Abstract: A method of removing features from a cast workpiece includes generating a nominal toolpath for machining the cast workpiece. The cast workpiece is mounted onto a platform of a computer numeric control machine. The cast workpiece is inspected with a probe to generate probe data. Features to be removed are identified based upon the probe data generated during the inspection. Any expected features of the cast workpiece that are missing from the cast workpiece are identified. A transformation matrix is applied to the nominal toolpath with a controller of the computer numeric control machine, wherein the transformation matrix is based upon the probe data. Alignment of the cast workpiece is adjusted relative to the computer numeric control machine based on the transformation matrix with the computer numeric control machine. Features are removed from the cast workpiece that were identified during inspection.

Abstract: An airfoil for a gas turbine engine includes a substrate portion extending from an airfoil leading edge to an airfoil trailing edge portion. The airfoil trailing edge portion includes a flared portion wherein a substrate portion thickness increases along a camber line of the airfoil, and a trailing edge defined as a full constant radius extending from a pressure side of the airfoil to a suction side of the airfoil. A coating portion includes a coating applied over at least a portion of the substrate portion.

Abstract: A system for automated adaptive manufacturing of airfoil castings is disclosed. The system may receive a three dimensional scan of a work piece. The system may compare the three dimensional scan to a digital model of the work piece. The system may identify an area of dimensional abnormality on the work piece based on the comparison. The system may alter the area of dimensional abnormality on the work piece.

Abstract: A method of manufacturing an airfoil. The method includes fixing the airfoil in a workpiece space, detecting a position of the airfoil in the workpiece space using a force-sensing element, and removing material from the airfoil to reduce a dimension of the airfoil. In various embodiments, detecting the position of the airfoil includes moving the force-sensing element across a surface of the airfoil. For example, the surface of the airfoil may be a first surface, wherein removing material from the airfoil to reduce the dimension of the airfoil comprises removing material from a second surface of the airfoil opposite the first surface. Removing material from the second surface of the airfoil may be performed without moving the force-sensing element across the second surface of the airfoil.

Abstract: A finishing apparatus including a central control machine having a computerized controller, at least one articulating device controlled by the central control machine and operable to move the machining tool, and at least one of a touch sensor apparatus and a visual sensor apparatus mounted to said machining tool and communicatively coupled to the computerized controller. The computerized controller configured to cause the finishing apparatus to position a machining element in contact with an exterior surface of a film cooled article, move the machining element along the exterior surface while maintaining contact between the machining element and the surface, identify an actual position of a film opening based on sensory feedback while maintaining contact between the machining element and the surface, and remove material from the exterior surface at the film opening using said machining element.

Abstract: A blade outer air seal for a turbomachine includes a base portion configured to attach to a turbomachine housing, a thermal coating disposed on the base portion, and at least one groove defined in an external surface of the thermal coating. The groove can be machined. A method of manufacturing a blade outer air seal includes disposing a thermal coating on a base portion, and machining at least one groove into the thermal coating. The method can also include using an automated force sensing and vision sensing equipped robotic system.

Abstract: A method of polishing an outer surface of a ceramic coated gas turbine engine component includes applying a rotating diamond brush to the outer surface. The brush is configured to achieve a uniform finish of 150 microinches Ra or less over the surface. The brush contains diamond impregnated bristles, and is affixed to a rotary head of a robotic arm. A force sensing controller limits brush forces against the component. The component disclosed is a hot section turbine vane designed for directional control of high temperature, high-pressure combustion gases, but the method may be applied to other components contained within such aerospace applications. The polished coating provides an improved thermal barrier for maintaining structural integrity of the component in environments having temperatures ranging up to 2,000 degrees Celsius. The method limits abrasive removal of ceramic material to only 0.0005 to 0.00075 inch, and saves time and expense over past practices.

Abstract: A method for finishing a film cooled article includes providing a film cooled article including at least one inner cooling plenum and at least one opening connecting the inner cooling plenum to an exterior surface of the film cooled article, positioning a machining element in contact with the exterior surface of the film cooled article, automatically moving the machining element along the exterior surface while maintaining contact between the machining tool and the surface, identifying an actual position of at least one film opening based on sensory feedback from the machining element using a controller, removing material from the exterior surface at the at least one film opening using the machining element, thereby creating a depression at the at least one film opening.

Abstract: A method for finishing a film cooled article includes providing a film cooled article including at least one inner cooling plenum and at least one opening connecting the inner cooling plenum to an exterior surface of the film cooled article, positioning a machining element in contact with the exterior surface of the film cooled article, automatically moving the machining element along the exterior surface while maintaining contact between the machining tool and the surface, identifying an actual position of at least one film opening based on sensory feedback from the machining element using a controller, removing material from the exterior surface at the at least one film opening using the machining element, thereby creating a depression at the at least one film opening.

Abstract: A method of manufacturing an airfoil. The method includes fixing the airfoil in a workpiece space, detecting a position of the airfoil in the workpiece space using a force-sensing element, and removing material from the airfoil to reduce a dimension of the airfoil. In various embodiments, detecting the position of the airfoil includes moving the force-sensing element across a surface of the airfoil. For example, the surface of the airfoil may be a first surface, wherein removing material from the airfoil to reduce the dimension of the airfoil comprises removing material from a second surface of the airfoil opposite the first surface. Removing material from the second surface of the airfoil may be performed without moving the force-sensing element across the second surface of the airfoil.

Abstract: A method for drilling holes in a part includes positioning the part relative to a laser source, applying a first stress to the part, and applying a laser from the laser source to the part to drill a hole therein, wherein the first stress which is present during the application of the laser counteracts a second stress induced by the application of the laser.

Abstract: A coated article, comprising an article having at least one surface having disposed thereupon an oxidation resistant coating comprising at least two constituents to form a composition, a first constituent comprising at least one thermal expansion component comprising at least about 10% by volume to up to about 99% by volume of the composition, a second constituent comprising at least one oxygen scavenger comprising at least about 1% by volume to up to about 90% by volume of the composition.

Abstract: A method for applying anti-gallant coating to metal parts utilizes an ultrasonic sprayer driven by a precise manipulation device such as a robotic arm for high efficiency and precision. The method does not require masking adjacent or nearby metal parts, decreases time and money spent applying the anti-gallant coating, and is environmentally friendly.

Abstract: An abrasive profiling tool that may be part of a robotic machining system for machining a trailing edge of an airfoil, includes a shank extending along a rotational axis, a bearing guide rotationally secured to a distal end of the shank for riding upon the airfoil; and an abrasive profiler projecting radially and rigidly outward from the shank for grinding at least the trailing edge as the shank rotates. The profiler may include a round-over portion for grinding the trailing edge and a chamfered blending portion for grinding adjacent surfaces of the airfoil to produce a smooth transition from the adjacent surfaces and to the trailing edge.

Abstract: A modified organic matrix composite having a thermal barrier coating comprising a substrate comprising an organic matrix composite; a roughness layer coupled to the substrate; a bonding layer coupled to the roughness layer opposite the substrate; and a thermal barrier coating coupled to the bonding layer opposite the roughness layer.

Abstract: A method of polishing an outer surface of a ceramic coated gas turbine engine component includes applying a rotating diamond brush to the outer surface. The brush is configured to achieve a uniform finish of 150 microinches RA or less over the surface. The brush contains diamond impregnated bristles, and is affixed to a rotary head of a robotic arm. A force sensing controller limits brush forces against the component. The component disclosed is a hot section turbine vane designed for directional control of high temperature, high-pressure combustion gases, but the method may be applied to other components utilized in similar aerospace applications. The polished coating provides an improved thermal barrier for maintaining structural integrity of the component in environments having temperatures ranging up to 2,000 degrees Celsius. The method limits abrasive removal of ceramic material to only 0.0005 to 0.00075 inch, and saves time and expense over past practices.

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.

Abstract: A method for finishing a film cooled article includes providing a film cooled article including at least one inner cooling plenum and at least one opening connecting the inner cooling plenum to an exterior surface of the film cooled article, positioning a machining element in contact with the exterior surface of the film cooled article, automatically moving the machining element along the exterior surface while maintaining contact between the machining tool and the surface, identifying an actual position of at least one film opening based on sensory feedback from the machining element using a controller, removing material from the exterior surface at the at least one film opening using the machining element, thereby creating a depression at the at least one film opening.

Abstract: An abrasive profiling tool that may be part of a robotic machining system for machining a trailing edge of an airfoil, includes a shank extending along a rotational axis, a bearing guide rotationally secured to a distal end of the shank for riding upon the airfoil; and an abrasive profiler projecting radially and rigidly outward from the shank for grinding at least the trailing edge as the shank rotates. The profiler may include a round-over portion for grinding the trailing edge and a chamfered blending portion for grinding adjacent surfaces of the airfoil to produce a smooth transition from the adjacent surfaces and to the trailing edge.

Abstract: A blade outer air seal for a turbomachine includes a base portion configured to attach to a turbomachine housing, a thermal coating disposed on the base portion, and at least one groove defined in an external surface of the thermal coating. The groove can be machined. A method of manufacturing a blade outer air seal includes disposing a thermal coating on a base portion, and machining at least one groove into the thermal coating. The method can also include using an automated force sensing and vision sensing equipped robotic system.