Abstract: A method of modifying an end wall contour is provided. The method includes creating a weld pool using a laser, adding a metal or a ceramic powder or a wire filler to the melt pool and modifying the part of the turbine in a manner that results in a change of about 0.005 to about 50 volume percent in the part of the turbine. The weld pool is created on a turbine component and contains molten metal or ceramic derived as a result of a heat interaction between the laser and the turbine component.

Abstract: A laser machining system comprises a laser configured to generate a laser output for forming a molten pool on a substrate, a nozzle configured to supply a growth material to the molten pool for depositing the material on the substrate, and an optical unit configured to capture a plurality of grayscale images comprising temperature data during the laser deposition process, wherein the grayscale images correspond to respective ones of a plurality of radiation beams with different desired wavelengths. Further, the laser machining system comprises an image-processing unit configured to process the grayscale images to retrieve the temperature data according to linear relationships between temperatures in the laser deposition process and the corresponding grayscales of the respective images. A laser machining method is also presented.

Abstract: A profilometry apparatus is provided. The profilometry apparatus includes a fringe projection device configured to project a fringe pattern on an object and an optical unit configured to capture an image of a distorted fringe pattern modulated by the object. The profilometry apparatus also includes a signal processing unit configured to process the captured image from the optical unit to filter noise from the image and to obtain real-time estimation of parameters associated with manufacture or repair of the object.

Abstract: Disclosed herein is a method comprising creating a weld pool using a laser; wherein the weld pool is created on a part of a turbine; and wherein the weld pool comprises molten metal or ceramic derived as a result of a heat interaction between the laser and the part of the turbine; adding a metal or a ceramic powder or a wire filler to the melt pool; and modifying the part of the turbine in a manner that results in a change of about 0.005 to about 50 volume percent in the part of the turbine, while improving the aerodynamic efficiency of the turbine in an amount of about 0.1 to about 5 percent over a corresponding unmodified turbine.

Abstract: A profilometry apparatus is provided. The profilometry apparatus includes a fringe projection device configured to project a fringe pattern on an object and an optical unit configured to capture an image of a distorted fringe pattern modulated by the object. The profilometry apparatus also includes a signal processing unit configured to process the captured image from the optical unit to filter noise from the image and to obtain real-time estimation of parameters associated with manufacture or repair of the object.

Abstract: A laser repair method for a high gamma prime content Ni base superalloy substrate surface, with gamma prime content in the range of at least about 30 volume %, conducts the repair at ambient temperature without preheating the substrate surface and by controlling processing parameters to avoid cracking of the resulting weld bead during and after welding. The laser beam, operating in a power range of about 50-10000 watts per centimeter, is focused away from the substrate surface to provide a laser spot in the size range of about 0.03-0.2″. A relative movement between the substrate surface and the laser beam, for example at a rate in the range of about 1-100 inches per minute, provides an interaction time of no greater than about 10 seconds between the laser beam and the substrate surface. Concurrently, a repair alloy powder is deposited in the laser beam to melt and fuse the repair alloy powder into a molten repair alloy deposited on the substrate surface.

Abstract: A laser repair method for a high gamma prime content Ni base superalloy substrate surface, with gamma prime content in the range of at least about 30 volume %, conducts the repair at ambient temperature without preheating the substrate surface and by controlling processing parameters to avoid cracking of the resulting weld bead during and after welding. The laser beam, operating in a power range of about 50-10000 watts per centimeter, is focused away from the substrate surface to provide a laser spot in the size range of about 0.03-0.2″. A relative movement between the substrate surface and the laser beam, for example at a rate in the range of about 1-100 inches per minute, provides an interaction time of no greater than about 10 seconds between the laser beam and the substrate surface. Concurrently, a repair alloy powder is deposited in the laser beam to melt and fuse the repair alloy powder into a molten repair alloy deposited on the substrate surface.