A system and methods are provided for pre-stressing blade elements for a gas turbine engine. In one embodiment, a method includes rotating a blade element relative to an axis. The method may also include controlling rotational speed of the blade element to generate residual stress in the blade element. The method may also include rotating multiple blade elements and fan blade units to generate residual stress. Blade elements may be rotated to exceed a maximum operating speed of the blade element to 120% of the maximum operating speed of the blade element.

A finishing apparatus including a central control machine having a computerized controller, at least one articulating device controlled by the central control machine and operable to move the machining tool, and at least one of a touch sensor apparatus and a visual sensor apparatus mounted to said machining tool and communicatively coupled to the computerized controller. The computerized controller configured to cause the finishing apparatus to position a machining element in contact with an exterior surface of a film cooled article, move the machining element along the exterior surface while maintaining contact between the machining element and the surface, identify an actual position of a film opening based on sensory feedback while maintaining contact between the machining element and the surface, and remove material from the exterior surface at the film opening using said machining element.

A method for finishing a film cooled article includes providing a film cooled article including at least one inner cooling plenum and at least one opening connecting the inner cooling plenum to an exterior surface of the film cooled article, positioning a machining element in contact with the exterior surface of the film cooled article, automatically moving the machining element along the exterior surface while maintaining contact between the machining tool and the surface, identifying an actual position of at least one film opening based on sensory feedback from the machining element using a controller, removing material from the exterior surface at the at least one film opening using the machining element, thereby creating a depression at the at least one film opening.

A method for finishing a film cooled article includes providing a film cooled article including at least one inner cooling plenum and at least one opening connecting the inner cooling plenum to an exterior surface of the film cooled article, positioning a machining element in contact with the exterior surface of the film cooled article, automatically moving the machining element along the exterior surface while maintaining contact between the machining tool and the surface, identifying an actual position of at least one film opening based on sensory feedback from the machining element using a controller, removing material from the exterior surface at the at least one film opening using the machining element, thereby creating a depression at the at least one film opening.