Abstract: Method of forming or repairing a part with an overhung section. The method may include removing a portion, and adding a section to the part. The section includes the overhung section. The adding includes sequentially layering at least one plurality of material layers on the part, the at least one plurality of material layers approximating dimensions of the section including the overhung section. The sequential layering may include, for example, laser welding, and may be carried out in a number of ways that create varied layers within the overhung section. The method may include machining the at least one plurality of material layers to form the section including the overhung section.

Abstract: Method of forming or repairing a part with an overhung section. The method may include removing a portion, and adding a section to the part. The section includes the overhung section. The adding includes sequentially layering at least one plurality of material layers on the part, the at least one plurality of material layers approximating dimensions of the section including the overhung section. The sequential layering may include, for example, laser welding, and may be carried out in a number of ways that create varied layers within the overhung section. The method may include machining the at least one plurality of material layers to form the section including the overhung section.

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 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 process includes manufacturing a gas turbine fuel injector body having a stub flange extending radially outward about a circumference of the gas turbine fuel injector body. The stub flange is sized to engage a stepped ledge along a central opening of a mounting flange. The central opening is sized to receive the gas turbine fuel injector body. A gas turbine fuel injector includes a gas turbine fuel injector body and a mounting flange. A method of mounting a gas turbine fuel injector includes placing a stub flange of a gas turbine fuel injector body between a surface of an injector boss and a stepped ledge of a mounting flange. The method also includes securing the gas turbine fuel injector to the injector boss with a plurality of bolts, each bolt extending through a mounting hole in the mounting flange and into a threaded hole in the injector boss.

Abstract: Embodiments of the disclosure provide a test structure for additive manufacture and related methods for emitter alignment. A test structure according to the disclosure can include: a body having a reference surface, wherein the body is formed with a first beam scanner of the AM system; and a plurality of calibration features defined on the reference surface of the body, wherein each of the plurality of calibration features includes an alignment surface positioned at an offset distance relative to the reference surface, and wherein each of the plurality of calibration features is formed with a second beam scanner of the AM system different than the first beam scanner.

Abstract: An object includes a fluid chamber extending between a first surface and a vertically opposed second surface, the first surface including a fluid passage opening therethrough. A self-breaking support, initially configured to support the first surface, once broken creates a broken support disposed between the first surface and the vertically opposed second surface. The support includes: a base having a first end coupled to the first surface and a second opposing end. The first end of the base is wider than the second end, and a fluid passage extends through the first base for fluidly coupling the fluid chamber and the fluid passage opening in the first surface. A self-breaking link is disposed between the second opposing end of the first base and the second surface.

Abstract: Embodiments of the present disclosure relate to a material extraction tool, including: a body shaped to sealingly engage an aperture in a component, the aperture defining a fluid connection between a hollow interior of the component and an exterior of the component; a first passage within the body, the first passage fluidly connecting the hollow interior of the component to an air conduit outside the body, the air conduit fluidly coupled to a compressed air supply; and a second passage within the body, the second passage fluidly connecting the hollow interior of the component to an extraction conduit outside the body, the extraction conduit fluidly coupled to a material repository positioned outside the hollow interior of the component.

Abstract: This disclosure provides systems, methods, and tooling for additive manufacturing on a build surface of a pre-existing component. An additive manufacturing tool successively positions layers of powdered materials and selectively fuses the layers of powdered materials to create an additive component on the build surface of the pre-existing component. The pre-existing component is secured in a build plate by a thermal expansion fit during the additive manufacturing process.

Abstract: This disclosure provides components and methods for blade extensions with internal features. An airfoil extends from a root connector and includes an airfoil body defining at least one air channel enclosed within the airfoil body. The air channel extends to a build surface. An additive extension extends from the build surface of the airfoil body. The additive extension includes an additive structure extending the air channel from the build surface to an external surface of the additive extension.

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 damaged applicator identifier system for an additive manufacturing (AM) system, and AM system including the same are disclosed. The damaged applicator identifier system may include a damaged applicator identifier determining whether the active applicator is damaged by identifying a non-planar surface in a layer of raw material on a build platform of the AM system after formation of the layer by the active applicator. A damaged applicator controller is configured to cause replacement or repair of the damaged, active applicator in response to the damaged applicator identifier identifying the damaged, active applicator.

Abstract: The present disclosure is directed to an impingement insert for a gas turbine engine. The impingement insert includes an insert wall having an inner surface and an outer surface spaced apart from the inner surface. A nozzle extends outwardly from the outer surface of the insert wall. The nozzle includes an outer surface and a circumferential surface. The insert wall and the nozzle collectively define a cooling passage extending from the inner surface of the insert wall to the outer surface of the nozzle. The cooling passage includes an inlet portion, a throat portion, a converging portion extending from the inlet portion to the throat portion, an outlet portion, and a diverging portion extending from the throat portion to the outlet portion. The cooling passage further includes a cross-sectional shape having a semicircular portion and a non-circular portion.

Abstract: This disclosure provides systems and tooling for cooling components during additive manufacturing. A build plate supports layers of powdered materials as they are positioned and selectively fused to create the component. The build plate defines a build surface and the build surface retracts in a working direction opposite a build direction for the component. At least one vertical cooling structure is provided perpendicular to the build plate and protruding from the build plate as the build surface retracts. The vertical cooling structure cools at least a portion of the component through unfused powdered materials between the vertical cooling structure and the component.

Abstract: Various embodiments include a build plate for additive manufacturing, along with a related system. The build plate may include: a first build surface having at least one recess therein; and at least one block configured to matingly engage with, and disengage with, the at least one recess, the block including a second build surface.

Abstract: Aspects of the disclosure include a sealing insert, turbine component, and code for manufacturing a sealing insert. A sealing insert includes at least one insert wall for insertion proximate a component wall to define a space between the at least one insert wall and the component wall. At least one compressible seal is provided between the at least one insert wall and the component wall. The compressible seal or seals divide the space into a plurality of compartments.

Abstract: Various embodiments of the invention include an apparatus for removing particulates from the surface of a 3D printed workpiece. Various particular embodiments include a material removal apparatus having: an enclosure having a first inlet and a first outlet; a rotatable platform contained within the enclosure for positioning a 3D printed workpiece having particulate on a surface thereof; a pressurized fluid applicator connected to the first inlet and configured to selectively apply a pressurized fluid to the 3D printed workpiece; a vibration source configured to apply an adjustable vibratory frequency to at least one of the rotatable platform or the 3D printed workpiece; and a material reclamation unit connected to the first outlet configured to collect a material removed from the 3D printed workpiece.

Abstract: The present disclosure is directed to an impingement insert for a turbomachine. The impingement insert includes an insert body having an inner surface, an outer surface spaced apart from the inner surface, and a thickness extending from the inner surface to the outer surface. The insert body defines a first depression extending from one of the inner surface or the outer surface into the insert body. The first depression has a diameter. The insert body further defines an impingement aperture extending from the first depression through the insert body. The impingement aperture has a length and a diameter. The thickness of the insert body is greater than the length of the impingement aperture and the diameter of the first depression is greater than the diameter of the impingement aperture.

Abstract: A damaged applicator identifier system for an additive manufacturing (AM) system, and AM system including the same are disclosed. The damaged applicator identifier system may include a damaged applicator identifier determining whether the active applicator is damaged by identifying a non-planar surface in a layer of raw material on a build platform of the AM system after formation of the layer by the active applicator. A damaged applicator controller is configured to cause replacement or repair of the damaged, active applicator in response to the damaged applicator identifier identifying the damaged, active applicator.