A manufacturing method is provided. During this method, a preform component is provided for a turbine engine. The preform component includes a substrate comprising electrically conductive material having an outer coating comprising non-electrically conductive material applied over a surface of the substrate. A preform aperture is formed in the preform component using an electrical discharge machining electrode. The preform aperture includes a meter section of a cooling aperture in the substrate. The preform aperture also includes a pilot hole in the outer coating. A diffuser section of the cooling aperture is formed in at least the outer coating using a second machining process.

A laser cutting method includes a step of determining a material to be removed and dividing the material to be removed into a plurality of material chips so as thereby to organize a machining plan for laser cutting; and, a step of, according to the machining plan for laser cutting, moving a laser along a boundary defining the material to be removed on the workpiece to perform cutting in a first direction and a second direction, such that the material chips can be separated from the workpiece orderly piece by piece so as to form a specific pattern. While in laser cutting, the method removes the material piece by piece. With the laser to remove the material chips through cutting along the boundary, the pattern on the workpiece is thus finished equivalently by the laser. Thereupon, the machining time can be significantly reduced.

A laser welded assembly and method of making. The laser welded assembly includes a first work piece having a thickness (T1) defined between an external surface and a faying surface; a second work piece having a thickness (T2) defined between an external surface and a faying surface of the second work piece; a weld seam having a core fusion zone extending from the external surface of the first work piece through the faying interface and at least partially into the thickness (T2) of the second work piece; and a protruding fusion zone extending laterally from the core fusion zone adjacent to the external surface of the first work piece. The protruding fusion zone may be formed by post-heating or concurrently with the core fusion zone.

A method of making a fluid injector for a gas turbine engine includes depositing material onto a piece of tube stock. The method includes machining the deposited material into a fluid injector component. Depositing can include laser cladding the material onto the piece of tube stock. The method can include placing or flowing braze into a braze joint location between the deposited material and another fluid injector component and forming the braze into a braze joint in the braze joint location.

A process of modifying a passage in a component is provided. The process includes inserting a first material into the passage; blocking at least one end of the passage; inserting an elongated member into the passage through the first material; heat treating the passage, the first material, and the elongated member to form a solid interior in component; and machining through the solid interior to form a modified passage in the component.

A bi-metal variable geometry turbocharger (VGT) vane includes a structural, airfoil-shaped flag portion, and a functional, cylindrically-shaped shaft portion connected to the flag portion. The flag portion and the shaft portion are formed of a first metal alloy, and the shaft portion further includes a surface area formed of a second metal alloy different from the first metal alloy.

A method of making a fluid injector for a gas turbine engine includes depositing material onto a piece of tube stock. The method includes machining the deposited material into a fluid injector component. Depositing can include laser cladding the material onto the piece of tube stock. The method can include placing or flowing braze into a braze joint location between the deposited material and another fluid injector component and forming the braze into a braze joint in the braze joint location.

The present invention includes a laser-welded lap joint including a weld zone formed by laser lap welding in a lapped portion including a plurality of lapped steel sheets. The weld zone includes a main weld zone that penetrates the steel sheets in the lapped portion and a final weld zone formed at one end of the main weld zone and having a crater, and the weld zone satisfies formulas (1) to (4):
L≥15.0;  (1)
10.0≥L2≥2l.sub.c;  (2)
t1≥2d.sub.c;  (3)
w.sub.c>d.sub.c  (4).

A method and arrangement for testing and/or correction of a weld (34, 36, 38) of a test object (26, 102), including alignment of an ultrasonic probe (16, 128) guided by a robot (100) on a target position of the weld (28, 30, 32), determination of the actual position (34, 36, 38) of the weld by means of an optical sensor (22, 130) and alignment of the ultrasonic probe (16) on the actual position, and measurement of the weld, where CAD data of the target position of the weld (28, 30, 32) is made available, on the basis of the CAD data of the weld the ultrasonic probe (16, 128) is aligned on the target position of the weld, and the ultrasonic probe is placed on the weld with controlled force after determination of the actual position (34, 36, 38) of the weld by means of the optical sensor (22, 130).

Described herein is a single-sided welding head including a first welding electrode and a second welding electrode, where the first and second welding electrodes are carried by a body of said welding head. The first welding electrode is movable relative to the body of said welding head at least along a first coordinate of motion. The second welding electrode is movable relative to the body of said welding head at least along a second coordinate of motion; where said first coordinate of motion is a coordinate of angular motion that develops about a first axis of rotation, and said second coordinate of motion is a coordinate of linear motion that develops along a first axis of translation.