Abstract: A method of manufacture is provided during which a component is scanned using a computed tomography machine to provide scan data. The component includes a first member and a second member. A first member aperture extends through the first member to the second member. Aperture data is determined for the first member aperture based on the scan data. A center of the scanned geometry is located. An eigen vector is determined for the scanned geometry at the center. An exterior point of intersection between an exterior surface of the second member and an axis is located. The axis is coincident with the center and determined using the eigen vector. A second member aperture is formed in the second member according to a formation operation that aligns the second member aperture being formed with the first member aperture in the first member.

Abstract: A method of manufacture is provided during which a component is scanned using a computed tomography machine to provide scan data. The component includes a first member and a second member. A first member aperture extends through the first member to the second member. Aperture data is determined for the first member aperture based on the scan data. A center of the scanned geometry is located. An eigen vector is determined for the scanned geometry at the center. An exterior point of intersection between an exterior surface of the second member and an axis is located. The axis is coincident with the center and determined using the eigen vector. A second member aperture is formed in the second member according to a formation operation that aligns the second member aperture being formed with the first member aperture in the first member.

Abstract: A filler wire (consumable) for depositing wear-resistant materials in a system for any of brazing, cladding, building up, filling, hard-facing overlaying, welding, and joining applications. The consumable is composed of base filler materials consistent with commonly known compositions. For example, the base filler material can comprise standard materials used in many standard mild steel wires. In addition to the base filler materials, the consumable includes wear-resistant materials. The wear-resistant materials include at least one of diamond crystals, diamond powder, tungsten carbide, and aluminides.

Abstract: A system and method processes a structure comprising embedded material. The system includes a laser adapted to generate light and to irradiate an interaction region of the structure. The system further includes an optical system adapted to receive light from the interaction region and to generate a detection signal indicative of the presence of embedded material in the interaction region. The system further includes a controller operatively coupled to the laser and the optical system. The controller is adapted to receive the detection signal and to be responsive to the detection signal by selectively adjusting the laser.

Abstract: An apparatus processes a surface of an inhabitable structure. The apparatus includes a laser base unit adapted to provide laser light to an interaction region, the laser light removing material from the structure. The laser base unit includes a laser generator and a laser head coupled to the laser generator. The laser head is adapted to remove the material from the interaction region, thereby providing reduced disruption to activities within the structure. The apparatus further includes an anchoring mechanism adapted to be releasably coupled to the structure and releasably coupled to the laser head. The apparatus further includes a controller electrically coupled to the laser base unit. The controller is adapted to transmit control signals to the laser base unit in response to user input.

Abstract: An apparatus processes a surface of an inhabitable structure. The apparatus includes a base unit adapted to provide energy waves to an interaction region, the energy waves removing material from the structure. The base unit includes an energy wave generator and a head coupled to the energy wave generator. The head is adapted to remove the material from the interaction region, thereby providing reduced disruption to activities within the structure. The apparatus further includes a manipulation system which includes an anchoring mechanism adapted to be releasably coupled to the structure and a positioning mechanism coupled to the anchoring mechanism and coupled to the head. The manipulation system is adapted to controllably adjust the position of the head relative to the structure. The apparatus further includes a controller electrically coupled to the base unit. The controller is adapted to transmit control signals to the base unit in response to user input.

Abstract: A manipulation system controllably moves a head relative to a surface of an inhabitable structure for irradiating the surface with energy waves from the head. The manipulation system includes a positioning mechanism coupled to the head. The positioning mechanism includes a first-axis position system adapted to move the head along a first direction substantially parallel to the surface. The positioning mechanism further includes a second-axis position system coupled to the first-axis position system and adapted to move the head along a second direction substantially parallel to the surface. The manipulation system further includes an anchoring mechanism coupled to the positioning mechanism and releasably coupled to the structure.

Abstract: A containment plenum is adapted to deliver laser light to an interaction region of a structure to remove material from the structure. The containment plenum includes a window substantially transparent to the laser light. The window transmits laser light towards the interaction region and provides a barrier to transport of particulate matter generated by interaction of the laser light and the structure. The containment plenum further includes a nozzle fluidly coupled to a source of compressed gas. The laser light and the compressed gas are transmitted through the nozzle towards the interaction region of the structure. The nozzle is either gas-cooled or liquid-cooled. The containment plenum further includes a resilient interface that resiliently contacts the structure and substantially surrounds the interaction region, thereby confining the material and removing the material from the interaction region.

Abstract: A laser head for irradiating an interaction region of a structure with laser light to remove material from the structure. The laser head includes a housing, an anchoring mechanism, and a connector coupled to the housing and optically coupled to a laser generator. The anchoring mechanism is reversably coupled to the housing and releasably affixed to the structure by vacuum pressure. The anchoring mechanism releasably holds the laser head at a selected position in relation to the structure. The connector transmits laser light from the laser generator. The laser head further includes a plurality of optical elements contained in the housing. The laser head further includes a containment plenum coupled to the housing. The containment plenum is optically coupled to the plurality of optical elements to receive the laser light. The containment plenum confines the material and removes the material from the interaction region resulting from irradiating the structure with the laser light.

Abstract: An apparatus processes a surface of an inhabitable structure. The apparatus includes a laser base unit which irradiates an interaction region with laser light, the laser light removing material from the structure. The laser base unit includes a laser generator and a laser head coupled to the laser generator. The laser head includes a containment plenum which confines and removes material from the interaction region. The containment plenum includes a rubber seal which contacts the structure and which substantially surrounds the interaction region, thereby facilitating confinement and removal of material from the interaction region, and providing reduced disruption to activities within the structure. The apparatus further includes an anchoring mechanism releasably coupled to the structure and releasably coupled to the laser head. The apparatus further includes a controller electrically coupled to the laser base unit. The controller transmits control signals to the laser base unit in response to user input.

Abstract: A laser head is adapted to irradiate an interaction region of an inhabitable structure with laser light to remove material from the structure. The laser head includes a housing. The laser head further includes a connector coupled to the housing and optically coupled to a laser generator. The connector is adapted to transmit laser light from the laser generator. The laser head further includes at least one optical element contained in the housing and optically coupled to the connector. The optical element is adapted to receive laser light from the connector. The laser head further includes a containment plenum coupled to the housing. The containment plenum is optically coupled to the optical element to receive the laser light from the optical element. The containment plenum is adapted to confine the material and remove the material from the interaction region resulting from irradiating the structure with the laser light.