading profile between the blade dovetail and rotor disk. Load is cycled between the specimen dovetail and fixture for determining life of the dovetail.

Abstract: A method for modifying cooling holes in a gas turbine engine film-cooled component by machining cooling hole outlets to enlarge the outlets and remove any portion of the cooling hole walls which might exhibit cracks.

Abstract: A method and device for thermal creep-sizing an annular-shaped structure. The creep-sizing device includes a ring member with through-holes present between the inner and outer diametrical boundaries of the ring member, and with through-slots alternatingly extending from each through-hole to either the inner or outer diametrical boundary. In use, the ring member is placed within the annular-shaped structure, and pins are installed in the through-holes in the ring member to cause the outer diametrical boundary of the ring member to diametrically expand. The structure and creep-sizing device are then heated so that the mechanically expanded ring member causes the structure to undergo thermal creep-sizing.

Abstract: An ultrasonic inspection element and method of fabrication are provided for ultrasonic inspection of curved surface parts. Various points on a transducer are located. These points include the location where a ray starts, to the desired focal point in the material being inspected. The path of the ray is through a water medium and a water-metal boundary. These points are fitted onto a cylindrical surface. The ray is back propagated until it is focused at the desired focal point.

Abstract: A method of removing a ceramic coating, such as a thermal barrier coating (TBC) of yttria-stabilized zirconia (YSZ), from the surface of a component, such as a gas turbine engine component. The method generally entails subjecting the ceramic coating to an aqueous solution of ammonium bifluoride, optionally containing a wetting agent, such as by immersing the component in the solution while maintained at an elevated temperature. Using the method of the invention, a ceramic coating can be completely removed from the component and any cooling holes, with essentially no degradation of the bond coat.

Abstract: A plain blank is sized to produce an airfoil. The blank is plastically formed to include a pocket blending smoothly in one side thereof. Leading and trailing edges of the airfoil are benched. And, filler is placed into the pocket to effect an aerodynamic profile for the airfoil.

Abstract: A free flow abrasive hole polishing system and method improves air flow and resultant component cooling efficiency for an apertured article. The free flow abrasive hole polishing system mixes an abrasive particle component with a carrier media to create a free flowing abrasive particle carrier media mixture. This mixture is pumped through apertures defined by aperture walls in the article to improve air flow and resultant cooling efficiency of the article. Since the abrasive particles have mass and velocity and the free flowing media does not have resistance to flow, the abrasive particles impinge on peaks of the aperture walls, predominantly removing high spots in the aperture walls.

Abstract: A method for repairing the shroud surfaces of a gas turbine engine to provide corrosion and oxidation resistance of the shroud segments while also restoring the dimensional integrity of the shroud segments. The method entails removing the oxidation and corrosion products from the shroud segment, removing preexisting coating materials, applying a material compatible with the shroud segment substrate material, machining the surface, applying a corrosion-resistant, oxidation-resistant and rub-compliant material to the shroud segment using a HVOF process, machining the shroud segment to preselected dimensions and applying an aluminide coating for improved oxidation and corrosion resistance of the repaired surfaces.

Abstract: A fixture for holding a workpiece in a predetermined position during a manufacturing operation. The fixture includes a support having a surface for receiving the workpiece. The surface has a reference point for locating and orienting the workpiece in the predetermined position. The fixture also includes a clamp for clamping the workpiece in a fixed position with respect to the reference point to hold the workpiece in the predetermined position and a brace mounted on the support for bracing the workpiece to prevent the workpiece from deforming during the manufacturing operation. The brace has at least two jaws adapted for clamping the workpiece when received by the support to prevent movement of the workpiece toward or away from the support.

Abstract: An improved coating and method for applying the coating to minimize the consumption of substrate material during high temperature service by formation of an intermediate metal aluminide layer. A layer of Ni or Co or combinations of Ni and Co are added to the substrate material as an overlay by a process such as electroplating or electroless plating. A diffusion aluminide is then formed at the surface by exposing the plated substrate to a source of aluminum at an elevated temperature.

Abstract: Probe chord error compensation is provided in a machine tool including a rotary member for supporting a work piece and a probe having a path of travel. The compensation is accomplished by using the probe to measure an observed diameter of the work piece and then determining the crossover error of the machine tool. The observed diameter and the crossover error are then used to compute the work piece's actual diameter, thereby compensating for any probe chord error.

Abstract: Methods and apparatus for operating a press, such as a forge or trim press, are directed at activating a ram in a press having a lower die and an upper die connected to a ram by heating a workpiece to a first temperature above an impact temperature. The workpiece then is placed on the lower die, monitored during chill down of the workpiece from the first temperature, and the ram actuated based upon the monitoring in a controlled manner to effect an impact of the upper die against the workpiece. The monitoring includes measuring a characteristic parameter of the workpiece and the actuating includes actuating the ram after a predetermined fixed value of the measured parameter is measured. The placing of the workpiece on the lower die is done manually in the preferred embodiment.