Repaired rotors are provided. The rotors are repaired by using an indenter apparatus for plastically straining original portions of the rotor and adjacent repair welds. The weld nugget, adjacent heat affected zones, and the adjacent parent-metal portions or new metal portions, are indented at a weld nugget and heat affected zone, to produce threshold levels of uniform plastic strain which meet or exceed plastic strain levels that provide, when the weld nugget and heat affected zone is heat treated, a recrystallized grain structure metallurgically comparable to the grain structure of the original parent-metal of the rotor. Repaired integrally bladed rotors for gas turbine engines, such as aircraft engines, are provided. Blades for gas turbine engines, including integrally bladed rotors, may be advantageously provided, having been manufactured or repaired as described.

A calibration system, a calibration method, and a calibration device configured to determine base information of a polish head to polish a workpiece through the polish head are provided. The base information comprises a first position. The calibration system includes the polish head, a controller, and a sensor group. The controller is coupled to the polish head and controls the polish head to move along a first direction. The sensor group detects a force that at least one of the polish head and the workpiece senses to generate a first pressure value. The controller determines whether the first pressure value is greater than a predetermined value. According to that the first pressure value is greater than the predetermined value, the first position is determined.

A calibration system, a calibration method, and a calibration device configured to determine base information of a polish head to polish a workpiece through the polish head are provided. The base information comprises a first position. The calibration system includes the polish head, a controller, and a sensor group. The controller is coupled to the polish head and controls the polish head to move along a first direction. The sensor group detects a force that at least one of the polish head and the workpiece senses to generate a first pressure value. The controller determines whether the first pressure value is greater than a predetermined value. According to that the first pressure value is greater than the predetermined value, the first position is determined.

A method for surface treatment of a workpiece includes providing the workpiece with hardened workpiece surface, clamping the workpiece, removing material from the hardened workpiece surface with a material removal tool to produce a machined surface with first machining tracks, and rolling the machined surface with a rolling tool by overlapping the first machining tracks to produce a rolled surface with second machining tracks. A distance between the material removal tool and the rolling tool measured in an axial direction of the workpiece is varied in an oscillating manner. The material removal tool may be advanced in the axial direction at a constant speed and the rolling tool may be advanced in the axial direction at an oscillating speed, or the rolling tool may be advanced in the axial direction at a constant speed and the material removal tool may be advanced in the axial direction at an oscillating speed.

An installation tool assembly includes a workpiece and a tool. The workpiece includes a first wall having an aperture and a second wall spaced from the first wall relative to a first axis to present an access point therebetween. The installation tool assembly includes a fastener disposed in the aperture of the first wall at an initial position. The fastener includes a hole and a fastener locking feature disposed inside the hole. The tool includes a tool locking feature that is configured to engage the fastener locking feature to secure together the fastener and the tool in the initial position. The tool is operable to pull the fastener farther through the aperture into an interference fit with the first wall in an installed position. A tooling assembly includes the tool and the fastener. A method of installing the fastener to the workpiece uses the tool.

An installation tool assembly includes a workpiece and a tool. The workpiece includes a first wall having an aperture and a second wall spaced from the first wall relative to a first axis to present an access point therebetween. The installation tool assembly includes a fastener disposed in the aperture of the first wall at an initial position. The fastener includes a hole and a fastener locking feature disposed inside the hole. The tool includes a tool locking feature that is configured to engage the fastener locking feature to secure together the fastener and the tool in the initial position. The tool is operable to pull the fastener farther through the aperture into an interference fit with the first wall in an installed position. A tooling assembly includes the tool and the fastener. A method of installing the fastener to the workpiece uses the tool.

The system described herein relates to machining the running surface of a rail by means of at least one rotating, chip-removing shaping tool which can be moved along the rail and can be pressed at least against its running surface. In order to create advantageous design conditions, it is proposed that after the machining with the chip-removing shaping tool at least one rolling body which is adapted to the shape-machined rail surface is rolled over the rail, with cold deformation of the running surface of the rail, in order to level out unevenness of the running surface of the rail.

The system described herein relates to machining the running surface of a rail by means of at least one rotating, chip-removing shaping tool which can be moved along the rail and can be pressed at least against its running surface. In order to create advantageous design conditions, it is proposed that after the machining with the chip-removing shaping tool at least one rolling body which is adapted to the shape-machined rail surface is rolled over the rail, with cold deformation of the running surface of the rail, in order to level out unevenness of the running surface of the rail.

An ultrasonic roller burnishing system comprises a roller and a controller. The roller is configured to be pressed against a surface of a workpiece to a pressing depth, roll on the surface at a feed rate, and vibrate at an ultrasonic frequency under a back pressure. The roller is pressed and rolled by a motion unit which is driven by a drive motor. The vibrating of the roller is driven by an ultrasonic vibration unit with an input current inputted thereinto. The controller is configured to adjust at least one of the pressing depth, the back pressure, the input current and the feed rate based on an expected residual compressive stress and a real time output power of the drive motor, to generate a residual compressive stress in the workpiece which is in an expected range predetermined based on the expected residual compressive stress.

An ultrasonic roller burnishing system comprises a roller and a controller. The roller is configured to be pressed against a surface of a workpiece to a pressing depth, roll on the surface at a feed rate, and vibrate at an ultrasonic frequency under a back pressure. The roller is pressed and rolled by a motion unit which is driven by a drive motor. The vibrating of the roller is driven by an ultrasonic vibration unit with an input current inputted thereinto. The controller is configured to adjust at least one of the pressing depth, the back pressure, the input current and the feed rate based on an expected residual compressive stress and a real time output power of the drive motor, to generate a residual compressive stress in the workpiece which is in an expected range predetermined based on the expected residual compressive stress.