Abstract: A mold system and method for forming a casting article for investment casting is disclosed. The mold system includes a mold for receiving therein a selected core chosen from a plurality of varied cores. The mold includes a plurality of separable mold portions that are coupleable together to create the mold and configured to form a sacrificial material from a sacrificial material fluid about the selected core. At least one selected separable mold portion of the plurality of separable mold portions includes a set of varied interchangeable versions of the at least one selected separable mold portion. Each varied interchangeable version of the selected separable mold portion is configured to accommodate a different core of the plurality of varied cores. A number of systems for controlling a temperature of the mold are also disclosed.

Abstract: A coating method for a component with at least one aperture includes providing a component having at least one aperture formed in a surface thereof; additively manufacturing a hollow member on a portion of the surface to define a space above each aperture, the portion of the surface being adjacent to the aperture, the hollow member having an inner peripheral geometry complementary to a peripheral geometry at least one of aperture; applying at least one coating over the surface of the component and around hollow member to form an applied coating having an applied coating thickness; and removing at least a portion of the hollow member to make a top portion of the hollow member coplanar with the applied coating to expose the space through the applied coating; wherein a lower portion of the hollow member remains to define the space through the applied coating.

Abstract: A coating method for a component with at least one aperture includes providing a component having at least one aperture formed in a surface thereof; additively manufacturing a hollow member on a portion of the surface to define a space above each aperture, the portion of the surface being adjacent to the aperture, the hollow member having an inner peripheral geometry complementary to a peripheral geometry at least one of aperture; applying at least one coating over the surface of the component and around hollow member to form an applied coating having an applied coating thickness; and removing at least a portion of the hollow member to make a top portion of the hollow member coplanar with the applied coating to expose the space through the applied coating; wherein a lower portion of the hollow member remains to define the space through the applied coating.

Abstract: A mold system and method for forming a casting article for investment casting is disclosed. The mold system includes a mold for receiving therein a selected core chosen from a plurality of varied cores. The mold includes a plurality of separable mold portions that are coupleable together to create the mold and configured to form a sacrificial material from a sacrificial material fluid about the selected core. At least one selected separable mold portion of the plurality of separable mold portions includes a set of varied interchangeable versions of the at least one selected separable mold portion. Each varied interchangeable version of the selected separable mold portion is configured to accommodate a different core of the plurality of varied cores. A number of systems for controlling a temperature of the mold are also disclosed.

Abstract: Cleaning fixtures for a component(s) are disclosed. The cleaning fixtures may include a first and second component recess configured to receive a first and second component, respectively. Each component recess may be defined between a first and second member of the cleaning fixture. The cleaning fixture may also include a first solvent conduit in fluid communication with the first component recess, and a second solvent conduit in fluid communication with the second component recess. The first and second solvent conduit may include physical characteristic(s) configured to control delivery of solvent into the respective component recess at desired fluid parameter(s). The cleaning fixture may also include a first gas conduit in fluid communication with the first component recess, and a second gas conduit in fluid communication with the second component recess. Each of the first and second gas conduit may deliver a pressurized gas to the respective component recess.

Abstract: A coating method for a component with at least one aperture includes providing a component having at least one aperture formed in a surface thereof; additively manufacturing a hollow member on a portion of the surface to define a space above each aperture, the portion of the surface being adjacent to the aperture, the hollow member having an inner peripheral geometry complementary to a peripheral geometry at least one of aperture; applying at least one coating over the surface of the component and around hollow member to form an applied coating having an applied coating thickness; and removing at least a portion of the hollow member to make a top portion of the hollow member coplanar with the applied coating to expose the space through the applied coating; wherein a lower portion of the hollow member remains to define the space through the applied coating.

Abstract: A mold system and method for forming a casting article for investment casting is disclosed. The mold system includes a mold for receiving therein a selected core chosen from a plurality of varied cores. The mold includes a plurality of separable mold portions that are coupleable together to create the mold and configured to form a sacrificial material from a sacrificial material fluid about the selected core. At least one selected separable mold portion of the plurality of separable mold portions includes a set of varied interchangeable versions of the at least one selected separable mold portion. Each varied interchangeable version of the selected separable mold portion is configured to accommodate a different core of the plurality of varied cores. A number of systems for controlling a temperature of the mold are also disclosed.

Abstract: An alignment system and method for aligning the shaft centerline of rotating equipment positioned on opposing roller stands are provided. The system includes a laser transmission unit on the first stand and a target unit on the second stand. The laser transmission unit includes a laser that transmits a laser beam to a target on the target unit. When the laser beam contacts the center of the target, the roller stands are aligned. The system may be automated to detect the position of the laser beam relative to the target center and to adjust, as needed, the position of one of or both the roller stands using hydraulic cylinders coupled to a roller stand platform. The system and method reduce the time, effort, and manpower required to perform the alignment.

Abstract: A mold system and method for forming a casting article for investment casting is disclosed. The mold system includes a mold for receiving therein a selected core chosen from a plurality of varied cores. The mold includes a plurality of separable mold portions that are coupleable together to create the mold and configured to form a sacrificial material from a sacrificial material fluid about the selected core. At least one selected separable mold portion of the plurality of separable mold portions includes a set of varied interchangeable versions of the at least one selected separable mold portion. Each varied interchangeable version of the selected separable mold portion is configured to accommodate a different core of the plurality of varied cores. A number of systems for controlling a temperature of the mold are also disclosed.

Abstract: A mold system for forming a casting article for investment casting in which the mechanical integrity of a ceramic core can be tested by viscosity manipulation. A method for testing a ceramic core used for an investment casting includes: positioning the ceramic core within a mold for receiving a sacrificial material fluid to form a sacrificial material on at least a portion of the ceramic core, the ceramic core having a predefined layout; during casting of the sacrificial material fluid about the ceramic core using the mold, controlling a viscosity of the sacrificial material fluid to simulate an expected viscosity of a molten metal used during a subsequent investment casting using the ceramic core; and evaluating mechanical damage to at least one region of the ceramic core caused by the casting of the sacrificial material fluid.

Abstract: A mixer is disclosed including a sealed mixing chamber having an interior, and a rotating mixing bowl within the interior of the sealed mixing chamber. A stand operatively supports the sealed mixing chamber. The stand includes: a foundation, a mixing chamber base movably coupled to the foundation and positioning the sealed mixing chamber at an angle relative to horizontal, and a linear actuator system configured to move the mixing chamber base relative to the foundation in at least one linear direction. A rotating mixing head is operatively positioned and sealingly disposed within the sealed mixing chamber, the rotating mixing head rotating within the rotating mixing bowl. The mixer and a related method provide for ceramic suspension mixing with reduced cooling and possibly without cooling the suspension.

Abstract: A mixer is disclosed including a sealed mixing chamber having an interior, and a rotating mixing bowl within the interior of the sealed mixing chamber. A stand operatively supports the sealed mixing chamber. The stand includes: a foundation, a mixing chamber base movably coupled to the foundation and positioning the sealed mixing chamber at an angle relative to horizontal, and a linear actuator system configured to move the mixing chamber base relative to the foundation in at least one linear direction. A rotating mixing head is operatively positioned and sealingly disposed within the sealed mixing chamber, the rotating mixing head rotating within the rotating mixing bowl. The mixer and a related method provide for ceramic suspension mixing with reduced cooling and possibly without cooling the suspension.

Abstract: Cleaning fixtures for a component(s) are disclosed. The cleaning fixtures may include a first and second component recess configured to receive a first and second component, respectively. Each component recess may be defined between a first and second member of the cleaning fixture. The cleaning fixture may also include a first solvent conduit in fluid communication with the first component recess, and a second solvent conduit in fluid communication with the second component recess. The first and second solvent conduit may include physical characteristic(s) configured to control delivery of solvent into the respective component recess at desired fluid parameter(s). The cleaning fixture may also include a first gas conduit in fluid communication with the first component recess, and a second gas conduit in fluid communication with the second component recess. Each of the first and second gas conduit may deliver a pressurized gas to the respective component recess.

Abstract: A mixer is disclosed including a sealed mixing chamber having an interior, and a rotating mixing bowl within the interior of the sealed mixing chamber. A stand operatively supports the sealed mixing chamber. The stand includes: a foundation, a mixing chamber base movably coupled to the foundation and positioning the sealed mixing chamber at an angle relative to horizontal, and a linear actuator system configured to move the mixing chamber base relative to the foundation in at least one linear direction. A rotating mixing head is operatively positioned and sealingly disposed within the sealed mixing chamber, the rotating mixing head rotating within the rotating mixing bowl. The mixer and a related method provide for ceramic suspension mixing with reduced cooling and possibly without cooling the suspension.

Abstract: Cleaning fixtures for a component(s) are disclosed. The cleaning fixtures may include a first and second component recess configured to receive a first and second component, respectively. Each component recess may be defined between a first and second member of the cleaning fixture. The cleaning fixture may also include a first solvent conduit in fluid communication with the first component recess, and a second solvent conduit in fluid communication with the second component recess. The first and second solvent conduit may include physical characteristic(s) configured to control delivery of solvent into the respective component recess at desired fluid parameter(s). The cleaning fixture may also include a first gas conduit in fluid communication with the first component recess, and a second gas conduit in fluid communication with the second component recess. Each of the first and second gas conduit may deliver a pressurized gas to the respective component recess.

Abstract: A core for forming a casting article including a sacrificial material about the core is disclosed. The casting article is used for forming a mold for investment casting a component. The core may include a body having an external shape to form at least a section of an internal structure of the component during the investment casting; and a closed loop, core thermal conducting conduit inside a portion of the body. The closed loop, core thermal conducting conduit defines a path for a temperature controlled thermal fluid to pass through the portion of the body to control a temperature of the portion during forming of the casting article. A system may include the core and a thermal fluid controller for controlling the temperature of the thermal fluid. A related method is also disclosed.

Abstract: Vibration systems and systems including vibration systems for filling incomplete components with slurry material are disclosed. The vibration systems may include a vibration platform, and a component retention plate releasably coupled to the vibration platform. The component retention plate may include a plurality of component holders positioned on the component retention plate. Each of the plurality of component holders may receive a distinct, incomplete component in a predetermined orientation. The vibration systems may also include a motor operatively coupled to the vibration platform to vibrate the vibration platform at a predetermined frequency. The predetermined frequency may be based on characteristic(s) of each of the incomplete components.

Abstract: An alignment system and method for aligning the shaft centerline of rotating equipment positioned on opposing roller stands are provided. The system includes a laser transmission unit on the first stand and a target unit on the second stand. The laser transmission unit includes a laser that transmits a laser beam to a target on the target unit. When the laser beam contacts the center of the target, the roller stands are aligned. The system may be automated to detect the position of the laser beam relative to the target center and to adjust, as needed, the position of one of or both the roller stands using hydraulic cylinders coupled to a roller stand platform. The system and method reduce the time, effort, and manpower required to perform the alignment.

Abstract: A test feature is disclosed that is formed during metal powder additive manufacturing of a production part. The test feature may include a metal powder sample capsule including a chamber for capturing unfused powder from the metal powder additive manufacturing, and a removable cap closing an end of the chamber. Alternatively, a test feature may include a quality control (QC) part, and at least one additional test element including a metal powder sample capsule integrally coupled to the QC part and including a chamber for capturing unfused powder from the metal powder additive manufacturing. The QC part is identical to the production part excepting the at least one test element. The QC part and the at least one test element are formed during the same metal powder additive manufacturing as the production part.

Abstract: A platform cooling arrangement in a turbine rotor blade having a platform at an interface between an airfoil and a root, wherein the rotor blade includes an interior cooling passage formed therein that extends from a connection with a coolant source at the root to at least the approximate radial height of the platform. The platform cooling arrangement includes a platform slot formed through at least one of a pressure side slashface and a suction side slashface, the platform slot being in fluid communication with a high-pressure coolant region of the turbine rotor blade. An insert inserted in the platform slot, the insert having a blind channel extending inside the insert. The insert aligns with the platform slot to fluidly connect the channel to the high-pressure coolant region. At least one passage is in fluid communication with the channel and an exterior region of the turbine rotor blade.