Abstract: A method of making a component with an integral strain indicator includes forming the component from a first material, where the component has an outer surface and an internal volume; and directly depositing a plurality of fiducial markers on a portion of the outer surface. The fiducial markers are formed from a second material that is compatible with the first material, and the portion of the outer surface defines an analysis region on the outer surface of the component. The analysis region defines a gage length, and each fiducial marker of the plurality of fiducial markers has a maximum diameter of between one-tenth and one-twentieth of the gage length. Periodic measurement of the fiducial marker positions is performed to monitor component strain.

Abstract: A rework press assembly for reworking a dimensionally non-conformant component is provided. The rework press assembly includes a frame, a die coupled to the frame and configured to contact a first portion of the component, and a ram. The ram is coupled to the frame opposite the die with respect to an axis of the rework press assembly and is configured to contact a second portion of the component. The ram and the die define a component cavity therebetween. At least one of the die and the ram has a first length, relative to the axis, in response to the rework press assembly being at a first thermal condition. The at least one of the die and the ram has a second length, relative to the axis, in response to the rework press assembly being at a second thermal condition, and the second length is greater than the first length.

Abstract: A flow diverter for an air separator of a gas turbine includes a cylindrical body configured to fit within a cooling hole of the air separator. One or more air flow vents are defined through and around a partial circumference of the cylindrical body. A bottom panel closes the cylindrical body at one end. A mounting flange surrounds the cylindrical body at an open end and extends radially outward from the cylindrical body. When the flow diverter is installed, air flows through the open end in a radial direction and exits through the air flow vents in an axial direction. The cylindrical body may include a collapsible region that collapses to engage the air separator and prevent the flow diverter from being dislodged. The air separator may additionally or alternately include supplemental cooling holes in a recessed area proximate to its mounting flange.

Abstract: A method of treating a substrate of a turbomachine component includes applying a coating to a surface of the substrate of the turbomachine component and peening the substrate after applying the coating to the surface by directing a peening force onto the coating whereby the peening force on the coating is transferred through the coating to the substrate. A method of treating an internal surface of a turbomachine component includes directing a peening force at the internal surface within a cooling passage of the turbomachine component.

Abstract: A mold system for forming a casting article for investment casting in which the mechanical integrity of a ceramic core can be tested by viscosity manipulation. A method for testing a ceramic core used for an investment casting includes: positioning the ceramic core within a mold for receiving a sacrificial material fluid to form a sacrificial material on at least a portion of the ceramic core, the ceramic core having a predefined layout; during casting of the sacrificial material fluid about the ceramic core using the mold, controlling a viscosity of the sacrificial material fluid to simulate an expected viscosity of a molten metal used during a subsequent investment casting using the ceramic core; and evaluating mechanical damage to at least one region of the ceramic core caused by the casting of the sacrificial material fluid.

Abstract: A method of treating a substrate of a turbomachine component includes applying a coating to a surface of the substrate of the turbomachine component and peening the substrate after applying the coating to the surface by directing a peening force onto the coating whereby the peening force on the coating is transferred through the coating to the substrate. A method of treating an internal surface of a turbomachine component includes directing a peening force at the internal surface within a cooling passage of the turbomachine component.

Abstract: A piston for an internal combustion engine with a piston crown and a circumferentially arranged crown edge, whereby, near the periphery of the crown edge, a thermal barrier coating is applied, whereby the thermal barrier coating tapers off before the periphery of the crown edge.

Abstract: A flow diverter for an air separator of a gas turbine includes a cylindrical body configured to fit within a cooling hole of the air separator. One or more air flow vents are defined through and around a partial circumference of the cylindrical body. A bottom panel closes the cylindrical body at one end. A mounting flange surrounds the cylindrical body at an open end and extends radially outward from the cylindrical body. When the flow diverter is installed, air flows through the open end in a radial direction and exits through the air flow vents in an axial direction. The cylindrical body may include a collapsible region that collapses to engage the air separator and prevent the flow diverter from being dislodged. The air separator may additionally or alternately include supplemental cooling holes in a recessed area proximate to its mounting flange.

Abstract: A rework press assembly for reworking a dimensionally non-conformant component is provided. The rework press assembly includes a frame, a die coupled to the frame and configured to contact a first portion of the component, and a ram. The ram is coupled to the frame opposite the die with respect to an axis of the rework press assembly and is configured to contact a second portion of the component. The ram and the die define a component cavity therebetween. At least one of the die and the ram has a first length, relative to the axis, in response to the rework press assembly being at a first thermal condition. The at least one of the die and the ram has a second length, relative to the axis, in response to the rework press assembly being at a second thermal condition, and the second length is greater than the first length.

Abstract: Various aspects include a composite component (also known as a Shear Enabled Regionally Engineered Facet (SEREF)) and methods of forming such a component. In some cases, a method includes: forming a slot in a main body of a metal alloy component, the slot extending at least partially through a wall of the metal alloy component, the forming of the slot including forming an angled main body interface in the wall of the metal alloy component; forming a coupon for coupling with the slot in the metal alloy component, the coupon having an angled coupon interface complementing the angled main body interface; and brazing the coupon to the main body at the slot to form a composite component.

Abstract: Various aspects include a composite component (also known as a Shear Enabled Regionally Engineered Facet (SEREF)) and methods of forming such a component. In some cases, a method includes: forming a slot in a main body of a metal alloy component, the slot extending at least partially through a wall of the metal alloy component, the forming of the slot including forming an angled main body interface in the wall of the metal alloy component; forming a coupon for coupling with the slot in the metal alloy component, the coupon having an angled coupon interface complementing the angled main body interface; and brazing the coupon to the main body at the slot to form a composite component.

Abstract: A corrosion monitoring system includes at least one corrosion sensor. The corrosion sensor includes a metallic plug having at least one opening, at least one ceramic sheath in the opening of the metallic plug, and a plurality of probes. Each probe has a central portion with a predetermined cross sectional area extending from the metallic plug. The ceramic sheath electrically isolates each first end and each second end of the probes from the metallic plug and the other first ends and second ends. The probes are sized to provide a distribution of predetermined cross sectional areas of the central portions. The corrosion monitoring system also includes a resistance meter measuring an ohmic resistance for at least one of the probes and a computer determining a corrosion rate by correlating a rate of change of the ohmic resistance to the corrosion rate of the probe.

Abstract: A mold system for forming a casting article for investment casting in which the mechanical integrity of a ceramic core can be tested by viscosity manipulation. A method for testing a ceramic core used for an investment casting includes: positioning the ceramic core within a mold for receiving a sacrificial material fluid to form a sacrificial material on at least a portion of the ceramic core, the ceramic core having a predefined layout; during casting of the sacrificial material fluid about the ceramic core using the mold, controlling a viscosity of the sacrificial material fluid to simulate an expected viscosity of a molten metal used during a subsequent investment casting using the ceramic core; and evaluating mechanical damage to at least one region of the ceramic core caused by the casting of the sacrificial material fluid.

Abstract: A mold system for forming a casting article for investment casting in which the mechanical integrity of a ceramic core can be tested by viscosity manipulation. A method for testing a ceramic core used for an investment casting includes: positioning the ceramic core within a mold for receiving a sacrificial material fluid to form a sacrificial material on at least a portion of the ceramic core, the ceramic core having a predefined layout; during casting of the sacrificial material fluid about the ceramic core using the mold, controlling a viscosity of the sacrificial material fluid to simulate an expected viscosity of a molten metal used during a subsequent investment casting using the ceramic core; and evaluating mechanical damage to at least one region of the ceramic core caused by the casting of the sacrificial material fluid.

Abstract: A mold system for forming a casting article for investment casting in which the mechanical integrity of a ceramic core can be tested by viscosity manipulation. A method for testing a ceramic core used for an investment casting includes: positioning the ceramic core within a mold for receiving a sacrificial material fluid to form a sacrificial material on at least a portion of the ceramic core, the ceramic core having a predefined layout; during casting of the sacrificial material fluid about the ceramic core using the mold, controlling a viscosity of the sacrificial material fluid to simulate an expected viscosity of a molten metal used during a subsequent investment casting using the ceramic core; and evaluating mechanical damage to at least one region of the ceramic core caused by the casting of the sacrificial material fluid.

Abstract: A piston for an internal combustion engine with a piston crown and a circumferentially arranged crown edge, whereby, near the periphery of the crown edge, a thermal barrier coating is applied, whereby the thermal barrier coating tapers off before the periphery of the crown edge.

Abstract: Various aspects include a composite component (also known as a Shear Enabled Regionally Engineered Facet (SEREF)) and methods of forming such a component. In some cases, a method includes: forming a slot in a main body of a metal alloy component, the slot extending at least partially through a wall of the metal alloy component, the forming of the slot including forming an angled main body interface in the wall of the metal alloy component; forming a coupon for coupling with the slot in the metal alloy component, the coupon having an angled coupon interface complementing the angled main body interface; and brazing the coupon to the main body at the slot to form a composite component.

Abstract: Methods for monitoring component strain, and methods for making a component with an integral strain indicator. A method of making a component with an integral strain indicator includes forming the component with an internal volume formed from a first material and an outer surface and directly depositing a plurality of fiducial markers on a portion of the outer surface. The fiducial markers are formed from a second material that is compatible with the first material and the portion of the outer surface defines an analysis region on the outer surface of the component. The analysis region defines a gage length, and each fiducial marker of the plurality of fiducial markers has a maximum diameter of between one-tenth and one-twentieth of the gage length.

Abstract: A process of forming a calcium-magnesium-aluminosilicate (CMAS) penetration resistant coating, and a CMAS penetration resistant coating are disclosed. The process includes providing a thermal barrier coating having a dopant, and exposing the thermal barrier coating to calcium-magnesium-aluminosilicate and gas turbine operating conditions. The exposing forming a calcium-magnesium-aluminosilicate penetration resistant layer. The coating includes a thermal barrier coating composition comprising a dopant selected from the group consisting of rare earth elements, non-rare earth element solutes, and combinations thereof. Additional or alternatively, the coating includes a thermal barrier coating and an impermeable barrier layer or a washable sacrificial layer positioned on an outer surface of the thermal barrier coating.

Abstract: A ceramic matrix composite article and a process of fabricating a ceramic matrix composite are disclosed. The ceramic matrix composite article includes a matrix distribution pattern formed by a manifold and ceramic matrix composite plies laid up on the matrix distribution pattern, includes the manifold, or a combination thereof. The manifold includes one or more matrix distribution channels operably connected to a delivery interface, the delivery interface configured for providing matrix material to one or more of the ceramic matrix composite plies. The process includes providing the manifold, forming the matrix distribution pattern by transporting the matrix material through the manifold, and contacting the ceramic matrix composite plies with the matrix material.