Abstract: A method for removing a metal layer comprising the steps of providing a part having a slot, providing a porous metallic cathode comprising a recess bounded by a wall having an outer surface corresponding to the slot, inserting the porous metallic cathode into the slot, introducing an electrolyte into the recess of the porous metallic cathode, and removing a portion of an inner surface of the slot by flowing an electric current between the part and the porous metallic cathode.

Abstract: A method for removing a metal layer comprising the steps of providing a part having a slot, providing a porous metallic cathode comprising a recess bounded by a wall having an outer surface corresponding to the slot, inserting the porous metallic cathode into the slot, introducing an electrolyte into the recess of the porous metallic cathode, and removing a portion of an inner surface of the slot by flowing an electric current between the part and the porous metallic cathode.

Abstract: A suspended abrasive waterjet narrow kerf cutting method is reconfigured to simultaneously drill multiple, closely-spaced holes in a target, including holes in confined non line-of-sight locations. Working fluid nozzles can be located on a flat or non-flat tool surface and arranged in uniform or non-uniform patterns, in an angled or perpendicular orientation, and in parallel or non-parallel arrangements. Individual nozzles or nozzle groups can be easily changed to provide increased or diminished working diameters, allowing control over the hole sizes and resultant airflow thru the drilled workpiece.

Abstract: A vane cluster for a turbine engine compressor or turbine includes a shroud 12 with a nonlinear slot 26 extending therethrough to divide the shroud into thermally independent shroud segments 24. The slot is bordered by matching nonlinear surfaces 28 that are easy and inexpensive to produce with conventional wire EDM equipment. The nonlinear profile of the slots effectively resists fluid leakage.

Abstract: A vane cluster for a turbine engine compressor or turbine includes a shroud 12 with a nonlinear slot 26 extending therethrough to divide the shroud into thermally independent shroud segments 24. The slot is bordered by matching nonlinear surfaces 28 that are easy and inexpensive to produce with conventional wire EDM equipment. The nonlinear profile of the slots effectively resists fluid leakage.

Abstract: Electrochemical machining of ceramic particulate and metal matrix surfaces, and of other uneven or discontinuous surfaces, is conducted using an electrode which has a porous metal working face. Relatively low electrolyte pressures of the order of 5 kPa and low flow rates of the order of 6 ml/s/cm.sup.2 of electrode surface are used. Preferably the electrode face is made of sintered powder. Facing the electrode upward and the workpiece surface downward enables machining of workpieces without unwanted flow of electrolyte onto areas away from the machined surface.

Abstract: A method for obtaining a hole in a workpiece essentially free of a recast layer and heat affected zone with laser radiation is disclosed. Pulses of laser radiation having durations comparable to the time required to vaporize workpiece material, typically less than ten nanoseconds, and power densities at the workpiece sufficient to produce vaporization, typically in excess of a billion watts per square centimeter, are interacted with a workpiece in an oxidizing environment to produce vaporization of workpiece material. The vapor reacts with the gas to produce a vapor oxide which does not adhere to the workpiece resulting in the absence of a recast laywer. A hole having a desired size and shape is obtained by interacting the pulses of radiation with the workpiece at a high rate of repetition, typically in excess of ten pulses per second, until a desired amount of material is removed. The pulse duration is less than the thermal reaction time of the material resulting in the absence of a heat affected zone.