Abstract: A method includes removing a casting shell and core from a cast component, which may be a gas turbine blade. The method further includes utilizing a focused removal technique, such as a water jet or laser drill, to remove a portion of a virtual pattern cast (VPC) shell from the cast component. The cast component is then exposed to a leaching solution and high pressure water wash to remove an internal core material and a portion of the VPC shell remainder from the cast component. The method further includes exposing the cast component to a high agitation leaching solution and to the high pressure water wash for a minimal time. An electroless nickel-boron coating is then applied to the cast component, and an electrolytic palladium coating is further applied to the cast component. The cast component is further exposed to a high agitation leaching solution for an extended period.

Abstract: A method includes removing a casting shell and core from a cast component, which may be a gas turbine blade. The method further includes utilizing a focused removal technique, such as a water jet or laser drill, to remove a portion of a virtual pattern cast (VPC) shell from the cast component. The cast component is then exposed to a leaching solution and high pressure water wash to remove an internal core material and a portion of the VPC shell remainder from the cast component. The method further includes exposing the cast component to a high agitation leaching solution and to the high pressure water wash for a minimal time. An electroless nickel-boron coating is then applied to the cast component, and an electrolytic palladium coating is further applied to the cast component. The cast component is further exposed to a high agitation leaching solution for an extended period.

Abstract: The present invention provides a test specimen configured for mechanical load life characterization testing of a dual wall bonded airfoil for use in a turbomachinery device. The dual wall bonded airfoil has a spar and a skin bonded to the spar. The test specimen includes a main stress body, which includes a test spar component configured to represent the spar of the dual wall bonded airfoil; a test skin component configured to represent the skin of the dual wall bonded airfoil; and a test bond joint bonding the skin component to the spar component. The test bond joint is configured to represent the actual bond joint between the spar and the skin of the dual wall bonded airfoil. The test specimen is structured to simulate the dual wall bonded airfoil for testing in a mechanical testing machine.