Abstract: A method for in-frame repairing of a thermal barrier coating (12) on a gas turbine component includes cleaning a desired surface portion (10) of the component without removing the component from the gas turbine. The method also includes roughening the surface portion in-frame, applying a bond coat (68) to the surface portion in-frame, and applying a ceramic topcoat (70) to the bond coat, in-frame. A system (28) for cleaning the surface portion in-frame includes an abrasive media (34) having a state change characteristic occurring at a temperature lower than an operating temperature of the gas turbine so that the abrasive media changes from a solid state to another state allowing the media to exit the gas turbine during operation. The system also includes an abrasive media sprayer (36) to direct a spray of the abrasive media at the desired surface portion.

Abstract: A flaw inspection system (10) contains a substrate (12) to be inspected, such as a generator tube wall, a rotor of a generator, an aircraft skin, having or thought to have interior defects (24, 26) such as stress cracks, where the substrate (12) has attached reference blocks (14, 16) also containing defects (18, 20) of the type that might be found in the substrate, where an ultrasonic generator (28) emits sound waves (30) which contact all the defects, causing heat (32) which is sensed by a thermal camera (50) which, in association with a controller (54) causes images (60, 62) to appear on a monitor (52) from which the type and number of defects (24, 26) in the substrate (12) can be determined.

Abstract: A method for in-frame repairing of a thermal barrier coating (12) on a gas turbine component includes cleaning a desired surface portion (10) of the component without removing the component from the gas turbine. The method also includes roughening the surface portion in-frame, applying a bond coat (68) to the surface portion in-frame, and applying a ceramic topcoat (70) to the bond coat, in-frame. A system (28) for cleaning the surface portion in-frame includes an abrasive media (34) having a state change characteristic occurring at a temperature lower than an operating temperature of the gas turbine so that the abrasive media changes from a solid state to another state allowing the media to exit the gas turbine during operation. The system also includes an abrasive media sprayer (36) to direct a spray of the abrasive media at the desired surface portion.

Abstract: A defect detection system for thermally imaging a structure that has been energized by a sound energy. The system includes a transducer that couples a sound signal into the structure, where the sound signal causes defects in the structure to heat up. In one embodiment, the sound signal has one or more frequencies that are at or near an eigen-mode of the structure.

Abstract: A joint (32) having bond line grains (28) that nucleate in the joint region (32) and grow into the adjoined solid substrates (12, 14). The resulting bond line grains have a size that is greater than a thickness (T) of a molten region (15). The surfaces of the substrates are cold worked to a desired degree of residual stress prior to the bonding process so that the recrystallization of the substrate surface necessary for the grains to grow into the substrates results in a reduction in the local free energy.

Abstract: Method for welding objects having limited backside access to a cavity behind a region to be welded. The method includes inserting a fugitive backing material in an installation state into a first portion of the cavity proximate the region to be welded and then transforming the fugitive backing material to a rigid state. The method further includes forming a weld in the region and then transforming the fugitive backing material to a removable state and removing the fugitive backing material from the cavity. The method may also include placing a pre-formed weld backing in the cavity and filling the cavity with a fugitive backing material. The method further includes transforming the fugitive backing material to a rigid state, forming a weld, and transforming the fugitive backing material to a removable state. The method may further include removing the fugitive backing material and removing the pre-formed weld backing from the cavity.

Abstract: A flaw inspection system (10) contains a substrate (12) to be inspected, such as a generator tube wall, a rotor of a generator, an aircraft skin, having or thought to have interior defects (24, 26) such as stress cracks, where the substrate (12) has attached reference blocks (14, 16) also containing defects (18, 20) of the type that might be found in the substrate, where an ultrasonic generator (28) emits sound waves (30) which contact all the defects, causing heat (32) which is sensed by a thermal camera (50) which, in association with a controller (54) causes images (60, 62) to appear on a monitor (52) from which the type and number of defects (24, 26) in the substrate (12) can be determined.

Abstract: A mechanical ultrasonic device that includes a housing assembly, a mechanical vibration assembly disposed within the housing assembly, and having an impact member. The mechanical vibration assembly is structured to vibrate the impact member at a frequency between about 5 kHz to 40 kHz. The impact member may be brought into contact with a test object thereby causing the ultrasonic vibration, or high frequency sonic vibration, to be transmitted through the test object.