The present disclosure provides methods and systems for composite-to-metal hybrid bonded structures compromising the laser surface treatment on titanium alloys to promote adhesive bond performance. For example, a computer may be programmed to set a laser path corresponding to a predetermined geometric pattern. A laser may be coupled to the computer and apply a pulsed laser beam to a contact surface of the titanium alloy along the predefined geometric pattern. The laser may generate an open pore oxide layer on the contact surface of the substrate with a thickness of 100 and 500 nm. The open pore oxide layer may have a topography corresponding to the predefined geometric pattern. The topography may contain high degree of open pore structure and promote adhesive bond performance. Adhesive, primer or composite resin matrix may fully infiltrate into the open pore structures. Adhesive and composite laminate may co-cure to form composite-to-titanium hybrid bonded structures.

The present application provides a cooling hole location system for locating a cooling hole in a gas turbine component, wherein the cooling hole is covered by a thermal barrier coating. The cooling hole location system may include a light source positioned on a first side of the gas turbine component and an optical detector positioned on a second side of the gas turbine component. The optical detector detects light from the light source visible through the thermal barrier coating covering the cooling hole.

A manufacturing method is provided. During this method, a preform component for a turbine engine is provided that includes a substrate. A meter section of a cooling aperture is formed in the substrate. An external coating is applied over the substrate. At least a portion of the substrate and the external coating is scanned with an imaging system to provide scan data indicative of an internal structure of the portion of the substrate and the external coating. A diffuser section of the cooling aperture is formed in the external coating and the substrate based on the scan data.

A gas turbine engine component includes a wall that provides exterior and interior surfaces. The interior surface faces an internal cooling passage of the gas turbine engine component. An aperture extends through the wall and interconnects the interior and exterior surfaces to one another and is configured to provide a cooling fluid from the cooling passage to the exterior surface. The aperture has first and second outlet holes overlapping one another at an intersection to provide opposing sharp corners at the intersection.

An impingement baffle for a gas turbine engine is provided. The impingement baffle is a one piece impingement ring with one opening and with fastening elements at both free ends of the impingement ring to enable the closing of the impingement ring. A gas turbine engine including at least one such an impingement baffle is also provided.

A core for gas turbine engine component comprises a body extending between first and second ends to define a length, and extending between first and second edges to define a width. A plurality of core extensions are formed as part of the body. The plurality of core extensions are positioned to be staggered relative to each other such that at least two adjacent core extensions are variable relative to each other in at least one dimension. A gas turbine engine component is also disclosed.

The invention relates to a method for producing a rotor of a flow engine, namely an integrally bladed rotor with an integral outer shroud, comprising at least the following steps: a rotor blank comprising the integral rotor blades and the integral outer shroud is first produced by means of a generative production method; the rotor blank is then subjected to a separating surface treatment at flow-guiding sections and is subjected, separately therefrom, to a machining surface treatment at non-flow-guiding sections.

The present disclosure is directed to a system for performing in-situ laser machining on a component within a gas turbine engine, in which the component includes a substrate defining a surface. The system includes a laser system disposed externally of the gas turbine engine, a focusing optic, and a conduit. The laser system includes a laser unit that produces an output beam. The focusing optic is disposed between the laser unit and the component. The conduit defines a first end external of the engine and a second end that ingresses into the engine through an access port. The conduit includes a plurality of mirrors within the conduit. The plurality of mirrors directs the output beam from the laser system onto the component.

A method of forming a hole in an engine component. The hole is formed through a wall defining first and second opposing surfaces. An inlet is located on the first surface and an outlet on the second surface where a passage connects the inlet and the outlet. Fluid is passed through the passage, emitted from the passage, and redirected upon existing the outlet.

A method for repairing one or more holes in a near wall of a component is provided. The method includes determining updated hole information, including an updated location, of a first hole in the near wall of the component. The method also includes directing a confined laser beam of the confined laser drill towards the near wall of the component at the updated location of the first hole to drill through a coating of the component extending over and/or positioned in the first hole. The method also includes sensing a characteristic of light reflected from the updated location of the first hole and determining the confined laser beam of the confined laser drill has drilled through a portion of the coating of the component extending over and/or positioned in the first hole based on the sensed characteristic of light.