Abstract: A method for calibrating a machining system includes providing the machining system which includes a base, a cantilevered arm, and a rotary table positioned at the second arm end of the cantilevered arm. The rotary table is rotatable relative to the cantilevered arm about a first axis. The first axis has a first unloaded position and a first unloaded orientation with the machining system in an unloaded condition. The method further includes installing a measurement artifact on the rotary table, measuring a first position of the measurement artifact, and installing a load on the rotary table. The first axis has a first loaded position and a first loaded orientation with the machining system in a loaded condition. The method further includes measuring a second position of the measurement artifact and determining a positional deviation of the second position from the first position.

Abstract: A tool for validating a wire-electric-discharge-machining (wEDM) operation to be performed using a wEDM machine comprises a body including an engagement feature shaped to removably hold a validation coupon to be machined in the wEDM operation, the validation coupon sized larger than a size of a cut-out to be made in a part using the wEDM machine. A method of manufacturing the tool and a wEDM machine assembly are also provided.

Abstract: A method of wire electric discharge machining (wEDM) a feature in a part includes using wEDM, cutting and detaching a slug from a portion of the part that is to be detached from the part to define the feature, and thereby defining a validation cut-out in the portion, and using wEDM, cutting and detaching the portion having the validation cut-out from the part and thereby defining the feature.

Abstract: Methods and systems for wire-electro discharge machining of components are described. The method comprises machining a first component by moving a wire-EDM electrode along a first set of cutting paths associated with a plurality of cutting passes, the cutting paths determined based on a desired profile shape of the component, obtaining a cutting parameter of the first component post-machining, determining a first modified cutting path for a second component based on the cutting parameter, and machining the second component by moving the wire-EDM electrode along a second set of cutting paths associated with the plurality of cutting passes, the second set of cutting paths comprising the first modified cutting path.

Abstract: Methods of repairing a part having a firtree-shaped feature requiring rework are disclosed. An embodiment of the method includes receiving the part having the firtree-shaped feature requiring rework. The part is installed in a machine configured for wire electrical discharge machining (EDM). A location of the firtree-shaped feature relative to a datum of the machine is then determined. Wire EDM is performed on the firtree-shaped feature.

Abstract: A method of wire-electric-discharge-machining (wEDM) a feature in a part includes using wEDM, cutting and detaching a slug from a portion of the part that is to be detached from the part to define the feature, and thereby defining a validation cut-out in the portion, and using wEDM, cutting and detaching the portion having the validation cut-out from the part and thereby defining the feature.

Abstract: A tool for validating a wire-electric-discharge-machining (wEDM) operation to be performed using a wEDM machine comprises a body including an engagement feature shaped to removably hold a validation coupon to be machined in the wEDM operation, the validation coupon sized larger than a size of a cut-out to be made in a part using the wEDM machine. A method of manufacturing the tool and a wEDM machine assembly are also provided.

Abstract: Methods of repairing a part having a firtree-shaped feature requiring rework are disclosed. An embodiment of the method includes receiving the part having the firtree-shaped feature requiring rework. The part is installed in a machine configured for wire electrical discharge machining (EDM). A location of the firtree-shaped feature relative to a datum of the machine is then determined. Wire EDM is performed on the firtree-shaped feature.

Abstract: Methods and systems for wire-electro discharge machining of components are described. The method comprises machining a first component by moving a wire-EDM electrode along a first set of cutting paths associated with a plurality of cutting passes, the cutting paths determined based on a desired profile shape of the component, obtaining a cutting parameter of the first component post-machining, determining a first modified cutting path for a second component based on the cutting parameter, and machining the second component by moving the wire-EDM electrode along a second set of cutting paths associated with the plurality of cutting passes, the second set of cutting paths comprising the first modified cutting path.

Abstract: A method for providing a hole through a metal engine component having a base metal and thermal barrier coating layer forming a top surface of the component, the hole having a central axis extending at a hole angle of 20 degrees or less with respect to the top surface. The method includes laser trepanning through the thermal barrier coating layer without penetrating the base metal by moving a central axis of a pulse laser beam within a boundary of the hole, with the pulse laser beam having a first pulse energy level. The central axis of the pulse laser beam is then disposed within the boundary at the hole angle and shots of the pulse laser beam are applied to drill through the base metal and complete the hole, using a second pulse energy level different from the first pulse energy level.

Abstract: A method for drilling a shallow-angled hole through a thermal barrier coated component includes a step of applying a pulse laser beam to drill a section of the hole substantially within a thermal barrier coating of the component in a direction substantially perpendicular to a top surface of the component. A further step is conducted to apply the pulse laser beam to further drill through a base metal of the component to complete the formation of the hole extending through the component.

Abstract: A method for providing a shallow-angled hole through a thermal barrier coated component in accordance with one aspect thereof, includes a step of applying a pulse laser beam to pre-drill the hole through a base metal of the component. A thermal barrier coating is then applied to the base metal, covering the pre-drilled hole in the base metal. A further step is conducted to apply the pulse laser beam through the thermal barrier coating a location to coincide with pre-drilled hole in the base metal in order to complete the formation of the hole extending through the component.

Abstract: A method for drilling a shallow-angled hole through a thermal barrier coated component, in accordance with one aspect thereof, includes a step of applying a pulse laser beam with a first setting to drill a section of the hole substantially within a thermal barrier coating of the component. A further step is conducted to apply the pulse laser beam with a second setting through the initiated hole to further drill through a remainder of the component to complete the formation of the hole extending through the component.

Abstract: A method for drilling a shallow-angled hole through a thermal barrier coated component, in accordance with one aspect thereof, includes a step of applying a pulse laser beam with a first setting to drill a section of the hole substantially within a thermal barrier coating of the component. A further step is conducted to apply the pulse laser beam with a second setting through the initiated hole to further drill through a remainder of the component to complete the formation of the hole extending through the component.

Abstract: A method for drilling a shallow-angled hole through a thermal barrier coated component includes a step of applying a pulse laser beam to drill a section of the hole substantially within a thermal barrier coating of the component in a direction substantially perpendicular to a top surface of the component. A further step is conducted to apply the pulse laser beam to further drill through a base metal of the component to complete the formation of the hole extending through the component.

Abstract: A method for providing a shallow-angled hole through a thermal barrier coated component in accordance with one aspect thereof, includes a step of applying a pulse laser beam to pre-drill the hole through a base metal of the component. A thermal barrier coating is then applied to the base metal, covering the pre-drilled hole in the base metal. A further step is conducted to apply the pulse laser beam through the thermal barrier coating a location to coincide with pre-drilled hole in the base metal in order to complete the formation of the hole extending through the component.

Abstract: A method for providing a shallow-angled hole through a metal component, such as a turbine combustor, includes a step of applying a pulse laser beam to drill a section of the hole substantially within a thermal barrier coating of the component in a trepanning concept. A further step is conducted to apply the pulse laser beam through the completed section of the hole to further drill through a base metal of the component to complete the formation of the hole extending through the component.