Abstract: Aspects of the disclosure are directed to processing a component. A first coating is removed from a substrate of the component, the substrate including a first hole. Subsequent to removing the first coating from the substrate, a second coating is applied to the substrate, where a portion of the second coating at least partially blocks the first hole. Subsequent to applying the second coating to the substrate, the portion of the second coating is removed to generate a second hole through the second coating. The removal of the portion of the second coating creates a bore in the second coating that provides a clearance from an edge of the first hole on a surface of the substrate that interfaces to the second coating.

Abstract: A coolant distributor comprising a head having a plurality of ports, each of the ports being fluidly coupled to a flow control valve. A cap is demountably coupled to the head. The cap comprises at least one fixed nozzle fluidly coupled to at least one port. A controller is coupled to the flow control valve, wherein the controller is configured to actuate the flow control valve to pass a cooling fluid through the at least one fixed nozzle to direct the cooling fluid to at least one predetermined cutting region of a machine tool and work piece proximate the coolant distributor.

Abstract: A coolant distributor comprising a head having a plurality of ports, each of the ports being fluidly coupled to a flow control valve. A cap is demountably coupled to the head. The cap comprises at least one fixed nozzle fluidly coupled to at least one port. A controller is coupled to the flow control valve, wherein the controller is configured to actuate the flow control valve to pass a cooling fluid through the at least one fixed nozzle to direct the cooling fluid to at least one predetermined cutting region of a machine tool and work piece proximate the coolant distributor.

Abstract: A method is provided for inspecting at least one aperture of a component with curable material and an inspection system. At least a portion of the curable material is injected into the aperture. The curable material conforms to at least a portion the aperture and subsequently cures and forms a mold of at least a portion of the aperture. The mold is removed from the aperture. At least a portion of a geometry of the mold is compared to at least a portion of a geometry of a reference model for the aperture using the inspection system.

Abstract: Aspects of the disclosure are directed to processing a component. A first coating is removed from a substrate of the component, the substrate including a first hole. Subsequent to removing the first coating from the substrate, a second coating is applied to the substrate, where a portion of the second coating at least partially blocks the first hole. Subsequent to applying the second coating to the substrate, the portion of the second coating is removed to generate a second hole through the second coating. The removal of the portion of the second coating creates a bore in the second coating that provides a clearance from an edge of the first hole on a surface of the substrate that interfaces to the second coating.

Abstract: Systems and methods are disclosed herein for adding surface features to grinding wheels. A laser may be directed substantially perpendicular to a grinding surface of a grinding wheel. The laser may be pulsed and may ablate material from the grinding surface. The laser may move relative to the grinding wheel in order to ablate shaped surface features into the grinding surface.

Abstract: A method is provided for manufacturing a component using a body comprising metal. This method includes: cooling the body to provide at least a cooled region of the body; and machining the cooled region using a tool that contacts the cooled region.

Abstract: Systems and methods are disclosed herein for dressing and trueing grinding wheels. A laser may be directed substantially tangential to a grinding surface of a grinding wheel. The laser may be a continuous wave laser and may ablate material from the grinding surface. The laser may move relative to the grinding wheel in order to ablate shaped surface profiles into the grinding surface.

Abstract: A method is provided for inspecting at least one aperture of a component with curable material and an inspection system. At least a portion of the curable material is injected into the aperture. The curable material conforms to at least a portion the aperture and subsequently cures and forms a mold of at least a portion of the aperture. The mold is removed from the aperture. At least a portion of a geometry of the mold is compared to at least a portion of a geometry of a reference model for the aperture using the inspection system.

Abstract: Systems and methods are disclosed herein for dressing and trueing grinding wheels. A laser may be directed substantially tangential to a grinding surface of a grinding wheel. The laser may be a continuous wave laser and may ablate material from the grinding surface. The laser may move relative to the grinding wheel in order to ablate shaped surface profiles into the grinding surface.

Abstract: Systems and methods are disclosed herein for adding surface features to grinding wheels. A laser may be directed substantially perpendicular to a grinding surface of a grinding wheel. The laser may be pulsed and may ablate material from the grinding surface.

Abstract: Disclosed are various embodiments of an EDM electrode dressing template comprising a body made of an electrically conductive material. Bonded to the body is a pad with an electrically conductive material with hardness greater than the body. An electrode with an eroded end is positioned proximate the pad and a DC current pulses between the eroded end and the pad. After a period of time, the eroded end is shaped into a dressed tip. Since the pad is less susceptible to spark erosion than the body, the electrode is more consistently dressed and the template is replaced less frequently.

Abstract: A fixture for disposing laser blocking material on the interior of an airfoil is disclosed. Various construction details are developed which allow for the repetitive disposition of the laser blocking material in one airfoil after another. In one embodiment, the fixture includes a tool member and a nozzle adaptor for providing a sealing surface to a nozzle which extends into the tool member.

Abstract: A fixture for disposing laser blocking material on the interior of an airfoil is disclosed. Various construction details are developed which allow for the repetitive disposition of the laser blocking material in one airfoil after another. In one embodiment, the fixture includes a tool member and a nozzle adaptor for providing a sealing surface to a nozzle which extends into the tool member.

Abstract: A method for disposing laser blocking material 52 on the interior of an airfoil 10, such as a rotor blade or stator vane, includes shear thinning the material. Various steps are developed which promote decreases in viscosity of the blocking material. In one detailed embodiment, the material is passed through an injection molding machine 54 to provide shear thinning.

Abstract: A tool 12 for disposing laser blocking material 52 on the interior of an airfoil 10 is disclosed. Various construction details are developed which speed the process. In one detailed embodiment, the tool has reciprocatable jaws 92, 94 which open and close to urge a mask 78 into engagement with the airfoil.

Abstract: A method for orienting an airfoil 10 during filling of an airfoil with laser blocking material 52 prior to a laser machining operation is provide and includes making a mask 78 for the airfoil.

Abstract: A fixture 56 for disposing laser blocking material 52 on the interior of an airfoil 10 is disclosed. Various construction details are developed which allow for the repetitive disposition of the laser blocking material in one airfoil after another. In one embodiment, the fixture includes a sprue plate 62 and locating block 126 which are spanwisely spaced and engage the ends 14, 18 of the airfoil.

Abstract: Blade attachment slots for gas turbine engines are prepared by grinding to a stepped, generally straight sided configuration, semi-finish grinding to an envelope about 0.005 inches to 0.010 inches above the blueprint configuration, and finishing by broaching. This reduces the overall cost of the manufacturing process, permits a more economical use of existing broach machines, and allows greater versatility for short model runs and "just-in-time" production.

Abstract: A method for removing a predetermined amount of material from the inner surface of a circular article which deviates from a true circular configuration. The outer surface of the article is touch probed to determine its true location in space, and the data are stored in a computer memory. These data are then compared to engineering design data to establish the location of the surface to which material removal is desired. A control computer compares the measured data with the design data, and sends commands to the machine control system, causing the machine to remove the excess material down to the desired dimension. Any deviations from circular are compensated for by moving the article radially relative to the cutting tool as the article moves circumferentially relative to the cutting tool.