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 of removing scale from a casting may include positioning the casting relative to a laser emitter. The casting may comprise a superalloy and the scale may have formed on the surfaces thereof, with the scale being a byproduct of a method of manufacturing the casting. The method may also include passing a laser beam emitted from the laser emitter across the casting such that the laser beam causes the scale to at least one of crack, break, shatter, and spall. The superalloy may be a nickel-based superalloy and the scale may include a metal carbide layer.

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 joined article includes a first metal piece with a first bonding surface, having one or more recessed areas, a second metal piece with a second bonding surface with the second bonding surface having one or more recessed areas, and an adhesive layer between the first bonding surface of the first metal piece and the second bonding surface of the second metal piece. The adhesive layer occupies a space between the first and second bonding surfaces and occupies the recessed areas of both the first and second bonding surfaces of the first and second metal pieces.

Abstract: A method of removing scale from a casting may include positioning the casting relative to a laser emitter. The casting may comprise a superalloy and the scale may have formed on the surfaces thereof, with the scale being a byproduct of a method of manufacturing the casting. The method may also include passing a laser beam emitted from the laser emitter across the casting such that the laser beam causes the scale to at least one of crack, break, shatter, and spall. The superalloy may be a nickel-based superalloy and the scale may include a metal carbide layer.

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 smoothing surface roughness within a passageway is disclosed. In various embodiments, the method comprises flowing an abrasive media through the passageway and positioning a mandrel within the passageway, the mandrel being sized to create a gap between an outer surface of the mandrel and an inner surface of the passageway, wherein the abrasive media is caused to flow through the gap, abrading the inner surface of the passageway.

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: A cluster-tool assembly for abrasive flow machining a plurality of airfoils is disclosed. The cluster-tool assembly comprises an airfoil cluster, the airfoil cluster including a supporting rail and the plurality of airfoils spaced about the supporting rail, and a sacrificial tool unitarily formed with the airfoil cluster, the sacrificial tool including a body and a plurality of prongs extending from the body.

Abstract: A process for coating a gas turbine blade with an abrasive. The process includes positioning the gas turbine blade in a nest, the gas turbine blade comprising a tip having a top surface; prepositioning a metal powder material on the top surface; fusing the metal powder material to the top surface by use of a laser to form a base layer on the top surface; prepositioning an abrasive composite material on the base layer opposite the top surface; fusing the abrasive composite material to the base layer by use of the laser to form an abrasive coating on the base layer; and removing the gas turbine blade from the nest.

Abstract: An additive manufacturing system for fabricating a hybrid component includes a build platform having a platform surface at a first elevation and at least one preform structure secured proximate to the build platform. The preform structure includes a first preform surface located at a second elevation. The system further includes a powder deposition device disposed above the build platform at a third elevation, the third elevation being greater than the first and second elevations.

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: 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 of polishing an outer surface of a ceramic coated gas turbine engine component includes applying a rotating diamond brush to the outer surface. The brush is configured to achieve a uniform finish of 150 microinches Ra or less over the surface. The brush contains diamond impregnated bristles, and is affixed to a rotary head of a robotic arm. A force sensing controller limits brush forces against the component. The component disclosed is a hot section turbine vane designed for directional control of high temperature, high-pressure combustion gases, but the method may be applied to other components contained within such aerospace applications. The polished coating provides an improved thermal barrier for maintaining structural integrity of the component in environments having temperatures ranging up to 2,000 degrees Celsius. The method limits abrasive removal of ceramic material to only 0.0005 to 0.00075 inch, and saves time and expense over past practices.

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.

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.

Abstract: A method of polishing an outer surface of a ceramic coated gas turbine engine component includes applying a rotating diamond brush to the outer surface. The brush is configured to achieve a uniform finish of 150 microinches RA or less over the surface. The brush contains diamond impregnated bristles, and is affixed to a rotary head of a robotic arm. A force sensing controller limits brush forces against the component. The component disclosed is a hot section turbine vane designed for directional control of high temperature, high-pressure combustion gases, but the method may be applied to other components utilized in similar aerospace applications. The polished coating provides an improved thermal barrier for maintaining structural integrity of the component in environments having temperatures ranging up to 2,000 degrees Celsius. The method limits abrasive removal of ceramic material to only 0.0005 to 0.00075 inch, and saves time and expense over past practices.

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 coating a part according to an aspect of the disclosure includes the step binding a metallic powder to a section of the part. The metallic powder is then energized which at least partially melts and resolidifies the metallic powder to form a first metallic coating. After the first layer of metallic coating is formed a second layer of metallic coating is deposited on substantially all of the part.