A manufacturing method is provided. During this method, a preform component is provided for a turbine engine. The preform component includes a substrate. A preform meter section and a preform diffuser section are formed in the substrate. An internal coating is applied to at least the preform meter section to provide a meter section of a cooling aperture. External coating material is applied over the substrate. The applying of the external coating material forms an external coating over the substrate. The applying of the external coating also builds up the external coating material within the preform diffuser section to form a diffuser section of the cooling aperture.

The present invention is directed to in situ methods for maintaining turbine assemblies. One such method includes: disposing a maintenance apparatus on the rotor; positioning the maintenance apparatus proximate to the damaged region by rotating the rotor; and repairing the damaged region by operating a repair tool disposed on the apparatus. Another method includes: disposing a maintenance apparatus on the stator; positioning the damaged region proximate to the maintenance apparatus by rotating the rotor; and repairing the damaged region by operating a repair tool disposed on the apparatus.

Ceramic matrix composite articles include, for example a first plurality of plies of ceramic fibers in a ceramic matrix defining a first extent, and a local at least one second ply in said ceramic matrix defining a second extent on and/or in said first plurality of plies with the second extent being less than said first extent. The first plurality of plies has a first property, the at least one second ply has at least one second property, and said first property being different from said at least one second property. The different properties may include one or more different mechanical (stress/strain) properties, one or more different thermal conductivity properties, one or more different electrical conductivity properties, one or more different other properties, and combinations thereof.

A coupon for replacing a cutout in a hot gas path component of a turbomachine is provided. In one embodiment, the coupon includes a body having an outer surface; and a plurality of grinding depth indicators in the outer surface of the body. In another embodiment, the coupon includes a body having an edge periphery configured to mate with an edge periphery of the cutout, and at least a portion of the edge periphery of the body has a wall thickness greater than a wall thickness of an edge periphery of the cutout. The embodiments may be used together or separately.

A coupon for replacing a cutout in a hot gas path component of a turbomachine is provided. The coupon includes a body having an outer surface; a chamber within the body for receiving a flow of a coolant; and a passage extending from the chamber to the outer surface of the body. The passage includes an internal portion within a wall of the body having a first perpendicular, cross-sectional area and an exit portion at the outer surface of the body having a second perpendicular, cross-sectional area that is greater than the first perpendicular, cross-sectional area.

A pressure tool for rotor blade repair including a mobile support system including a support surface, a first bladder support assembly including a first inflatable bladder fixedly mounted to the support surface, a second bladder support assembly including a second inflatable bladder pivotally mounted relative to the support surface, and an activation mechanism operatively coupled to the second bladder support assembly. The activation mechanism is operable to selectively shift the second bladder support assembly relative to the first bladder support assembly. A fluid delivery system is operable to direct a fluid into each of the first inflatable bladder and the second inflatable bladder.

A mobile machine tool for segmentally machining, in situ, a component, in particular a component of a turbine, which is rotatable about an axis of rotation. The machine tool has a main body, a support element which is held on the main body so as to be movable about a C-axis along a circular-arc-shaped guide path, and a tool module which is held on the support element and is designed to receive a tool. The tool module is located on the support element so as to be linearly movable. A method segmentally machines, in-situ, a component which is mounted in a stationary body so as to be rotatable about an axis of rotation.

A method of reworking an aerospace component includes removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity. The cavity is then at least partially filled with a multiple of layers of discrete laser powder deposition spots of a filler alloy. A cast component for a gas turbine engine includes a cast component non-fusion weldable base alloy with a cavity filled with a multiple of layers of laser powder deposition spots of a filler alloy. The filler alloy may be different than the non-fusion weldable base alloy. A layer of non-fusion weldable base alloy is at least partially within the cavity and over the filler alloy.

The invention relates to a method for repairing a damaged blade tip of a turbine blade which is armor-plated and provided with a blade coating, of a thermal gas turbine. The method according to the invention comprises the steps of removing a blade tip armor plating of the turbine blade at least in the region of the damaged blade tip and producing a repair surface (12), removing only a part of the blade coating of the turbine blade in the region of the repair surface while preserving a part of the blade coating separated from the repair surface (14), restoring the blade tip reinforcement (20), and restoring the blade coating in the region of the repaired blade tip (22). The invention furthermore relates to a device for carrying out such a method.

A method of forming a build in a powder bed includes providing a first diode laser fiber array and a second diode laser fiber array, emitting a plurality of laser beams from selected fibers of the second diode laser fiber array onto the powder bed, corresponding to a pattern of a layer of the build, simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build, scanning a first diode laser fiber array along an outer boundary of the powder bed and emitting a plurality of laser beams from selected fibers of the first diode laser fiber array and simultaneously melting powder in the powder bed corresponding to the outer boundary of the layer of the build to contour the layer of the build. An apparatus for forming a build in a powder bed including a first diode laser fiber array and a second diode laser fiber array is also disclosed. The first diode laser fiber array configured to contour the layer of the build.