Abstract: A method for smoothing surface roughness within an internal passageway is disclosed. In various embodiments, the method comprises developing a first sphere progression through a length of the internal passageway, each sphere within the first sphere progression having a first sphere diameter greater than or equal to a diameter of the internal passageway; and developing a second sphere progression through the length of the internal passageway, each sphere within the second sphere progression having a second sphere diameter greater than the first sphere diameter, whereby the inner surface of the internal passageway is smoothed, first by the first sphere progression and then by the second sphere progression.

Abstract: A method for stripping ceramic from a component includes applying a liquid to a ceramic coating of an outer surface of the component. The method also includes directing a plurality of laser pulses at the ceramic coating with the applied liquid in order to spall the ceramic coating from the component.

Abstract: A method for smoothing surface roughness within an internal passageway is disclosed. In various embodiments, the method comprises developing a first sphere progression through a length of the internal passageway, each sphere within the first sphere progression having a first sphere diameter greater than or equal to a diameter of the internal passageway; and developing a second sphere progression through the length of the internal passageway, each sphere within the second sphere progression having a second sphere diameter greater than the first sphere diameter, whereby the inner surface of the internal passageway is smoothed, first by the first sphere progression and then by the second sphere progression.

Abstract: A method for treating a surface of a contoured titanium substrate used for adhesively bonded engine components. The method including applying energy from a fiber laser system to a contoured surface of a titanium substrate, the laser energy is distributed to the contoured titanium surface by at least one of direct light of sight, reflection, or scattering of one or more laser beam.

Abstract: A method for stripping ceramic from a component includes applying a liquid to a ceramic coating of an outer surface of the component. The method also includes directing a plurality of laser pulses at the ceramic coating with the applied liquid in order to spall the ceramic coating from the component.

Abstract: A process for forming a thermal barrier coating on a part comprising depositing an aluminum containing bond coat on the part, the bond coat comprising a surface; cleaning the surface to remove oxides and debris from the surface of the bond coat; forming a gamma phase layer proximate the surface of the bond coat; forming an aluminum oxide layer on the surface of the bond coat; and depositing a ceramic topcoat on the aluminum oxide layer on the bond coat.

Abstract: A method for stripping ceramic from a component includes applying a liquid to a ceramic coating of an outer surface of the component. The method also includes directing a plurality of laser pulses at the ceramic coating with the applied liquid in order to spall the ceramic coating from the component.

Abstract: An insert apparatus for protecting a curved inner surface within a passageway from abrasion during an abrasive machining operation is disclosed. In various embodiments, the insert apparatus includes a shield having a shell shaped to match a curved portion of the curved inner surface of the passageway and a shaft having a first end connected to the shell and a second end connected to a member configured to maintain the shaft within the passageway and the shell positioned against the curved inner surface during the abrasive machining operation.

Abstract: An insert apparatus for protecting a curved inner surface within a passageway from abrasion during an abrasive machining operation is disclosed. In various embodiments, the insert apparatus includes a shield having a shell shaped to match a curved portion of the curved inner surface of the passageway and a shaft having a first end connected to the shell and a second end connected to a member configured to maintain the shaft within the passageway and the shell positioned against the curved inner surface during the abrasive machining operation.

Abstract: An apparatus for finishing a component includes at least one articulating arm, at least one plasma gun disposed at an end of a first articulating arm of the at least one articulating arm, at least one shot peen nozzle maintained in a fixed positioned relative to the plasma gun, and a controller controllably coupled to the articulating arm such that output signals from the controller control motions of the articulating arm.

Abstract: A method for smoothing surface roughness within an internal passageway is disclosed. In various embodiments, the method comprises developing a first sphere progression through a length of the internal passageway, each sphere within the first sphere progression having a first sphere diameter greater than or equal to a diameter of the internal passageway; and developing a second sphere progression through the length of the internal passageway, each sphere within the second sphere progression having a second sphere diameter greater than the first sphere diameter, whereby the inner surface of the internal passageway is smoothed, first by the first sphere progression and then by the second sphere progression.

Abstract: A method for smoothing surface roughness within an internal passageway is disclosed. In various embodiments, the method comprises developing a first sphere progression through a length of the internal passageway, each sphere within the first sphere progression having a first sphere diameter greater than or equal to a diameter of the internal passageway; and developing a second sphere progression through the length of the internal passageway, each sphere within the second sphere progression having a second sphere diameter greater than the first sphere diameter, whereby the inner surface of the internal passageway is smoothed, first by the first sphere progression and then by the second sphere progression.

Abstract: The present disclosure relates generally to a system and method for applying a metallic coating. A first metallic coating may be applied to a portion of a total surface of a part and a second metallic coating may be applied to substantially the total surface. The metallic coating may be applied to a vane cluster for use in a turbomachine.

Abstract: A method for forming a hollow component includes injecting a fluid into an internal cavity of the hollow component to achieve a pressure of the fluid within the internal cavity that is greater than an ambient pressure. The method further includes drilling at least one hole through the hollow component from an external surface of the hollow component to the internal cavity by applying a laser beam to the hollow component with a laser generator. The method further includes directing the fluid from the internal cavity and through the at least one hole so as to exit the hollow component via the at least one hole.

Abstract: A process of forming a shaped cooling passage in an article comprising positioning the article within a laser drilling apparatus; laser ablating a near net-shaped cooling passage having a meter section and a diffuser section; forming a re-recast on an interior wall of said cooling passage in both the meter section and the diffuser section; positioning the article within an electric discharge machining apparatus; and electric discharge machining said re-cast from said interior wall at both the meter section and diffusor section with the same electric discharge machine electrode to form a finished shaped cooling passage.

Abstract: An apparatus for finishing a component includes at least one articulating arm, at least one plasma gun disposed at an end of a first articulating arm of the at least one articulating arm, at least one shot peen nozzle maintained in a fixed positioned relative to the plasma gun, and a controller controllably coupled to the articulating arm such that output signals from the controller control motions of the articulating arm.

Abstract: An apparatus for finishing a component includes at least one articulating arm, at least one plasma gun disposed at an end of a first articulating arm of the at least one articulating arm, at least one shot peen nozzle maintained in a fixed positioned relative to the plasma gun, and a controller controllably coupled to the articulating arm such that output signals from the controller control motions of the articulating arm.

Abstract: An apparatus for finishing a component includes at least one articulating arm having a shot peening apparatus and at least one laser source. A plurality of laser redirectors are configured to redirect a laser originating from the laser source. Each laser redirector in the plurality of laser redirectors is mounted to a first rail and a second rail. A controller is controllably coupled to the articulating arm and each of the rails such that output signals from the controller control a position of the articulating arm, and a position of each laser redirector in the plurality of laser redirectors.

Abstract: A method for treating a substrate prior to metallic coating includes the steps of providing a substrate having a surface to be coated and at least one contaminant selected from as-delivered organics and post-burn out oxides on the surface; treating the surface with a laser to remove the at least one contaminant to produce a cleaned surface on the substrate; and applying a metallic coating to the cleaned surface. Grit blasting can be avoided, and reverse arc transfer cleaning is avoided or minimized, resulting in time savings and less stress on the substrate.

Abstract: A plasma spray system including a turntable subsystem operable to position a multiple of work pieces on a respective multiple of workpiece mounts; a plasma spray subsystem operable to plasma spray the multiple of work pieces on said turntable subsystem; and an overspray wash subsystem operable to wash the multiple of work pieces on said turntable subsystem subsequent to plasma spray of the multiple of work pieces.