Abstract: An additive manufactured workpiece includes one or more cavities having an inner surface. A dielectric interface is formed in the cavity, and conforms to the inner surface. The additive manufactured workpiece further includes an in-situ electrode in the cavities. The dielectric interface is interposed between the in-situ electrode and the inner surface of the workpiece.

Abstract: An abrasive coating for a substrate comprises a strike layer is formed on a substrate top surface; a base layer is coupled to the strike layer; a tack layer is coupled to the base layer, wherein the tack layer is configured to adhere first grit particles to the base layer; a plurality of first grit particles are adapted to be coupled to the tack layer, a plurality of second grit particles are placed between each of the plurality of first grit particles, the second grit particles having a nominal size smaller than the first grit particles; and an overplate layer comprising a matrix material is bonded to the tack layer; the matrix material envelops the second grit particles and bonds and partially surrounds the first grit particles, wherein the first grit particles extend above the overplate layer.

Abstract: An additive manufactured workpiece includes one or more cavities having an inner surface. A dielectric interface is formed in the cavity, and conforms to the inner surface. The additive manufactured workpiece further includes an in-situ electrode in the cavities. The dielectric interface is interposed between the in-situ electrode and the inner surface of the workpiece.

Abstract: An additive manufactured workpiece includes one or more cavities having an inner surface. A dielectric interface is formed in the cavity, and conforms to the inner surface. The additive manufactured workpiece further includes an in-situ electrode in the cavities. The dielectric interface is interposed between the in-situ electrode and the inner surface of the workpiece.

Abstract: An abrasive coating for a substrate comprises a strike layer is formed on a substrate top surface; a base layer is coupled to the strike layer; a tack layer is coupled to the base layer, wherein the tack layer is configured to adhere first grit particles to the base layer; a plurality of first grit particles are adapted to be coupled to the tack layer, a plurality of second grit particles are placed between each of the plurality of first grit particles, the second grit particles having a nominal size smaller than the first grit particles; and an overplate layer comprising a matrix material is bonded to the tack layer; the matrix material envelops the second grit particles and bonds and partially surrounds the first grit particles, wherein the first grit particles extend above the overplate layer.

Abstract: Manufacturing methods are disclosed that can electropolish a metal surface by disposing an electrode over the metal surface, and a permeable dielectric spacer between the metal surface and the electrode. An electrolyte is infiltrated into the permeable dielectric spacer, and an electrical voltage differential is applied to the electrode and the metal surface.

Abstract: An additive manufactured workpiece includes one or more cavities having an inner surface. A dielectric interface is formed in the cavity, and conforms to the inner surface. The additive manufactured workpiece further includes an in-situ electrode in the cavities. The dielectric interface is interposed between the in-situ electrode and the inner surface of the workpiece.

Abstract: A composite component and a plated polymer component are disclosed. The composite component may comprise a body portion formed from an organic matrix composite, a first metal coating applied to a surface of the body portion, and an outer metal layer on the first metal coating that is erosion-resistant. The plated polymer component may comprise a polymer substrate, a metal plating layer applied to a surface of the polymer substrate, and at least one selectively thickened region in the metal plating layer. The at least one selectively thickened region may assist in protecting the plated polymer component against wear and/or erosion.

Abstract: A method for reducing surface roughness of a component according to an example of the present disclosure includes forming a layer of reactive material on a surface of a component, the surface of the component having at least one partially attached particle, whereby the reactive material substantially covers the at least one partially attached particle, and dissolving the reactive material, wherein dissolving the reactive material covering the partially attached particles causes the partially attached particles to break free from the surface of the component, leaving a new smooth surface.

Abstract: Manufacturing methods are disclosed that can electropolish a metal surface by disposing an electrode over the metal surface, and a permeable dielectric spacer between the metal surface and the electrode. An electrolyte is infiltrated into the permeable dielectric spacer, and an electrical voltage differential is applied to the electrode and the metal surface.

Abstract: A method for balancing a rotatable component is disclosed This method comprises and then plating the component to deposit a metal layer onto the component until the component is balanced. In addition, and alternative method for balancing a rotatable component is disclosed. This method comprises attaching a balancing weight to the rotatable component and rotating the component. This is followed by plating the component and the balancing weight to deposit a metal layer onto the balancing weight and the component until the component is balanced.

Abstract: An abrasive coating for a substrate comprises a strike layer is formed on a substrate top surface; a base layer is coupled to the strike layer; a tack layer is coupled to the base layer, wherein the tack layer is configured to adhere first grit particles to the base layer; a plurality of first grit particles are adapted to be coupled to the tack layer, a plurality of second grit particles are placed between each of the plurality of first grit particles, the second grit particles having a nominal size smaller than the first grit particles; and an overplate layer comprising a matrix material is bonded to the tack layer; the matrix material envelops the second grit particles and bonds and partially surrounds the first grit particles, wherein the first grit particles extend above the overplate layer.

Abstract: A composite component and a plated polymer component are disclosed. The composite component may comprise a body portion formed from an organic matrix composite, a first metal coating applied to a surface of the body portion, and an outer metal layer on the first metal coating that is erosion-resistant. The plated polymer component may comprise a polymer substrate, a metal plating layer applied to a surface of the polymer substrate, and at least one selectively thickened region in the metal plating layer. The at least one selectively thickened region may assist in protecting the plated polymer component against wear and/or erosion.

Abstract: Plated polymeric gas turbine engine parts and methods for fabricating lightweight plated polymeric gas turbine engine parts are disclosed. The parts include a polymeric substrate plated with one or more metal layers. The polymeric material of the polymeric substrate may be structurally reinforced with materials that may include carbon, metal, or glass. The polymeric substrate may also include a plurality of layers to form a composite layup structure.

Abstract: A method for fabricating a ceramic component is disclosed. The method may comprise: 1) forming a polymer template having a shape that is an inverse of a shape of the ceramic component, 2) placing the polymer template in a mold; 3) injecting the polymer template with a ceramic slurry, 4) firing the ceramic slurry at a temperature to produce a green body, and 5) sintering the green body at an elevated temperature to provide the ceramic component.

Abstract: Methods for repairing plated metallic layers on plated polymeric parts are disclosed. First, a polymer is formed into an article of a desired shape or geometry. The outer surface of the article is prepared to receive a catalyst and then the outer surface is activated with the catalyst. A first metallic layer is then plated onto the outer surface to form a structure. Optional additional metallic layers may be applied. Then, a defect in a damaged metal layer is repaired by brush plating or brush electroplating.

Abstract: A method for balancing a rotatable component is disclosed This method comprises and then plating the component to deposit a metal layer onto the component until the component is balanced. In addition, and alternative method for balancing a rotatable component is disclosed. This method comprises attaching a balancing weight to the rotatable component and rotating the component. This is followed by plating the component and the balancing weight to deposit a metal layer onto the balancing weight and the component until the component is balanced.

Abstract: A disk made of a first material has a groove in which a blade made of a second material is retained. A strip is placed between the blade and the disk to minimize rubbing damage to the blade and the disk and an insulating material is place between the rub strip and the blade for minimizing damaging responses of the blade to galvanic forces created by rubbing of the first material and the second material.

Abstract: A non-destructive inspection method for detecting the presence of a contaminant that has alloyed with a metallic alloy of a part includes exposing the metallic alloy of the part to an extraction solution. The extraction solution extracts at least a portion of any of the contaminant that has alloyed with the metallic alloy. The extraction solution can then be analyzed to determine whether the solution includes any of the contaminant element, which indicates whether the part includes any of the contaminant element.

Abstract: In a method for coating a copper-containing aluminum alloy, the alloy is treated with a solution of at least one polyamino carboxylic acid ligand. A trivalent chromium coating is thereafter applied.