Abstract: An article may include a substrate. An article may include a barrier layer on the substrate, the barrier layer including: a bond coat comprising a matrix, diffusive particles disposed in the matrix, and gettering particles disposed in the matrix, and a topcoat comprising a first top coat layer adjacent the bond coat and a second top coat layer disposed on the first top coat layer, the first top coat layer having a lower porosity than the second top coat layer.

Abstract: A tool for ultrasonic impact grinding apparatus driven to vibrate along a longitudinal axis at an applied operating frequency includes a tool body disposed on the longitudinal axis, a first tip extending from an output end of the tool body, and a second tip extending in parallel to the first tip from the output end of the tool body. The first tip has a first length. The second tip has a second length greater than the first length. A mass of the first and second tip is substantially balanced across the output end of the tool body and with respect to the longitudinal axis.

Abstract: A method of forming an aerodynamic component for use in a gas turbine engine using ceramic matrix composites (CMCs) is provided. The method includes executing a full densification of the CMCs once a final shape of the aerodynamic component is achieved, identifying first and second sectors of an exterior surfaces of the aerodynamic component which have a surface roughness of less than a first roughness level and identifying second sectors of the exterior surface of the component which have a surface roughness of greater than a second roughness level, machining the first sectors to increase the surface roughness to greater than the first roughness level and machining the second sectors to decrease the surface roughness to less than the second roughness level.

Abstract: A method of applying a top coat to an article according to an exemplary embodiment of this disclosure, among other possible things includes applying a first feedstock comprising particles of oxide-based material having diameters between about 1 and about 80 microns via a thermal spray process to form a first top coat layer on an article having a bond coat and applying a second feedstock comprising particles of oxide-based material having diameters between about 15 and about 60 microns via the thermal spray process to form a second top coat layer on the first top coat layer. An article and a barrier layer for an article are also disclosed.

Abstract: A tool for ultrasonic impact grinding apparatus driven to vibrate along a longitudinal axis at an applied operating frequency includes a tool body disposed on the longitudinal axis, a first tip extending from an output end of the tool body, and a second tip extending in parallel to the first tip from the output end of the tool body. The first tip has a first length. The second tip has a second length greater than the first length. A mass of the first and second tip is substantially balanced across the output end of the tool body and with respect to the longitudinal axis.

Abstract: A method of machining ceramic matrix composite components includes providing an ultrasonic vibration tool having a tool tip, and exciting the tool by providing a control current, such that the tool tip is repeatedly vibrated towards and away from a ceramic matrix composite workpiece. A slurry feed is supplied including abrasive particles to a surface to be machined by the tool tip. A vibration amplitude of the tool tip is controlled by sensing load on the tool and communicating with a computing device. The computing device controls the vibration amplitude of the tool tip. The computing device is provided with at least one memory programmed with historic data, and is operable to modify the vibration amplitude signal being sent to the tool, and comparing resulting load levels due to the change in vibration amplitude signals, and storing the change in vibration amplitude signals at the memory.

Abstract: A system for detecting an edge of a substrate, comprising a coated assembly. The coated assembly includes a conductive substrate having at least one edge portion and a dielectric coating coupled along the conductive substrate, the dielectric coating covering the at least one edge portion of the conductive substrate. The system also includes a conductive tool configured to interact with the coated assembly and a substrate sensing system. The substrate sensing system includes a power source coupled with the conductive tool, the coated assembly, and an electrical circuit including the power source and the coated assembly and a sensor configured to sense a change between an open configuration and a closed configuration of the electrical circuit. In an open configuration the conductive tool is engaged with the coated assembly and disengaged from the conductive substrate and in a closed configuration the conductive tool is engaged with the conductive substrate.

Abstract: A method of machining a workpiece includes receiving at least one input parameter from an ultrasonic impact grinding system having an ultrasonic vibration tool. The input parameter includes a material property of a workpiece and a tool parameter. A physics-based model is applied to the input parameter and an estimation is made of a vibration amplitude for a power level to be provided to the vibration tool and a particle size for abrasive particles to be used with the vibration tool. The power level is provided to an adaptive profile control for the tool.

Abstract: A method of machining a workpiece using an ultrasonic vibration tool to engage abrasive particles in a slurry includes capturing a power output from the ultrasonic vibration tool. The power output is related to a vibration amplitude of a tool tip of the ultrasonic vibration tool. A controller connected to an ultrasonic power supply receives the captured power output. The ultrasonic power supply supplies power to the ultrasonic vibration tool. The controller determines the captured power output when it has reached a specified level. A control signal from the controller to the ultrasonic power supply is used to modify the power to the ultrasonic vibration tool.

Abstract: A method of machining a feature in a workpiece includes orienting a waterjet guided laser device about the workpiece, ejecting a waterjet from a nozzle of the waterjet guided laser device, impinging the waterjet against the workpiece along a tool path causing a corresponding removal of material therefrom, and generating a non-uniform electric field proximate the waterjet to cause a deflection of the waterjet as the waterjet is impinging against the workpiece.

Abstract: An ultrasonic impact grinding assembly includes a base with a mount for connecting a workpiece to the base and a first tool arm. The ultrasonic impact grinding assembly also includes a second tool arm. The first tool arm and the second tool arm each include a base end, a distal end, at least one joint between the base end and the distal end, and at least one actuator configured to move the at least one joint. A first ultrasonic impact grinding tool head is connected to the distal end of the first tool arm. A second ultrasonic impact grinding tool head is connected to the distal end of the second tool arm.

Abstract: A tool for an ultrasonic impact grinding machine driven to vibrate along a longitudinal axis includes a hollow tool body and a hollow tip extending from an end of the hollow tool body. The hollow tip has an outer surface comprising a plurality of grooves. The hollow tool body and the hollow tip are disposed about the longitudinal axis and the hollow tip and hollow tool body are each defined in part by a common bore extending along the longitudinal axis.

Abstract: A tool for ultrasonic impact grinding apparatus driven to vibrate along a longitudinal axis at an applied operating frequency includes a tool body disposed on the longitudinal axis, a first tip extending from an output end of the tool body, and a second tip extending in parallel to the first tip from the output end of the tool body. The first tip has a first length. The second tip has a second length greater than the first length. A mass of the first and second tip is substantially balanced across the output end of the tool body and with respect to the longitudinal axis.

Abstract: A method of machining ceramic matrix composite components includes providing an ultrasonic vibration tool having a tool tip, and exciting the tool by providing a control current, such that the tool tip is repeatedly vibrated towards and away from a ceramic matrix composite workpiece. A slurry feed is supplied including abrasive particles to a surface to be machined by the tool tip. A vibration amplitude of the tool tip is controlled by sensing load on the tool and communicating with a computing device. The computing device controls the vibration amplitude of the tool tip. The computing device is provided with at least one memory programmed with historic data, and is operable to modify the vibration amplitude signal being sent to the tool, and comparing resulting load levels due to the change in vibration amplitude signals, and storing the change in vibration amplitude signals at the memory.

Abstract: A method of applying a top coat to an article according to an exemplary embodiment of this disclosure, among other possible things includes applying a first feedstock comprising particles of oxide-based material having diameters between about 1 and about 80 microns via a thermal spray process to form a first top coat layer on an article having a bond coat and applying a second feedstock comprising particles of oxide-based material having diameters between about 15 and about 60 microns via the thermal spray process to form a second top coat layer on the first top coat layer. An article and a barrier layer for an article are also disclosed.

Abstract: A process for coating a component includes applying a bond coat on a substrate of a component; applying a thermal barrier material to the bond coat; and applying a conforming reflective layer to the thermal barrier material, the conforming reflective layer conforming to porous microstructure of the ceramic coating.

Abstract: A method of forming an aerodynamic component for use in a gas turbine engine using ceramic matrix composites (CMCs) is provided. The method includes executing a full densification of the CMCs once a final shape of the aerodynamic component is achieved, identifying first and second sectors of an exterior surfaces of the aerodynamic component which have a surface roughness of less than a first roughness level and identifying second sectors of the exterior surface of the component which have a surface roughness of greater than a second roughness level, machining the first sectors to increase the surface roughness to greater than the first roughness level and machining the second sectors to decrease the surface roughness to less than the second roughness level.

Abstract: A method of forming a component for a gas turbine engine using ceramic matrix composites (CMCs) is provided. The method includes preforming the aerodynamic component into an initial desired shape using the CMCs, executing partial densification of the CMCs, repeating the preforming operations and the executing of the partial densification until a final desired shape of the aerodynamic component is achieved, machining or cutting the CMCs during one or more of the preforming operations and the executing of the partial densification to remove defects from the CMCs and executing a full densification of the CMCs.

Abstract: A method of forming an aerodynamic component for use in a gas turbine engine using ceramic matrix composites (CMCs) is provided. The method includes executing a full densification of the CMCs once a final shape of the aerodynamic component is achieved, identifying first and second sectors of an exterior surfaces of the aerodynamic component which have a surface roughness of less than a first roughness level and identifying second sectors of the exterior surface of the component which have a surface roughness of greater than a second roughness level, machining the first sectors to increase the surface roughness to greater than the first roughness level and machining the second sectors to decrease the surface roughness to less than the second roughness level.

Abstract: A refractory metal core (RMC) finishing method according to an exemplary aspect of the present disclosure includes, among other things, performing a plurality of finishing operations on a plurality of RMC samples, analyzing one or more properties of at least a portion of the plurality of RMC samples and selecting a combination of finishing operations for generating an RMC having desirable properties for manufacturing a part free from defects.