A tool for validating a wire-electric-discharge-machining (wEDM) operation to be performed using a wEDM machine comprises a body including an engagement feature shaped to removably hold a validation coupon to be machined in the wEDM operation, the validation coupon sized larger than a size of a cut-out to be made in a part using the wEDM machine. A method of manufacturing the tool and a wEDM machine assembly are also provided.

A method of wire-electric-discharge-machining (wEDM) a feature in a part includes using wEDM, cutting and detaching a slug from a portion of the part that is to be detached from the part to define the feature, and thereby defining a validation cut-out in the portion, and using wEDM, cutting and detaching the portion having the validation cut-out from the part and thereby defining the feature.

Electric discharge electrodes are disposed at equal intervals along a circumference about a rotary shaft, and provided so as to be capable of being brought into and out of contact with vanes such that one electric discharge electrode corresponds to one vane. The electric discharge electrodes each have an electrode surface along a surface to be machined of a corresponding one of the vanes. After the electric discharge electrodes each move radially inward toward the rotary shaft, the rotary shaft rotates and electrochemical machining is thus performed while the electrode surface and the surface to be machined are close to and thus face each other.

Electric discharge electrodes are disposed at equal intervals along a circumference about a rotary shaft, and provided so as to be capable of being brought into and out of contact with vanes such that one electric discharge electrode corresponds to one vane. The electric discharge electrodes each have an electrode surface along a surface to be machined of a corresponding one of the vanes. After the electric discharge electrodes each move radially inward toward the rotary shaft, the rotary shaft rotates and electrochemical machining is thus performed while the electrode surface and the surface to be machined are close to and thus face each other.

Methods and systems of electrochemically machining are provided. The methods may include applying a first potential to a tool electrode of an electrochemical machining system to generate a primary electric field. The electrochemical machining system may include a workpiece opposite the tool electrode, at least one bias electrode, and at least one fluid delivery channel within the at least one bias electrode. The method may further include applying at least one second potential to the at least one bias electrode. The method may further include delivering a charged electrolyte solution through the at least one fluid delivery channel into the electrolyte solution. Applying at least one second potential and the delivering the charged electrolyte solution generates at least one secondary electric field adjacent to the primary electric field and quenches at least one location of the primary electric field.

Methods and systems of electrochemically machining a component are provided. The method may include applying two or more potentials to a tool electrode comprising an array of two or more individual electrodes to generate two or more electric fields in between the tool electrode and a workpiece opposite of the tool electrode, wherein each of the two or more electric fields is generated by one of the array of two or more individual electrodes.

Methods of forming a cooling passage on a turbine component having a component wall with an internal surface and an external surface, are disclosed. An opening is formed passing through the component wall and fluidly connecting the internal and external surfaces. The opening includes a metering section extending from the internal surface to a metering end, and a diffuser area extending from the metering end to the external surface. A preformed cap element is added to close a portion of the diffuser area to form the cooling passage with a diffusion section extending from the metering end to the external surface. The preformed metal cap element includes a projection extending internally of the external surface and into the diffusion area to define an internally facing section of the diffusion section. The cooling passage extends through the component wall and fluidly connects the internal surface and the external surface.

Methods of forming a cooling passage on a turbine component having a component wall with an internal surface and an external surface, are disclosed. An opening is formed passing through the component wall and fluidly connecting the internal and external surfaces. The opening includes a metering section extending from the internal surface to a metering end, and a diffuser area extending from the metering end to the external surface. A preformed cap element is added to close a portion of the diffuser area to form the cooling passage with a diffusion section extending from the metering end to the external surface. The preformed metal cap element includes a projection extending internally of the external surface and into the diffusion area to define an internally facing section of the diffusion section. The cooling passage extends through the component wall and fluidly connects the internal surface and the external surface.

A process of forming a shaped cooling passage in an article comprising positioning the article within a laser drilling apparatus; laser ablating a near net-shaped cooling passage having a meter section and a diffuser section; forming a re-recast on an interior wall of said cooling passage in both the meter section and the diffuser section; positioning the article within an electric discharge machining apparatus; and electric discharge machining said re-cast from said interior wall at both the meter section and diffusor section with the same electric discharge machine electrode to form a finished shaped cooling passage.

A process of forming a shaped cooling passage in an article comprising positioning the article within a laser drilling apparatus; laser ablating a near net-shaped cooling passage having a meter section and a diffuser section; forming a re-recast on an interior wall of said cooling passage in both the meter section and the diffuser section; positioning the article within an electric discharge machining apparatus; and electric discharge machining said re-cast from said interior wall at both the meter section and diffusor section with the same electric discharge machine electrode to form a finished shaped cooling passage.