Abstract: A computer-implemented method for forming a three-dimensional workpiece from a block of material using a fluid jet cutting device is implemented by a fabrication system. The method includes receiving an indication of the geometry of the workpiece and generating a three-dimensional tool path to control a cutting head to form the workpiece. Generating the tool path includes receiving an indication of a desired cutting surface on the workpiece, determining a length of the cutting surface, and designating a plurality of waypoints along an edge of the cutting surface. Generating the tool path also includes determining at least one geometric parameter of the cutting surface at each waypoint of the plurality of waypoints, and calculating a speed of the cutting head at each waypoint of the plurality of waypoints based on the determined geometric parameter such that the speed of the cutting head varies along the cutting surface length.

Abstract: A system for manufacturing an airfoil includes a laser beam and a first fluid column surrounding the laser beam to create a confined laser beam directed at the airfoil. A liquid flowing inside the airfoil disrupts the first fluid column inside the airfoil. A method for manufacturing an airfoil includes confining a laser beam inside a first fluid column to create a confined laser beam and directing the confined laser beam at a surface of the airfoil. The method further includes creating a hole through the surface of the airfoil with the confined laser beam, flowing a liquid inside the airfoil, and disrupting the first fluid column with the liquid flowing inside the airfoil.

Abstract: A process is provided for forming shaped air holes, such as for use in turbine blades. Aspects of the disclosure relate to forming shaped portions of air holes using a short pulse laser, forming a metered hole corresponding to each shaped portion, and separately finishing the shaped portion using a short-pulse laser. In other embodiments, the order of these operations may be varied, such as to form the shaped portions and to finish the shaped portions using the short-pulse laser prior to forming the corresponding metered holes.

Abstract: Disclosed herein is an erosion and corrosion resistant coating comprising a metallic binder, a plurality of hard particles, and a plurality of sacrificial particles. Also disclosed is a method of improving erosion and corrosion resistance of a metal component comprising disposing on a surface of the metal component the foregoing erosion and corrosion resistant coating comprising, and a metal component comprising a metal component surface and the foregoing erosion and corrosion resistant coating comprising a first surface and a second surface opposite the first surface, wherein the first surface is disposed on the metal component surface.

Abstract: A coating system and a method of applying the coating system on an article. The coating system includes a sacrificial coating on a surface of the article and an erosion-resistant coating on the sacrificial coating, wherein the erosion-resistant coating comprises a layer of a polymeric material. The sacrificial coating is more anodic than the surface or the erosion-resistant coating.

Abstract: A system for manufacturing an airfoil includes a laser beam and a first fluid column surrounding the laser beam to create a confined laser beam directed at the airfoil. A liquid flowing inside the airfoil disrupts the first fluid column inside the airfoil. A method for manufacturing an airfoil includes confining a laser beam inside a first fluid column to create a confined laser beam and directing the confined laser beam at a surface of the airfoil. The method further includes creating a hole through the surface of the airfoil with the confined laser beam, flowing a liquid inside the airfoil, and disrupting the first fluid column with the liquid flowing inside the airfoil.

Abstract: A process and system are provided for forming shaped air holes, such as for use in turbine blades. Aspects of the disclosure relate to forming shaped portions of air holes using a short pulse laser, forming a metered hole corresponding to each shaped portion, and separately finishing the shaped portion using a short-pulse laser. In other embodiments, the order of these operations may be varied, such as to form the shaped portions and to finish the shaped portions using the short-pulse laser prior to forming the corresponding metered holes.

Abstract: A sacrificial and erosion-resistant turbine compressor airfoil includes a turbine compressor airfoil having a modified airfoil surface. The airfoil surface has an airfoil coating that includes a sacrificial coating comprising a layer of Al, Cr, Zn, an Ni—Al alloy, an Al—Si alloy, an Al-based alloy, a Cr-based alloy or a Zn-based alloy, an Al polymer composite, or a combination thereof, or a layer of a conductive undercoat and an overcoat of an inorganic matrix binder having a plurality of ceramic particles and conductive particles embedded therein disposed on the undercoat. The airfoil coating also includes an sacrificial coating, wherein one of the sacrificial coating or the erosion-resistant coating is disposed on the airfoil surface and the other of the corrosion-resistant coating or the erosion-resistant coating is disposed on the respective one, and wherein the sacrificial coating is more anodic than the airfoil surface or the erosion-resistant coating.

Abstract: Disclosed herein is an erosion and corrosion resistant coating comprising a metallic binder, a plurality of hard particles, and a plurality of sacrificial particles. Also disclosed is a method of improving erosion and corrosion resistance of a metal component comprising disposing on a surface of the metal component the foregoing erosion and corrosion resistant coating comprising, and a metal component comprising a metal component surface and the foregoing erosion and corrosion resistant coating comprising a first surface and a second surface opposite the first surface, wherein the first surface is disposed on the metal component surface.

Abstract: A coating system and process capable of providing erosion and corrosion-resistance to a component, particularly a steel compressor blade of an industrial gas turbine. The coating system includes a metallic sacrificial undercoat on a surface of the component substrate, and a ceramic topcoat deposited by thermal spray on the undercoat. The undercoat contains a metal or metal alloy that is more active in the galvanic series than iron, and electrically contacts the surface of the substrate. The ceramic topcoat consists essentially of a ceramic material chosen from the group consisting of mixtures of alumina and titania, mixtures of chromia and silica, mixtures of chromia and titania, mixtures of chromia, silica, and titania, and mixtures of zirconia, titania, and yttria.

Abstract: A method for removing debris from a turbine component includes routing a cleaning composition comprising fluosilicic acid through an internal passage of the turbine component, without contacting an external surface of the turbine component, to remove the debris.