A method for forming a diffusion cooling hole in a substrate includes removing material from the substrate to form a metering section having an inlet on a first side of the substrate and removing material from the substrate to form a diffusing section that extends between the metering section and an outlet located on a second side of the substrate generally opposite the first side. The method also includes forming a feature on a substrate surface within one of the metering section and the diffusing section. Forming the feature includes depositing a material on the substrate surface and selectively heating the material to join the material with the substrate surface and form the feature.

Method for constructing impingement/effusion cooling features in a component of a combustion turbine engine is provided. A pocket 102 may be arranged between an outer wall 104 and an inner wall 106 of the component. A lasing device 108 allows drilling through the component to form an effusion hole 110. The lasing device further allows welding closed an opening 117 formed at outer wall 104 of the component during the drilling with the lasing device through the component. Lasing device 108 further allows drilling through outer wall 104 of the component to form an impingement hole 118 for the impingement/effusion cooling feature. The proposed methodology in a multi-panel arrangement, for example, eliminates a need of having to pre-drill such holes in individual panels prior to the bonding and forming of the component, which overcomes various drawbacks commonly associated with such pre-drilling.

A gas turbine part with a cooling hole, is fabricated by first forming a model of a wall of a gas turbine part. The wall is defined by first and second surfaces, the first surface having an aperture indentation possessing a complex geometry and extending into but not all the way through the wall of the gas turbine part. A mold of the wall of the gas turbine part is formed using the model and is used to cast the wall of the gas turbine part by lost-material casting. A passage is drilled through the resulting casting. This passage extends from the aperture indentation in the first surface through to the second surface.

A gas turbine engine component has an engine component body and at least one hole formed within the engine component body and extends between a hole inlet and a hole outlet. The hole has a first portion with a first roughness and a second portion having a second roughness that is less than the first roughness. The first portion is upstream of the second portion. A gas turbine engine and a method of forming a cooling hole are also disclosed.

Systems and methods are disclosed herein for repairing components. A material layer may be deposited on a surface of a component. The material layer may cover a cooling hole. A pulsed heat source may heat the component and the material layer. An infrared camera may take a series of images of the component. A location of the cooling hole may be identified based on thermal properties of the component. A removal tool may remove a portion of the material layer in order to expose the cooling hole.

Methods provided for remotely stopping a crack in a component of a gas turbine engine are provided, along with methods of remotely cleaning a surface area of a component of a gas turbine engine. The method can include inserting an integrated repair interface attached to a cable delivery system within a gas turbine engine; positioning the tip adjacent to a defect within a surface of the component; temporarily attaching the tip adjacent to the defect within the surface on the component; and drilling a hole into the base of the defect. An integrated repair interface is also provided.

Methods for repairing a coated part with holes extending therethrough are disclosed. In one embodiment, a method comprises receiving a part where a coating on a first side of the part at least partially obstructs a first opening of a hole on the first side of the part. Measured hole data indicative of a position of a second opening of the hole on a second side of the part opposite the first side is then acquired. Based on the measured hole data, the first opening of the hole is cleared of the coating by laser drilling via the second opening of the hole.

An air seal may comprise an annular ring defined by at least a proximal surface, a distal surface, an aft side and a forward side. A channel may be disposed in the forward side of the air seal and/or the aft side of the air seal and may extend between the proximal surface and the distal surface. An additional channel extending from at least one of the forward side or the aft side may be disposed in the distal surface. The channel and the additional channel may be circumferentially in line. The channels may define a flow path for direction cooling air from a proximal side of the air seal to a distal side of the air seal. The radial channel may interface with the axial channel at an edge of the air seal.

A system is provided for performing an operation on a component of an engine. The component includes a first side positioned within an interior of the engine. The system includes a first robotic arm defining a first distal end and including a first utility member positioned at the first distal end, the first robotic arm moveable to the interior of the engine to a location operably adjacent to the first side of the component; and a second robotic arm defining a second distal end and including a second utility member positioned at the second distal end, the second robotic arm also moveable to the interior of the engine to facilitate the first and second utility members performing the operation on the component of the engine.

A method of manufacturing an airfoil includes creating a plurality of cavities separated by a plurality of internal ribs in an airfoil forging. At least one hole is drilled in at least one of the plurality of internal ribs with a laser drilling tool. At least one hole extends perpendicularly to a wall of the rib.