Abstract: A method for defining an airfoil with a radiused shape edge includes joining a filler material to the airfoil such that the filler material defines excess material that extends beyond an operational condition edge location of the edge of the airfoil, placing the airfoil within a barrel, providing an abrasive finishing media in the barrel with the airfoil, rotating the barrel to produce relative motion between the abrasive finishing media and the airfoil. Contact between the abrasive finishing material and the airfoil facilitates removing the excess material that extended beyond the operational condition edge location of the edge of the airfoil.

Abstract: A fixture assembly for retaining a workpiece during a coining process includes a mounting block. The workpiece includes an airfoil portion, a platform, and feet extending from the platform opposite the airfoil portion configured to engage a retention slot in a gas turbine engine, each foot defining a substantially arcuate engagement surface. The mounting block includes a first portion having a slot defined therein between opposite first and second lateral edges and having an exposed front face, first and second retaining structures positioned adjacent to the first and second lateral edges, respectively. Each of the first and second retaining structures overhangs the slot and defines an engagement surface facing the slot, such that during engagement of the workpiece the substantially arcuate engagement surfaces of the feet contact the engagement surfaces of the first and second retaining structures to provide a pivotable engagement.

Abstract: A method of repairing a variable vane for a gas turbine engine includes the steps of positioning a trunnion of a variable vane within an electrical discharge machine environment, and connecting the trunnion as a first electrode through an electrical discharge machine power generator to a second electrode. The second electrode is formed of a hard metal coating. A spark is created between the trunnion and the second electrode such that material from the second electrode is deposited on an outer surface of said trunnion. Further, a variable vane having a trunnion reconditioned by this method is disclosed and claimed.

Abstract: A fixture assembly for retaining a workpiece during a coining process includes a mounting block. The workpiece includes an airfoil portion, a platform, and feet extending from the platform opposite the airfoil portion configured to engage a retention slot in a gas turbine engine, each foot defining a substantially arcuate engagement surface. The mounting block includes a first portion having a slot defined therein between opposite first and second lateral edges and having an exposed front face, first and second retaining structures positioned adjacent to the first and second lateral edges, respectively. Each of the first and second retaining structures overhangs the slot and defines an engagement surface facing the slot, such that during engagement of the workpiece the substantially arcuate engagement surfaces of the feet contact the engagement surfaces of the first and second retaining structures to provide a pivotable engagement.

Abstract: A method for defining an airfoil with a radiused shape edge includes joining a filler material to the airfoil such that the filler material defines excess material that extends beyond an operational condition edge location of the edge of the airfoil, placing the airfoil within a barrel, providing an abrasive finishing media in the barrel with the airfoil, rotating the barrel to produce relative motion between the abrasive finishing media and the airfoil. Contact between the abrasive finishing material and the airfoil facilitates removing the excess material that extended beyond the operational condition edge location of the edge of the airfoil.