A forming tool for forming leading edges of turbine blades is disclosed. In various embodiments, a forming tool may comprise a cylindrically-shaped body having a notch around the circumference of the cylindrically-shaped body. The notch may be positioned perpendicularly to a center axis of the cylindrically-shaped body. Further, the notch may have a notch contour with an upper notch contour and a lower notch contour, and where the notch contour is a relief of a selected turbine blade leading edge. The forming tool may be a grinding tool or a cutting tool. Moreover, a forming process may comprise forming, by a forming tool, a first portion of a turbine blade leading edge with a rough edge result, and forming, by a milling cutter, a second portion of the turbine blade leading edge with a rough edge result.

A method for modifying an aperture in a component, a system for modifying flow through a component, and a turbine component are disclosed. The method includes providing a substrate having at least one aperture having an electrically-conductive surface, providing a deposition device including an ESD torch, the ESD torch including an aperture penetrating electrode including a conductive material, inserting the aperture penetrating electrode at least partially into the aperture, and generating an arc between the aperture penetrating electrode and the electrically-conductive surface to deposit electrode material within the aperture. The system includes the ESD torch removably supported in an electrode holder. The turbine component includes at least one aperture having an electrospark deposited material along an electrically-conductive surface, the electrospark deposited material providing modified fluid flow through the turbine component.

A method for modifying an aperture in a component, a system for modifying flow through a component, and a turbine component are disclosed. The method includes providing a substrate having at least one aperture having an electrically-conductive surface, providing a deposition device including an ESD torch, the ESD torch including an aperture penetrating electrode including a conductive material, inserting the aperture penetrating electrode at least partially into the aperture, and generating an arc between the aperture penetrating electrode and the electrically-conductive surface to deposit electrode material within the aperture. The system includes the ESD torch removably supported in an electrode holder. The turbine component includes at least one aperture having an electrospark deposited material along an electrically-conductive surface, the electrospark deposited material providing modified fluid flow through the turbine component.

A method comprises: providing a spiral metallic workpiece having a cast structure associated with such spiral; and at least partially flattening the workpiece.

A system (24) and method are described herein for manufacturing a wind turbine blade (22) proximate to the final installation site of a wind turbine (10). The system (24) includes a creel (72) of feeders (74) configured to apply strengthening elements (62) onto a plurality of shell core sections (26) coupled together and fed through the creel (72). The shell core sections (26) include an external surface (56) with a plurality of external grooves (58) recessed into the external surface (56) such that the strengthening elements (62) are laid into the external grooves (58). The system (24) also includes a deposition station (78) configured to apply an outer surface material layer (82) in fluid form to cover the external surface (56) and the plurality of strengthening elements (62). A curing station (86) heats and consolidates the shell core sections (26), the strengthening elements (62), and the outer surface material layer (82) together into a final consolidated part, with the outer surface material layer (82) defining an external profile of the blade (22) following curing.

Additive-based electroforming manufacturing methods for producing turbomachine components and other metallic articles are provided, as are metallic articles manufactured utilizing such manufacturing methods. In various embodiments, the method includes providing a sacrificial tooling structure having a component-defining surface region. A metallic body layer or shell is deposited over the component-defining surface region utilizing an electroforming process. The tooling structure is removed, while the metallic body layer is left substantially intact. After tooling structure removal, the metallic body layer is further processed to complete fabrication of the metallic component.

Additive-based electroforming manufacturing methods for producing turbomachine components and other metallic articles are provided, as are metallic articles manufactured utilizing such manufacturing methods. In various embodiments, the method includes providing a sacrificial tooling structure having a component-defining surface region. A metallic body layer or shell is deposited over the component-defining surface region utilizing an electroforming process. The tooling structure is removed, while the metallic body layer is left substantially intact. After tooling structure removal, the metallic body layer is further processed to complete fabrication of the metallic component.

Removing unfused powder from internal passages of an additive-manufacture part includes attaching piezoelectric transducers to a plurality of locations on an exterior of the part. The part is vibrated by driving the piezoelectric transducers at varying amplitudes and frequencies. An amount of the unfused powder that exits the part is monitored.

Removing unfused powder from internal passages of an additive-manufacture part includes attaching piezoelectric transducers to a plurality of locations on an exterior of the part. The part is vibrated by driving the piezoelectric transducers at varying amplitudes and frequencies. An amount of the unfused powder that exits the part is monitored.

A magnetorheological support method for blisk processing is disclosed. In the method, a fork structure and a soft film are used to wrap magnetorheological fluid. The magnetorheological fluid is used for flow filling under certain pressure. The bulged soft film can conduct shape matching on the surface of a blisk blade. The magnetorheological fluid can be cured through magnetic field excitation, thereby ensuring the flexible support for a weak rigid component. Electric permanent magnets are symmetrically arranged at both ends of the fork structure to construct a uniform magnetic field that can realize a global excitation of magnetorheological fluid, so that the magnetorheological fluid works in a shear mode to achieve damping force controlling by magnetic field. The solid-liquid conversion of the magnetorheological fluid is controlled by an electric permanent magnet field.