A method for accurately producing the drilled hole in a wall of a component fabricated by investment casting process, such as for use in a blade or steam turbine includes the following steps. The 3D data of actual component is obtained from the measurements or from the numerical simulation. The actual model and the ideal model are aligned and compared, a series of cutting planes are given to establish a series of 2D cross-sections of the actual and ideal models after registration. Each cross-section is dispersed into discrete points, the distance between each corresponding points are calculated and formed into 2D displacement. The accurate parametric model consisting of the depth, hole center, and the nominal vector is obtained on the basis of considering the deviations in geometrical and positional values. The drilled hole is then produced according to the corrected parametric drilled-hole geometrical and positional value.

A method of forming a passage in a turbine component that includes using an additive manufacturing process to form a first support structure on a first surface of the turbine component; and forming a passage through the first support structure and the turbine component.

A baffle for airfoil cooling contains multiple segments capable of nesting within each other. When the segments are nested within each other, the baffle is in a collapsed state, and is capable of insertion into an airfoil around an obstruction platform or rail. The multiple segments can be expanded after insertion so that the cavity of the airfoil is filled with the baffle.

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.

A method and device for coating a component wherein the cooling fluid ducts contained in the component have to be reopened following the coating step. The component has a first region and a second region, where the first region includes at least one cooling fluid opening having an adjoining cooling fluid channel and where the first region is to be coated with a coating material which is not to be applied in the second region.

A process of repairing a component includes identifying a void in a component; determining at least one approximate physical configuration of the void; inserting borescope into the component in order to view the void; providing a repair rod approximately equivalent to at least one of the least one approximate physical configuration of the void; inserting the repair rod into component; confirming insertion of the repair rod in the void; separating the repair rod to leave a repair plug in the void; and depositing braze paste over the repair plug in the void.

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.

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 turbine blade having a labyrinth of internal channels for circulation of coolant received through an inlet formed in a terminal portion of a blade root. A labyrinth geometry includes: (i) the inlet arranged on an axially upstream face of the terminal portion leading to an upstream duct portion having a first section adjacent the inlet and a second section having a reduced cross-section compared to the first section, (ii) a leading edge passage intersecting with the first section and extending through a blade body towards a tip of the blade, where a proximal end of the leading edge passage is angled towards a direction of incoming air flow, (iii) a main blade passage intersecting with a downstream duct portion arranged in axial alignment with, and separate from, the upstream duct portion, and (iv) a restrictor passage intersecting with a mid-blade passage and extending towards a mid-blade duct portion.

A method for the removal of debris (75) from an aperture (60), the aperture comprising a first aperture diameter (64) and extending along a first axis (62) over a first distance (63), the method comprising the steps of aligning a beam of energy (80) with the first axis such that the beam of energy is coaxially aligned with the aperture, the beam of energy comprising both an energy sufficient to remove the debris, and a first beam diameter (82) which is less than the first aperture diameter; and, exposing the debris to the beam of energy in order to remove the debris from the aperture.