Abstract: An exemplary shroud milling method includes milling a convex side of a shroud, milling a concave side of the shroud, and holding a shroud within a common fixture when milling the convex side and when milling the concave side.

Abstract: A plunger assembly for a die casting machine shot sleeve includes a plunger body that has an outer diameter. The plunger includes a head that provides a wall. A piston ring is arranged on the plunger body adjacent to the wall. A nut is secured to the outer diameter and urges the piston ring toward the wall to retain the piston ring securely on the plunger body.

Abstract: A die casting assembly has a cavity defined by multiple dies, the cavity includes at least one sharp corner. Each of the dies includes multiple die segments. A die segment joint between at least two of the die segments is aligned with the sharp corner.

Abstract: An example component polishing method includes polishing a component protecting portions of the component during the polishing using a barrier spaced from the component. The barrier is configured to move together with the component during the polishing.

Abstract: A shot sleeve assembly for a die casting process includes a housing defining a bore open at both a front end and a rear end and a pour opening for receiving molten material, the housing includes a first coefficient of thermal expansion. A core is received within the bore and includes a second coefficient of thermal expansion lower than the first coefficient of thermal expansion. Front and rear covers attached to the housing hold the core in place within the bore and accommodate differences in thermal expansion between the housing and core.

Abstract: A method for defining an airfoil with a radiused shape edge includes joining a filler material to the airfoil such that the filler material defines excess material that extends beyond an operational condition edge location of the edge of the airfoil, placing the airfoil within a barrel, providing an abrasive finishing media in the barrel with the airfoil, rotating the barrel to produce relative motion between the abrasive finishing media and the airfoil. Contact between the abrasive finishing material and the airfoil facilitates removing the excess material that extended beyond the operational condition edge location of the edge of the airfoil.

Abstract: An example component polishing method includes polishing a component, and protecting at least a portion of a component during the polishing using a sacrificial mask. Some of the sacrificial mask is removed during the polishing.

Abstract: An example component polishing method includes polishing a component protecting portions of the component during the polishing using a barrier spaced from the component. The barrier is configured to move together with the component during the polishing.

Abstract: An electrical discharge assembly for processing a workpiece having a cooling passage with first and second portions includes a first electrode having a first shape for machining the first portion of the cooling passage and a second electrode having a second shape for machining the second portion of the cooling passage. In a method for repairing cooling passages in a workpiece, a first electrode having a first shape is positioned in a cooling passage. The first electrode is electrically powered to machine a first portion of the cooling passage. A second electrode having a second shape is positioned in the cooling passage. The second electrode is electrically powered to machine a second portion of the cooling passage.

Abstract: A fixture assembly for retaining a workpiece during a coining process includes a mounting block. The workpiece includes an airfoil portion, a platform, and feet extending from the platform opposite the airfoil portion configured to engage a retention slot in a gas turbine engine, each foot defining a substantially arcuate engagement surface. The mounting block includes a first portion having a slot defined therein between opposite first and second lateral edges and having an exposed front face, first and second retaining structures positioned adjacent to the first and second lateral edges, respectively. Each of the first and second retaining structures overhangs the slot and defines an engagement surface facing the slot, such that during engagement of the workpiece the substantially arcuate engagement surfaces of the feet contact the engagement surfaces of the first and second retaining structures to provide a pivotable engagement.

Abstract: A mask for performing high speed media finishing on airfoils includes a thicker portion and a thinner portion. The thicker portion is spaced further from an edge that will become a leading edge in the final airfoil than the thinner portion. The media is redirected by the thicker portion toward the edge where the finishing is to occur.

Abstract: A mask for performing high speed media finishing on airfoils includes a thicker portion and a thinner portion. The thicker portion is spaced further from an edge that will become a leading edge in the final airfoil than the thinner portion. The media is redirected by the thicker portion toward the edge where the finishing is to occur.

Abstract: An electrical discharge assembly for processing a workpiece having a cooling passage with first and second portions includes a first electrode having a first shape for machining the first portion of the cooling passage and a second electrode having a second shape for machining the second portion of the cooling passage. In a method for repairing cooling passages in a workpiece, a first electrode having a first shape is positioned in a cooling passage. The first electrode is electrically powered to machine a first portion of the cooling passage. A second electrode having a second shape is positioned in the cooling passage. The second electrode is electrically powered to machine a second portion of the cooling passage.

Abstract: A fixture assembly for retaining a workpiece during a coining process includes a mounting block. The workpiece includes an airfoil portion, a platform, and feet extending from the platform opposite the airfoil portion configured to engage a retention slot in a gas turbine engine, each foot defining a substantially arcuate engagement surface. The mounting block includes a first portion having a slot defined therein between opposite first and second lateral edges and having an exposed front face, first and second retaining structures positioned adjacent to the first and second lateral edges, respectively. Each of the first and second retaining structures overhangs the slot and defines an engagement surface facing the slot, such that during engagement of the workpiece the substantially arcuate engagement surfaces of the feet contact the engagement surfaces of the first and second retaining structures to provide a pivotable engagement.

Abstract: A method for defining an airfoil with a radiused shape edge includes joining a filler material to the airfoil such that the filler material defines excess material that extends beyond an operational condition edge location of the edge of the airfoil, placing the airfoil within a barrel, providing an abrasive finishing media in the barrel with the airfoil, rotating the barrel to produce relative motion between the abrasive finishing media and the airfoil. Contact between the abrasive finishing material and the airfoil facilitates removing the excess material that extended beyond the operational condition edge location of the edge of the airfoil.