A method for disposing blocking material within an interior of a component for blocking a beam of radiation from a laser during a laser drilling operation, the method including forming one of a multiple of apertures formed via a first process and forming the remainder of the multiple of apertures formed via a laser drilling process. A component for a gas turbine engine includes a surface with at least one of a multiple of apertures formed via a first process, the at least one of the multiple of apertures formed via the first process in communication with a cavity, a remainder of the multiple of apertures formed via a laser drilling process, the remainder of the multiple of apertures in communication with the cavity.

Methods and apparatus are provided for repairing a damaged area within a cored passage of a component. The method includes providing a repair tool that has a support portion, a leading portion extending from a first end of the support portion, and a trailing portion extending from a second end of the support portion. The leading portion of the repair tool is inserted into a first opening of the cored passage, and is threaded through the cored passage until the support portion is positioned at the damaged area within the cored passage. A restoration activity is performed on the damaged area as the support portion supports the cored passage proximate to the damaged area. Upon completion of the restoration activity, the repair tool is removed from the cored passage.

A method of forming a passage in a turbine component includes: using an additive manufacturing process to form a first support structure on a first surface of the turbine component; forming a second support structure on a second surface of the turbine component, the second support structure being spaced apart from the first support structure; and forming a passage in the turbine component between the first and second support structures.

An airfoil for a gas turbine engine is provided that includes a first portion formed from a first plurality of plies of a ceramic matrix composite material and defining an inner surface of the airfoil, as well as a second portion formed from a second plurality of plies of a ceramic matrix composite material and defining an outer surface of the airfoil. The first portion and the second portion define a non-line of sight cooling aperture extending from the inner surface to the outer surface of the airfoil. In one embodiment, a surface angle that is less than 45 is defined between a second aperture and the outer surface. A method for forming an airfoil for a gas turbine engine also is provided.

A method of forming a film cooling hole in a component having an internal surface and an external surface is disclosed herein that includes forming the component with a first feature on the external surface, measuring a geometry of the external surface to determine a first placement of the first feature, and drilling the film cooling hole through the component at the first placement.

Method for constructing impingement/effusion cooling features in a component of a combustion turbine engine is provided. A pocket 102 may be arranged between an outer wall 104 and an inner wall 106 of the component. A lasing device 108 allows drilling through the component to form an effusion hole 110. The lasing device further allows welding closed an opening 117 formed at outer wall 104 of the component during the drilling with the lasing device through the component. Lasing device 108 further allows drilling through outer wall 104 of the component to form an impingement hole 118 for the impingement/effusion cooling feature. The proposed methodology in a multi-panel arrangement, for example, eliminates a need of having to pre-drill such holes in individual panels prior to the bonding and forming of the component, which overcomes various drawbacks commonly associated with such pre-drilling.

A method for applying a coating to a substrate having a plurality of holes. The method comprises: applying a braze material to a substrate having a plurality of holes; heating the substrate to melt the braze material to form a melt; cooling the substrate to solidify the melt to form plugs in the respective holes; applying a coating to the substrate; and further heating the substrate to melt the plugs.

Systems and methods are disclosed herein for repairing components. A material layer may be deposited on a surface of a component. The material layer may cover a cooling hole. A pulsed heat source may heat the component and the material layer. An infrared camera may take a series of images of the component. A location of the cooling hole may be identified based on thermal properties of the component. A removal tool may remove a portion of the material layer in order to expose the cooling hole.

Methods and systems for characterizing holes in a combustor liner of a gas turbine engine, and associated repair methods are provided. One method comprises receiving first measured data of the combustor liner in an uncoated state. The method includes determining a first location and a first orientation of a first hole and a first location and a first orientation of a second hole in the combustor liner using the first measured data. The method includes receiving second measured data of the combustor liner in a coated state where the second hole is at least partially obstructed by a coating and the first hole is substantially unobstructed by the coating. The method includes inferring a second location of the second hole of the combustor liner in the coated state using a known spacing between the first location of the first hole and the first location of the second hole. The characterization of the holes may be used to re-drill the obstructed second hole.

A manufacturing method is provided. During this method, a preform component is provided for a turbine engine. The preform component includes a substrate. A preform meter section and a preform diffuser section are formed in the substrate. An internal coating is applied to at least the preform meter section to provide a meter section of a cooling aperture. External coating material is applied over the substrate. The applying of the external coating material forms an external coating over the substrate. The applying of the external coating also builds up the external coating material within the preform diffuser section to form a diffuser section of the cooling aperture.