A method of making a light weight component is provided. The method including the steps of: forming a metallic foam core into a desired configuration; applying an external metallic shell to an exterior surface of the metallic foam core after it has been formed into the desired configuration; forming an inlet opening and an outlet opening in the external metallic shell in order to provide a fluid path through the metallic foam core; and injecting a thermoplastic material into the metallic foam core via the inlet opening.

A method of making a light weight component including the steps of: forming a metallic foam core into a desired configuration; applying an external metallic shell to an exterior surface of the metallic foam core after it has been formed into the desired configuration; forming an inlet opening and an outlet opening in the external metallic shell in order to provide a fluid path through the metallic foam core; and injecting a thermoplastic material into the metallic foam core via the inlet opening.

A system is configured for machining a workpiece of a lattice structure, the system includes an electrode of a lattice structure, an electrolyte supply, and a power supply. The workpiece and the electrode are intertwined with each other and electrically isolated from each other. The electrolyte supply is configured for circulating an electrolyte around and between the workpiece and the electrode. The power supply is configured for applying a voltage between the workpiece and the electrode to facilitate smoothing surfaces of the workpiece.

A method of working a gas turbine engine component, for example, a turbine airfoil platform having a heat crack, is disclosed. The presented method may allow turbine airfoils to be repaired, modified, manufactured or otherwise worked and subsequently assembled into a turbine section of a gas turbine engine. This method may help to reduce the costs of operating a gas turbine engine by allowing damaged turbine airfoils to be repaired rather than discarded.

A method for chemical processing an internal cavity of an additive manufactured (AM) metal workpiece is disclosed in which a connector is provided in fluid connection with the internal cavity and a chemical polishing solution is flowed through the connector and the internal cavity to process the internal cavity to a desired finish.

The invention concerns a procedure for the manufacture of at least one supporting structure (2) comprising support element (11) for at least sectional support of a generatively formed three-dimensional object (3) on the support structure (2) through generatively configured successive layered selective solidification of built material layers from a solidifiable built material (4), by means of an energy beam (6), with at least one attack structure (12) being configured, on which electrochemical material removal can be initiated or is initiated on at least one support element (11).

A system of manufacturing a component comprises forming a component on a conductive build plate. The component defines at least one access port and includes an inner surface that defines at least one internal passage. The system further includes forming at least one electrode within the at least one internal passage, wherein the at least one electrode is electrically isolated from the component. An electromotive force is applied to the at least one electrode to facilitate smoothing the inner surface.

A downhole tool, for removing sections of metal tubing, said downhole tool comprising at least one conductive element being arranged to corrode a section of metal tubing using an electrolytic process, said conductive element being made of electric conductive material, an apparatus to establish a connection to the metal tubing, and a source of electrical power.

A system is configured for machining a workpiece of a lattice structure, the system includes an electrode of a lattice structure, an electrolyte supply, and a power supply. The workpiece and the electrode are intertwined with each other and electrically isolated from each other. The electrolyte supply is configured for circulating an electrolyte around and between the workpiece and the electrode. The power supply is configured for applying a voltage between the workpiece and the electrode to facilitate smoothing surfaces of the workpiece.

Erosion electrodes and associated devices, systems, and methods for providing improved performance during a process driven by FEED and facilitated by fluid flushing of a worksite is disclosed. Use of erosion electrodes having varying cross-sectional geometries result in customizable channels, within which the FEED process may proceed, improving efficiency and efficacy of the process as the erosion electrode is advanced longitudinally into a workpiece.