Abstract: An integrated compressor disk and compressor blade (BLISK) having a specified shape is prepared by an electrochemical machining process having a cathode defined by a set of cathode shape parameters. A trial BLISK is prepared using a cathode defined by a set of trial shape parameters, and a set of deviations of the trial shape from the specified shape at a plurality of surface grid points on a surface of the trial article is measured. A set of revised cathode shape parameters is determined using at least one reshaping routine specific to the BLISK. A reshaped article is prepared using the electrochemical machining process and a reshaped cathode defined by the revised cathode shape parameters.

Abstract: An eddy current inspection probe for inspecting a preselected surface at least partially defining an opening in a component. The eddy current inspection probe includes a core moveable between a retracted position and an expanded position in which the probe is sized and shaped for at least partially filling the opening and contacting the preselected surface for inspecting the surface. The probe includes a compliant covering positioned over the exterior surface of the core and an eddy current array positioned over the outer face of the covering. Further, the probe includes an element positioned between an exterior surface of the core and an inner face of the covering having a coefficient of friction selected to permit the inner face of the covering to move tangentially with respect to the exterior surface of the core as the core is moved from the retracted position to the expanded position to ensure intimate contact between probe and the preselected surface of the component being inspected.

Abstract: A method of forming cooling holes in a gas turbine engine component. The method includes the steps of forming a hole in the component extending between a first surface of the component and a second surface of the component opposite the first surface and supplying pressurized air to the hole from the second surface of the component. The method also includes the step of sensing a parameter representative of air flow through the hole. Further, the method includes enlarging the hole until the sensed parameter represents a preselected air flow rate through the hole.

Abstract: An inspection apparatus includes a component engagement apparatus, a detection apparatus, and a movement apparatus and is controlled by a cam. A drawer is slidably attached to the component engagement apparatus to receive and align a component including a TV-shaped opening. The detection apparatus is sized to receive an eddy current probe and is attached to the movement apparatus with an adjustable fixture. The movement apparatus identifies a relative position of the eddy current probe in relation to the TV-shaped opening being inspected and guides the movement of the detection apparatus.

Abstract: A method for setting up a transparent confinement media nozzle for flowing the confinement media during laser shock peening of a work piece includes the following steps: Step A) flowing a confinement media and setting a flow rate of the confinement media through a confinement media flow nozzle; Step B) positioning the nozzle to flow the confinement media through the nozzle and onto the correlation surface; and Step C) measuring a confinement media layer thickness on the correlation surface using an ultrasonic transducer attached to a side of the test piece opposite that of the correlation surface. The ultrasonic transducer is attached to a side of the test piece opposite that of the correlation surface. One embodiment of the invention employs the work piece as the test piece and the correlation surface is a first laser shock peening surface on a first side of the work piece.

Abstract: A process for forming a diffusion aluminide-hafnide coating on an article, such as a component for a gas turbine engine. The process is a vapor phase process that generally entails placing the article in a coating chamber containing a halide activator and at least one donor material. The donor material collectively consists essentially of at least 0.5 weight percent hafnium and at least 20 weight percent aluminum with the balance being chromium and/or cobalt.

Abstract: A method of forming a shaped hole in a substrate, including substrates protected by coatings, as is the case where an air-cooled component has a thermal barrier coating for protection from a hostile thermal environment, such as the turbine, combustor and augmentor sections of a gas turbine engine. In particular, cooling holes are formed in an air-cooled component after a ceramic layer has been deposited on the surface of the component without damaging or spalling the ceramic layer. Processing steps generally include forming a hole through the ceramic layer and a substrate protected by the ceramic layer, thereby defining an opening at the surface of the ceramic layer. The diameter of the hole is less than the final size required for the cooling hole.

Abstract: An electrical discharge machining (EDM) apparatus includes at least one work station having an electrode fixedly mounted to a base and a workpiece fixture slidingly mounted to the base above the electrode. A servomotor is mounted to the base and arranged to drive the workpiece fixture toward and away from the workpiece. Preferably, the EDM apparatus will include a number of such work stations, and each work station will be connected to a separate control system for independently controlling and energizing the work station.

Abstract: An electric discharge machine includes a machine base configured to support a work piece, a y-axis alignment assembly having a first direction of travel and mounted to the machine base, and an electrode alignment assembly mounted to the machine base and configured to hold an electrode during a machining process. The electrode alignment assembly has a second, a third, and a fourth direction of travel, and an attached rotary indexer has a fifth direction of travel. Movements in the first, second, third, fourth, and fifth directions of travel are automatically controlled by a processor.

Abstract: A process for forming a diffusion aluminide coating on an article, such as a component for a gas turbine engine. The process is a vapor phase process that generally entails placing the article in a coating chamber containing an aluminum donor material, without any halide carrier or inert filler present. The aluminum donor material consists essentially of about 20 to about 70 weight percent aluminum, with the balance being chromium or cobalt. While the article is held out of contact with the donor material, coating is initiated in an inert or reducing atmosphere by heating the article and the donor material to vaporize the aluminum constituent of the donor material, which then condenses on the surface of the article and diffuses into the surface to form a diffusion aluminide coating on the article.