Abstract: A coating process and TBC system suitable for protecting the surface of a component subjected to a hostile thermal environment. The TBC system has a first layer with a columnar microstructure, and a second layer on the first layer and with a microstructure characterized by irregular flattened grains. According to one aspect, the first layer is present and the second layer is not present on a first surface portion of the component, and the first and second layers are both present on a second surface portion of the component. According to another aspect, the first and second layers contain the same base ceramic compound.

Abstract: A coating process and TBC system suitable for protecting the surface of a component subjected to a hostile thermal environment. The TBC system has a first layer with a columnar microstructure, and a second layer on the first layer and with a microstructure characterized by irregular flattened grains. According to one aspect, the first layer is present and the second layer is not present on a first surface portion of the component, and the first and second layers are both present on a second surface portion of the component. According to another aspect, the first and second layers contain the same base ceramic compound.

Abstract: A method for fabricating a component using an electric-discharge machining (EDM) apparatus includes moving a tool holder of the apparatus to a position adjacent a source of a plurality of differently at least one of sized and shaped electrodes, gripping an electrode of the plurality of differently at least one of sized and shaped electrodes with the tool holder, moving the tool holder and the gripped electrode from adjacent the electrode source to a position adjacent a fixture having the component coupled thereto, and machining the component using the electrode.

Abstract: A method for fabricating a turbine rotor blade includes casting a turbine rotor blade including a dovetail, a platform having an outer surface, an inner surface, and a cast-in plenum defined between the outer surface and the inner surface, and an airfoil, and forming a plurality of openings between the platform inner surface and the platform outer surface to facilitate cooling an exterior surface of the platform.

Abstract: A method for fabricating a turbine rotor blade includes casting a turbine rotor blade including a dovetail, a platform having an outer surface, an inner surface, and a cast-in plenum defined between the outer surface and the inner surface, and an airfoil, and forming a plurality of openings between the platform inner surface and the platform outer surface to facilitate cooling an exterior surface of the platform.

Abstract: A method for fabricating a rotor blade includes casting the turbine rotor blade to include a shank, and a platform having an upper surface and a lower surface, and coupling a first component to the rotor blade such that a first substantially hollow plenum is defined between the first component, the shank, and the platform lower surface.

Abstract: A method facilitates fabricating a rotor assembly for a gas turbine engine. The method comprises providing a plurality of rotor blades that each include an airfoil, a dovetail, a shank, and a platform, wherein the platform extends between the shank and the airfoil, and wherein the dovetail extends outwardly from the shank, and forming a cooling circuit within a portion of the shank to supply cooling air to the rotor blade for supplying cooling air to the rotor blade for impingement cooling a portion of the rotor blade and for supplying cooling air to the rotor blade for purging a cavity defined downstream from the rotor blade.