Abstract: Lost wax casting bonding methods and systems. A method for bonding a wax component in a feeder system for a lost wax casting process comprises embedding conductive nano-particles in wax to form a sacrificial susceptor. The method includes coupling the wax component to another component such that the sacrificial susceptor is at an interface of the wax component and the other component. The method comprises inductively heating the sacrificial susceptor to cause the wax of the sacrificial susceptor and at least a portion of wax of the wax component to melt to thereby form a bond between the wax component and the other component.

Abstract: Lost wax casting bonding methods and systems. A method for bonding a wax component in a feeder system for a lost wax casting process comprises embedding conductive nano-particles in wax to form a sacrificial susceptor. The method includes coupling the wax component to another component such that the sacrificial susceptor is at an interface of the wax component and the other component. The method comprises inductively heating the sacrificial susceptor to cause the wax of the sacrificial susceptor and at least a portion of wax of the wax component to melt to thereby form a bond between the wax component and the other component.

Abstract: A fastening system for securing a mounting tool configured to retain a component that is to undergo a high-temperature process. The mounting tool has a first portion having a first tab with a first slot and a second portion having a second tab with a second slot. The fastening system comprises an outer clip including outer clip arms and a central portion. The outer clip arms have a gap therebetween. The central portion protrudes into the gap. The fastening system includes an inner clip including inner clip arms. The inner clip is pushed into the gap such that each inner clip arm contacts and pushes one outer clip arm towards the first tab and the second tab. When the fastening system is inserted into the first slot and the second slot, the fastening system limits relative movement between the first tab and the second tab.

Abstract: Lost wax casting bonding methods and systems. A method for bonding a wax component in a feeder system for a lost wax casting process comprises embedding conductive nano-particles in wax to form a sacrificial susceptor. The method includes coupling the wax component to another component such that the sacrificial susceptor is at an interface of the wax component and the other component. The method comprises inductively heating the sacrificial susceptor to cause the wax of the sacrificial susceptor and at least a portion of wax of the wax component to melt to thereby form a bond between the wax component and the other component.

Abstract: Lost wax casting bonding methods and systems. A method for bonding a wax component in a feeder system for a lost wax casting process comprises embedding conductive nano-particles in wax to form a sacrificial susceptor. The method includes coupling the wax component to another component such that the sacrificial susceptor is at an interface of the wax component and the other component. The method comprises inductively heating the sacrificial susceptor to cause the wax of the sacrificial susceptor and at least a portion of wax of the wax component to melt to thereby form a bond between the wax component and the other component.

Abstract: A system for securing a component for an electrically-driven process is disclosed. The system includes a mai015134n body having an opening, a retention slot configured for retaining the component, and a channel. The system includes a fastener extending through the opening in the main body, and an insert inserted into the channel. The system has a shank movably coupled to the fastener and configured to contact the insert. The insert is configured to maintain electrical contact between the shank and the component when the component is retained within the retention slot.

Abstract: Systems and methods are provided for repairing compressor blades using hybrid manufacturing. A mounting tool for use in repairing a turbine component includes a slot formed in the mounting tool. The slot is configured to receive the turbine component for securing the turbine component to the mounting tool. The mounting tool includes at least one fastener engageable with the turbine component and capable of retaining the turbine component within the slot; and at least a pair of support bases provided on the mounting tool. Each of the at least a pair of support bases is positioned adjacent a respect edge of the turbine component when the turbine component is retained in the mounting tool. Each of the at least a pair of support bases is configured for additively building a sacrificial support on each of the at least a pair of support bases for enabling repair of the turbine component.

Abstract: A method of using a masking device to mask a portion of a gas turbine engine component for an electroplating process is provided. The masking device includes a main body having sidewalls, a removeable coverplate having an end plate and one or more locking tabs, a fastener located at least partially within the main body, and a shank engaged with the fastener. The method includes placing the gas turbine engine component through an opening in the main body such that the component is held within the main body by a retention slot. The method includes sliding the one or more locking tabs of the removeable coverplate through the opening in the main body such that the removeable coverplate covers the opening of the main body. The method includes securing the one or more locking tabs in one or more relief slots in the sidewalls of the main body.

Abstract: Systems and methods for repairing compressor blades using hybrid manufacturing techniques. A tool for repairing a compressor blade has a plurality of support bases, and a slot configured for securement of said compressor blade to said mounting tool. The tool has a pair of support bases, each of which is configured for the building of a sacrificial support thereon to stabilize the compressor blade during repair. The tool is coupled to a hybrid manufacturing machinery and the sacrificial supports stabilize the compressor blade during additive and subtractive manufacturing processes.

Abstract: A method of using a masking device to mask a portion of a gas turbine engine component for an electroplating process is provided. The masking device includes a main body having sidewalls, a removeable coverplate having an end plate and one or more locking tabs, a fastener located at least partially within the main body, and a shank engaged with the fastener. The method includes placing the gas turbine engine component through an opening in the main body such that the component is held within the main body by a retention slot. The method includes sliding the one or more locking tabs of the removeable coverplate through the opening in the main body such that the removeable coverplate covers the opening of the main body. The method includes securing the one or more locking tabs in one or more relief slots in the sidewalls of the main body.

Abstract: The present disclosure provides for improvements in fixturing parts in preparation for an electroplating process, thus reducing part handling. The system provides a reusable masking tool comprising a main body having an opening with a removeable coverplate positioned within the opening and one or more locking tabs engaging a corresponding relief slot in at least one of the sidewalls of the main body. The system also comprises a fastener moveably secured within the main body and extending through a top surface of the main body. The main body, fastener, and coverplate may be fabricated from a polymer material by way of an additive manufacturing process. A shank, fabricated from a conductive material, extends through the fastener and is engaged with the fastener such that upon rotation of the fastener, the shank is drawn into contact with the gas turbine engine component, thus providing a conduit for the electroplating process.

Abstract: The present disclosure provides for improvements in fixturing parts in preparation for an electroplating process, thus reducing part handling. The system provides a reusable masking tool comprising a main body having an opening with a removeable coverplate positioned within the opening and one or more locking tabs engaging a corresponding relief slot in at least one of the sidewalls of the main body. The system also comprises a fastener moveably secured within the main body and extending through a top surface of the main body. The main body, fastener, and coverplate may be fabricated from a polymer material by way of an additive manufacturing process. A shank, fabricated from a conductive material, extends through the fastener and is engaged with the fastener such that upon rotation of the fastener, the shank is drawn into contact with the gas turbine engine component, thus providing a conduit for the electroplating process.

Abstract: A preformed hinged foam sump for use on a flat roof includes two mirror image sides connected along the hinge which folds from an 8×8 structure to a 4×8 structure. Each of the mirror image panels includes a central panel which is a right isosceles triangle which slopes to the 90 degree angle of the right isosceles triangles. Each side includes two side panels which are sloped to the same point as the central panel and are also right isosceles triangles. The panels are bonded together to form each side which is connected by a flexible material or tape along the bottom side to allow the two sides to fold relative to each other to change from an 8×8 structure to a 4×8 structure and open up to an 8×8 structure for use on a roof surface.

Abstract: A preformed hinged foam sump for use on a flat roof includes two mirror image sides connected along the hinge which folds from an 8×8 structure to a 4×8 structure. Each of the mirror image panels includes a central panel which is a right isosceles triangle which slopes to the 90 degree angle of the right isosceles triangles. Each side includes two side panels which are sloped to the same point as the central panel and are also right isosceles triangles. The panels are bonded together to form each side which is connected by a flexible material or tape along the bottom side to allow the two sides to fold relative to each other to change from an 8×8 structure to a 4×8 structure and open up to an 8×8 structure for use on a roof surface.

Abstract: A method and material 52 for blocking a laser beam L during laser machining is disclosed. The material comprises a thermoplastic polymer. Various details are developed which promote filling and removing the blocking material from a component 10. In one detailed embodiment, the thermoplastic polymer is formed of only carbon and hydrogen and forms harmless effluent during burnout of the material.

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 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.