A system for forming features within composite components includes a tubular electrode extending along a longitudinal direction from a proximal end to a distal end. The distal end is, in turn, configured to be positioned relative to a machining surface of the composite component such that a spark gap is defined between the distal end and the machining surface. Furthermore, the tubular electrode further extends in a radial direction between an inner surface and an outer surface, with the inner surface defining a central passage configured to supply a dielectric fluid to the machining surface. The outer surface of the tubular electrode includes at least one a channel defined therein or a non-circular cross-sectional shape.

A system for forming features within composite components includes a tubular electrode extending along a longitudinal direction from a proximal end to a distal end. The distal end is, in turn, configured to be positioned relative to a machining surface of the composite component such that a spark gap is defined between the distal end and the machining surface. Furthermore, the tubular electrode further extends in a radial direction between an inner surface and an outer surface, with the inner surface defining a central passage configured to supply a dielectric fluid to the machining surface. The outer surface of the tubular electrode includes at least one a channel defined therein or a non-circular cross-sectional shape.

A method for machining a blade and a blade for a turbomachine comprising a shroud which is positioned on a tip side of the blade. The shroud has an outer surface with at least one circumferential fin arranged thereon, whereby at least one section of the outer surface beside the at least one fin is processed in at least two manufacturing steps. At least one first section of the outer surface is processed to have a first shape and at least one second section of the outer surface is processed to have a second shape.

A method for machining a blade and a blade for a turbomachine comprising a shroud which is positioned on a tip side of the blade. The shroud has an outer surface with at least one circumferential fin arranged thereon, whereby at least one section of the outer surface beside the at least one fin is processed in at least two manufacturing steps. At least one first section of the outer surface is processed to have a first shape and at least one second section of the outer surface is processed to have a second shape.

In order to stably produce a structured article made of a metal with a complex shape, such as a turbine stator blade, while securing a sufficient mechanical strength, there is provided a method for manufacturing a cobalt-based alloy structure, the cobalt-based alloy structure including a first structure region comprising a hollow space and a second structure region filled in the hollow space. The method includes the steps of: forming the first structure region by additive manufacturing from a first cobalt-based alloy powder having a particle size distribution within a range of 5-85 μm and in D90 within a range of 40-80 μm; and forming the second structure region in the hollow space by hot isostatic pressing, the hollow space being filled with a second cobalt-based alloy powder with a particle size distribution within a range of 5-85 μm and in D90 within a range of 40-80 μm.

An embodiment of a method includes fabricating a first single crystal boule having a uniform composition and grain orientation. The first uniform single crystal boule is divided into a first plurality of layered shapes. The shapes of the first plurality are stacked with at least a second plurality of layered shapes along a first axis. The second plurality of layered shapes have at least one physical aspect differing from at least one corresponding physical aspect of the first plurality of layered shapes. The first plurality of layered shapes and at least the second plurality of layered shapes are joined via a field assisted sintering technique (FAST) to form a bulk component.

A method of manufacturing a casting is provided and includes establishing desired dimensions of a nominal casting, executing a casting process to produce multiple actual castings with each of the multiple actual castings having respective dimensions that differ from each other and from the desired dimensions of the nominal casting and engaging one or more tools to adaptively machine, without rigidly-programmed toolpaths, each of the multiple actual castings to reduce the respective differences between the actual dimensions of each of the multiple actual castings and the desired dimensions.

A method of manufacturing a casting is provided and includes establishing desired dimensions of a nominal casting, executing a casting process to produce multiple actual castings with each of the multiple actual castings having respective dimensions that differ from each other and from the desired dimensions of the nominal casting and engaging one or more tools to adaptively machine, without rigidly-programmed toolpaths, each of the multiple actual castings to reduce the respective differences between the actual dimensions of each of the multiple actual castings and the desired dimensions.

A method is disclosed herein. In various embodiments, the method comprises: coupling a sheath to an airfoil of an integrally bladed rotor, the sheath comprising a plurality of apertures disposed therein; and coupling a plurality of locators to the integrally bladed rotor, each locator in the plurality of locators disposed through a corresponding aperture in the plurality of apertures.

A method is disclosed herein. In various embodiments, the method comprises: coupling a sheath to an airfoil of an integrally bladed rotor, the sheath comprising a plurality of apertures disposed therein; and coupling a plurality of locators to the integrally bladed rotor, each locator in the plurality of locators disposed through a corresponding aperture in the plurality of apertures.