Abstract: An exemplary method of manufacturing an electrical discharge machining electrode includes, among other things, immersing at least a portion of an electrode base in a fluid, and electroplating an electrode coating containing diamond to an electrode base.

Abstract: An example electrical discharge machining electrode assembly includes an electrode base and an electrode coating containing diamond that is electroplated to the electrode base.

Abstract: A method for abrasive flow machining includes moving an abrasive media through a high-aspect passage of a workpiece. Local pressure of the abrasive media is increased at target abrasion surfaces of the high-aspect passage using a passage geometry that is configured to direct flow of the abrasive media into the target abrasion surfaces such that the target abrasion surfaces are preferentially polished by the abrasive media over other, non-targeted surfaces of the high-aspect passage at which the flow of the abrasive media is not directed into.

Abstract: An abrasive profiling tool that may be part of a robotic machining system for machining a trailing edge of an airfoil, includes a shank extending along a rotational axis, a bearing guide rotationally secured to a distal end of the shank for riding upon the airfoil; and an abrasive profiler projecting radially and rigidly outward from the shank for grinding at least the trailing edge as the shank rotates. The profiler may include a round-over portion for grinding the trailing edge and a chamfered blending portion for grinding adjacent surfaces of the airfoil to produce a smooth transition from the adjacent surfaces and to the trailing edge.

Abstract: The present disclosure relates generally to a machining tool and method for using the machining tool. The machining tool includes a machining arm including a first arm section, a second arm section, a proximate end, a distal end, and a machining arm longitudinal axis, a belt disposed around the machining arm; and a first motor operably coupled to the machining arm, wherein at least a portion of the machining arm is configured to pivot such that an angle is formed between the distal end and the machining arm longitudinal axis. The method includes the steps of placing the pivotable machining arm in a first orientation, inserting the pivotable machining arm in the desired location, determining whether the belt is in a desired position relative to the raised surface, operating the motor to rotate the belt around the pivotable machining arm, and placing the belt in contact with the raised surface.

Abstract: An additively manufactured component with an internal passage; and a multiple of ultrasonic horns additively manufactured within the internal passage.

Abstract: A method of removing partially sintered powder from an internal passage in a metal component formed by electron beam additive manufacturing (EBAM) includes co-forming a solid wire cutter in the passage during the EBAM forming process and removing partially sintered powder from the cavity by extracting the cutter from the cavity.

Abstract: A method of making a part includes creating a computer file defining the part in layers and a model of a body blank to represent a space defined by a cavity in the part. The part is built using an additive manufacturing process. A layer of powdered material is deposited into a powder bed. The powder bed is preheated by applying a first beam current with a first energy. A second beam current with a second energy level greater than the first energy level is applied to a first region of the layer of the powder bed not including a portion of the cavity. A second region of the powdered material is selectively melted. The partially built part and layer of the powdered material are lowered. Steps are repeated for additional layers in accordance with the computer file to create the part.

Abstract: An embodiment of an apparatus includes a centrifugal drive unit, an arm assembly, an optional dynamic balancing ring, and a workpiece fixture. The arm assembly is operatively connected to the centrifugal drive unit and configured to revolve about a primary axis perpendicular to the arm. The workpiece fixture is mounted to the arm assembly, and is configured to rotate at least one workpiece about at least one secondary axis outboard of the primary axis.

Abstract: A system and methods are provided for grinding a workpiece. In one embodiment, a method includes controlling rotation of a workpiece, wherein the workpiece is rotated relative to a first axis, and controlling grinding of the workpiece by a first grinding tool to shape the workpiece, wherein the first grinding tool is rotated relative to a second axis. The method may also include controlling grinding of the workpiece by the grinding tool and rotation of the workpiece to provide grinding of the workpiece with a generally constant surface footage.

Abstract: A method of making a gas turbine engine component includes providing a nickel based alloy workpiece and removing material from the workpiece surface using an abrasive machining operation to form an axisymmetric surface on the workpiece using the abrasive machining operation. The workpiece axisymmetric surface and workpiece interior portion have uniform hardness and micro structure following the removing operation.

Abstract: A grinding tool is provided that includes an axial grinding wheel having a circumferential cutting slot formed therein, the cutting slot having a cross-sectional profile that includes a floor having a first radius of curvature, a first side wall rising upward from the floor and having a second radius of curvature, a second side wall rising upward from the floor opposite the first side wall and having a third radius of curvature. At least one radius of curvature corresponds to a surface, such as a leading edge of a gas turbine engine airfoil.

Abstract: An additively manufactured assembly including an additively manufactured component with an edge oriented with respect to a recoater blade direction and an non-contact support that does not form a part of the additively manufactured component, the additively manufactured support located adjacent the edge. A method of additively manufacturing a component includes additively manufacturing an component with an edge oriented with respect to a recoater blade direction simultaneous with additively manufacturing an non-contact support that does not form a part of the component, the additively manufactured support located adjacent the edge.

Abstract: A method of forming a component using electro-chemical machining includes the steps of providing a shield in a current distribution path between a workpiece and an electrode, with the shield concentrating current distribution upon an end of the workpiece.

Abstract: An additive manufacturing process includes simultaneously constructing a component and a non-contacting thermal support for the component. The non-contacting thermal support includes a three dimensional negative of the component. The non-contacting thermal support transfers heat from the component into a heat sink.

Abstract: Systems and methods for creating grinding wheels are provided. The systems and methods may employ aligned abrasive grains. In this regard, the abrasive grains may have a known polarity and cutting orientation. The abrasive grains may be alignable in response to being exposed to an electrical current and/or a magnetic field. The abrasive grains may be aligned of a film that is processed into a grinding wheel.

Abstract: An exemplary method for determining a set of additive manufacturing parameters includes, a) determining a nominal parameter of at least one surface of a component, b) determining at least a second order variation in the nominal parameter, c) predicting an actual resultant dimension based at least in part on the nominal parameter and the second order variation, and d) adjusting at least one additive manufacturing process parameter in response to the predicted actual resultant dimension.

Abstract: A method for manufacturing a gas turbine engine component from a molybdenum-rich alloy. The method includes the steps of providing a molybdenum powder of at least 50% molybdenum by weight, extruding the molybdenum powder to provide a first shape, forming the first shape to a second shape and forging the second shape to provide a third shape.

Abstract: The present disclosure relates generally to a machining tool and method for using said machining tool. The machining tool includes a machining arm including a first arm section, a second arm section, a proximate end, a distal end, and a machining arm longitudinal axis, a belt disposed around the machining arm; and a first motor operably coupled to the machining arm, wherein at least a portion of the machining arm is configured to pivot such that an angle is formed between the distal end and the machining arm longitudinal axis. The method includes the steps of placing the pivotable machining arm in a first orientation, inserting the pivotable machining arm in the desired location, determining whether the belt is in a desired position relative to the raised surface, operating the motor to rotate the belt around the pivotable machining arm, and placing the belt in contact with the raised surface.

Abstract: An abrasive profiling tool that may be part of a robotic machining system for machining a trailing edge of an airfoil, includes a shank extending along a rotational axis, a bearing guide rotationally secured to a distal end of the shank for riding upon the airfoil; and an abrasive profiler projecting radially and rigidly outward from the shank for grinding at least the trailing edge as the shank rotates. The profiler may include a round-over portion for grinding the trailing edge and a chamfered blending portion for grinding adjacent surfaces of the airfoil to produce a smooth transition from the adjacent surfaces and to the trailing edge.