A method for drilling holes in a part includes positioning the part relative to a laser source, applying a first stress to the part, and applying a laser from the laser source to the part to drill a hole therein, wherein the first stress which is present during the application of the laser counteracts a second stress induced by the application of the laser.

A method of machining cooling holes includes providing a workpiece in which a cooling hole is to be formed. The cooling hole, once formed, defines distinct first and second sections. The workpiece is secured in a fixture that is mounted in a first machine. In the first machine, a laser is used to drill a through-hole in a wall of the workpiece. The through-hole is spatially common to the first and second sections of the cooling hole. After drilling the through-hole, the fixture with the workpiece secured therein is removed from the first machine and mounted in a second machine. In the second machine, ultrasonic machining is used to expand a portion of the through-hole to form the second section. An abrasive slurry used in the process is drained through the through-hole during the ultrasonic machining.

A turbine component includes a root and an airfoil extending from the root to a tip opposite the root. The airfoil forms a leading edge and a trailing edge portion extending to a trailing edge. A plurality of nested cooling channels in the trailing edge portion of the airfoil permit passage of a cooling fluid from an interior of the turbine component to an exterior of the turbine component at the trailing edge portion. A method of making a turbine component includes forming an airfoil having a leading edge, a trailing edge portion extending to a trailing edge, and a plurality of nested cooling channels in the trailing edge portion. Each nested cooling channel fluidly connects an interior of the turbine component with an exterior of the turbine component at the trailing edge portion. A method of cooling a turbine component is also disclosed.

A method for stripping ceramic from a component includes applying a liquid to a ceramic coating of an outer surface of the component. The method also includes directing a plurality of laser pulses at the ceramic coating with the applied liquid in order to spall the ceramic coating from the component.

A method is provided for fabricating a coolant channel closeout jacket on a structure having coolant channels formed in an outer surface thereof. A line of tangency relative to the outer surface is defined for each point on the outer surface. Linear rows of a metal feedstock are directed towards and deposited on the outer surface of the structure as a beam of weld energy is directed to the metal feedstock so-deposited. A first angle between the metal feedstock so-directed and the line of tangency is maintained in a range of 20-90°. The beam is directed towards a portion of the linear rows such that less than 30% of the cross-sectional area of the beam impinges on a currently-deposited one of the linear rows. A second angle between the beam and the line of tangency is maintained in a range of 5-65°.

Methods for fabricating high-strength aluminum-boron nitride nanotube (Al—BNNT) wires or wire feedstock from Al—BNNT composite raw materials by mechanical deformation using wire drawing and extrusion are provided, as well as large-scale, high-strength Al—BNNT composite components (e.g., with a length on the order of meters (m) and/or a mass on the order of hundreds of kilograms (kg)). The large-scale, high-strength Al—BNNT composite components can be made via wire-based additive manufacturing.

A method of manufacturing a component of a rotary machine, the component has at least one inner passage that extends from a center up to a boundary surface of the component and is at least partly closed, and a blank is provided that includes the boundary surface and a top surface. The Method includes a first subtractive machining step that is carried out in which a part of the passage that at least includes an opening of the passage into the boundary surface as well as a cut-out in the top surface are manufactured by machining production, and subsequently the passage is completed by build-up production on the blank.

A manufacturing method is provided. During this method, a preform component is provided for a turbine engine. The preform component includes a substrate comprising electrically conductive material having an outer coating comprising non-electrically conductive material applied over a surface of the substrate. A preform aperture is formed in the preform component using an electrical discharge machining electrode. The preform aperture includes a meter section of a cooling aperture in the substrate. The preform aperture also includes a pilot hole in the outer coating. A diffuser section of the cooling aperture is formed in at least the outer coating using a second machining process.

A method can include co-axially locating a turbine wheel and a shaft where a force applicator applies an axially directed force to the turbine wheel, where the turbine wheel transfers at least a portion of the force to shaft and where a rotatable shaft collet supports the shaft; rotating the rotatable shaft collet; energizing at least one laser beam; and, via the at least one laser beam, forming a weld between the turbine wheel and the shaft.

A method and an apparatus of a powder bed fusion additive manufacturing system that enables a quick change in the optical beam delivery size and intensity across locations of a print surface for different powdered materials while ensuring high availability of the system. A dynamic optical assembly containing a set of lens assemblies of different magnification ratios and a mechanical assembly may change the magnification ratios as needed. The dynamic optical assembly may include a transitional and rotational position control of the optics to minimize variations of the optical beam sizes across the print surface.