Abstract: A system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold.

Abstract: A method includes removing a casting shell and core from a cast component, which may be a gas turbine blade. The method further includes utilizing a focused removal technique, such as a water jet or laser drill, to remove a portion of a virtual pattern cast (VPC) shell from the cast component. The cast component is then exposed to a leaching solution and high pressure water wash to remove an internal core material and a portion of the VPC shell remainder from the cast component. The method further includes exposing the cast component to a high agitation leaching solution and to the high pressure water wash for a minimal time. An electroless nickel-boron coating is then applied to the cast component, and an electrolytic palladium coating is further applied to the cast component. The cast component is further exposed to a high agitation leaching solution for an extended period.

Abstract: A system including a positioning system with a component manipulator structured to position a component in response to a positioning algorithm; a scanning system capable of producing a set of light waves directed at a surface of the component, detecting a set of reflected light waves from the surface of the component, and producing a reflectivity data set in response to the set of reflected light waves; and a microprocessor structured to apply a fuzzy logic algorithm to the reflectivity signal to determine a solution set and produce a grain structure characterization in response to the solution set.

Abstract: An apparatus includes a positioning system; a surface indicator system to collect an indication data set from a surface of a component utilizing a fluorescent penetration process; an indication data processing system to create an output data set in response to the indication data set utilizing a fuzzy logic algorithm; and a microprocessor to provide at least one surface variance in response to the indication data set and the output data set. A method including conducting a surface indication technique for a component; utilizing a positioning algorithm to manipulate positioning equipment in response to the component; directing an indication source to a surface of the component; collecting an indication data set in response to directing the indication source; applying a fuzzy logic analysis in response to the indication data set to provide an output data set; and providing at least one surface variance in response to the output data set.

Abstract: A method includes removing a casting shell and core from a cast component, which may be a gas turbine blade. The method further includes utilizing a focused removal technique, such as a water jet or laser drill, to remove a portion of a virtual pattern cast (VPC) shell from the cast component. The cast component is then exposed to a leaching solution and high pressure water wash to remove an internal core material and a portion of the VPC shell remainder from the cast component. The method further includes exposing the cast component to a high agitation leaching solution and to the high pressure water wash for a minimal time. An electroless nickel-boron coating is then applied to the cast component, and an electrolytic palladium coating is further applied to the cast component. The cast component is further exposed to a high agitation leaching solution for an extended period.

Abstract: A system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold.

Abstract: A system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold.

Abstract: A system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold.

Abstract: A system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold.

Abstract: A system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold.