A method for manufacturing a component of a rotary machine, the component extending to an axial direction and a radial direction vertical thereto, and has an inner channel, extending from a first end of a core of a center of the component and to a second end at a radial limiting surface of the component and which is at least partially closed. A blank includes the core of the component and is limited by an outer surface in the radial direction. The blank is subtractively processed in a first subtractive process step, such that an outer contour is elaborated in the area of the outer surface, which extends in the radial direction, and a part of the channel is manufactured, which radially extends in the blank to the first end. The channel is finished by a build-up process on the blank.

An apparatus and method regarding forming a cooling hole in a component for a turbine engine, with the component held in a hole-forming machine with a laser carried on a multi-axis carriage and defining an optical path, the method comprising forming a set of cooling holes in the component with a laser mounted to the multi-axis carriage, estimating a total airflow through the set of cooling holes based on a set of data regarding the flow effectiveness of the set of cooling holes, and forming a second set of cooling holes with the laser.

A method for manufacturing a component of a rotary machine, the component extends in an axial direction and a radial direction vertical thereto, and has an inner channel, extending from a first end in a center of the component to a second end at a radial limiting surface of the component and which is partially closed. A blank includes the center of the component and is limited by an outer surface in the radial direction. The maximum dimension of the outer surface in the radial direction is smaller than the dimension of the limiting surface in the radial direction, A first subtractive process step is performed such that a part of the channel is manufactured by a machining process, with the part extending from the first end of the channel to the outer surface of the blank. Afterwards the channel is finished by a build-up process on the blank.

A method for manufacturing a component of a rotary machine, the component extending to an axial direction and a radial direction vertical thereto, and has an inner channel, extending from a first end of a core of a center of the component and to a second end at a radial limiting surface of the component and which is at least partially closed. A blank includes the core of the component and is limited by an outer surface in the radial direction. The blank is subtractively processed in a first subtractive process step, such that an outer contour is elaborated in the area of the outer surface, which extends in the radial direction, and a part of the channel is manufactured, which radially extends in the blank to the first end. The channel is finished by a build-up process on the blank.

In an aspect, a method of filling a plurality of cooling holes in an airfoil component, the method comprises injecting a curable composition into a fill channel such that the curable composition flows through the fill channel to the plurality of cooling holes; forming a plurality of beads of the curable composition on a surface of the component over the plurality of cooling holes; directing a radiation to the respective beads in directions parallel to the respective central axes of the cooling holes associated with the respective beads to cure curable composition of the respective beads; and heating the component to cure the curable composition located in the fill channel.

A method of coating a component having a multiple of cooling holes including removing at least a portion of a prior coating from a component; mapping a location of each of the multiple of cooling holes to generate a map of cooling holes; applying a coat to the component; adjusting the map of cooling holes to account for said coat to generate a adjusted map of cooling holes; and re-drilling the multiple of cooling holes in response to the adjusted map of cooling holes.

An airflow mask tool incudes a pressure side mask portion to seal at least a portion of a pressure side of a component having an array of internal passageways and a suction side mask portion to seal at least a portion of a suction side of the component, at least one of the suction side mask portion and the pressure side mask portion comprising at least one opening to expose at least one exit from the array of internal passageways.

A repair method (72) for extending a service life of a power turbine disk (12) having corrosion damage, wherein the power turbine (14) includes stages (16, 18, 20, 22) and interstage gaps (26, 28, 30, 32). The method (72) includes conducting a first thermal analysis (74) of a baseline configuration of a baseline disk that does not have corrosion to determine a first steady state temperature distribution (44). A corrosion damaged disk (12) is then machined (76) to a depth suitable for repairing the corrosion to form a machined disk. A second thermal analysis (78) of the machined disk is conducted to determine a second steady state temperature distribution of the machined disk. A first predicted safe cyclic life (PSCL) (80) is then calculated for disk axisymmetric features (1-10) of the machined disk. A second PSCL (82) is also calculated for disk firtree features (70) of the machined disk. Further, the method (72) is qualified (84) to ensure that the quality of the machined disk is consistent with a new disk.

A laser hole drilling system includes a laser source that generates a laser beam along an optical axis; a spherical lens along the optical axis downstream of the laser source; and a control system in communication with the spherical lens and the laser source, the control system operable to locate the spherical lens with respect to the laser source to produce a light distribution in polar coordinates of a real portion of the Fourier Transform to generate an asymmetric teardrop shaped energy distribution at a focal plane.

A system includes a laser-line imaging subsystem to measure a feature. The laser-line imaging subsystem includes a laser to project a laser-line, and a digital video camera mounted at an angle with respect to an axis of said laser to obtain an optical image of the laser-line. A control subsystem is operable to compute three-dimensional coordinate points via triangulation of an intersection between the laser-line and the optical image of the laser-line, the three-dimensional coordinate points data used by the control subsystem to calculate predictive airflow through the workpiece with respect to the volume of the machined holes.