Abstract: An automated system is provided. The system includes: a manipulator coupled to: an opening forming device configured to create an opening having a predefined geometry partially into a multilayer component at a selected location on a surface of the multilayer component, where the multilayer component includes a plurality of material layers including at least a substrate and a bond coat, and where the opening exposes each of the plurality of material layers; and an imaging device configured to create an image of the exposed plurality of material layers in the opening; and a processor configured to calculate at least a thickness of the bond coat of the exposed plurality of material layers from the image and based on the predefined geometry of the opening. Methods of using the system to analyze layer thickness of a multilayer component and repair a multilayer component are also provided.

Abstract: An automated system is provided. The system includes: a manipulator coupled to: an opening forming device configured to create an opening having a predefined geometry partially into a multilayer component at a selected location on a surface of the multilayer component, where the multilayer component includes a plurality of material layers including at least a substrate and a bond coat, and where the opening exposes each of the plurality of material layers; and an imaging device configured to create an image of the exposed plurality of material layers in the opening; and a processor configured to calculate at least a thickness of the bond coat of the exposed plurality of material layers from the image and based on the predefined geometry of the opening. Methods of using the system to analyze layer thickness of a multilayer component and repair a multilayer component are also provided.

Abstract: A system includes a mounting plate having a plurality of reference members, an inspection system having a profiler device, and an additive manufacturing machine operatively coupled with the inspection system. A computer device scans the mounting plate with the profiler device to obtain position and orientation of the reference members and position and top surface profile data of any parts located on the mounting plate. A transmitting step transmits reference member position and orientation and part position and top surface profile data to the additive manufacturing machine. A detecting step detects mounting plate orientation and position inside the additive manufacturing machine. A combining step combines mounting plate orientation/position inside of the additive manufacturing machine and part position and top surface profile data to calculate a build path program for the additive manufacturing machine. A performing step performs a build process using the build path program to repair the parts.

Abstract: A system includes a mounting plate having a plurality of reference members, an inspection system having a profiler device, and an additive manufacturing machine operatively coupled with the inspection system. A computer device scans the mounting plate with the profiler device to obtain position and orientation of the reference members and position and top surface profile data of any parts located on the mounting plate. A transmitting step transmits reference member position and orientation and part position and top surface profile data to the additive manufacturing machine. A detecting step detects mounting plate orientation and position inside the additive manufacturing machine. A combining step combines mounting plate orientation/position inside of the additive manufacturing machine and part position and top surface profile data to calculate a build path program for the additive manufacturing machine. A performing step performs a build process using the build path program to repair the parts.

Abstract: A method to repair an opening in a metallic device including: mount the device on a positioner; while the device is mounted on the positioner, sense and record positions of a surface of an opening in the device using a probe operated by a manipulator; based on the recorded positions determine a centerline and diameter of the opening; orient a digital model of the opening with respect to the opening of the device based on the centerline and diameter of the opening, and apply an weld or cladding to the opening by a welding torch maneuvered automatically by the manipulator while the device is mounted to the positioner and based on the oriented digital model of the opening.

Abstract: A method to repair an opening in a metallic device including: mount the device on a positioner; while the device is mounted on the positioner, sense and record positions of a surface of an opening in the device using a probe operated by a manipulator; based on the recorded positions determine a centerline and diameter of the opening; orient a digital model of the opening with respect to the opening of the device based on the centerline and diameter of the opening, and apply an weld or cladding to the opening by a welding torch maneuvered automatically by the manipulator while the device is mounted to the positioner and based on the oriented digital model of the opening.

Abstract: Locating systems and methods for components are provided. A component has an exterior surface. A method includes locating a surface feature configured on the exterior surface along an X-axis and a Y-axis by analyzing an image of the component to obtain X-axis data points and Y-axis data points for the surface feature. The method further includes directly measuring the surface feature along a Z-axis to obtain Z-axis data points for the surface feature, wherein the X-axis, the Y-axis and the Z-axis are mutually orthogonal. The method further includes calculating at least two of a pitch value, a roll value or a yaw value for the surface feature.

Abstract: Locating systems and methods for components are provided. A component has an exterior surface. A method includes locating a surface feature configured on the exterior surface along an X-axis and a Y-axis by analyzing an image of the component to obtain X-axis data points and Y-axis data points for the surface feature. The method further includes directly measuring the surface feature along a Z-axis to obtain Z-axis data points for the surface feature, wherein the X-axis, the Y-axis and the Z-axis are mutually orthogonal. The method further includes calculating at least two of a pitch value, a roll value or a yaw value for the surface feature.

Abstract: A repair method is provided and includes deriving, from a model of a component, drilling vectors respectively associated with fluid flow passages of the component, obtaining location data of each of the fluid flow passages at least partially from a source other than the model and relying upon the derived drilling vectors and the obtained location data of each of the fluid flow passages to position a tool configured to modify each of the fluid flow passages.