A method to repair an opening in a metallic device including: mount the device on a positioner; while the device is mounted on the positioner, sense and record positions of a surface of an opening in the device using a probe operated by a manipulator; based on the recorded positions determine a centerline and diameter of the opening; orient a digital model of the opening with respect to the opening of the device based on the centerline and diameter of the opening, and apply an weld or cladding to the opening by a welding torch maneuvered automatically by the manipulator while the device is mounted to the positioner and based on the oriented digital model of the opening.

A method of manufacturing a last chance screen for an aircraft engine includes forming an array of holes through a metal sheet with a wire electrode using electrical discharge machining. The array of holes comprises a plurality of holes. Each hole of the plurality of holes comprises a first end and a second end and is surrounded by a wall section such that the last chance screen is defined by the plurality of holes and the plurality of wall sections. The first and second end of each hole are widened by either applying a flow of an abrasive flow medium to the array of holes in two directions or using a conical sinker electrode on either side of the metal sheet. Shaping the first and second end of each hole results in an airfoil-shaped cross-section of each wall section.

A method of reconditioning and fabricating turbine components is provided. In one embodiment, the method is performed on a fuel nozzle assembly of a gas turbine, and comprises providing a pre-assembled fuel nozzle assembly having a base, a body extending from the base to a fuel nozzle tip, an inner assembly, and an outer assembly. The method further comprises removing at least a portion of the fuel nozzle tip and the inner assembly, coupling and joining a replacement inner assembly to the base, and coupling and joining a replacement fuel nozzle tip to the replacement inner assembly and to the outer assembly to provide a reconditioned fuel nozzle.

The present application thus provides a method of filling an existing hole in a surface of a turbine component. The method may include the steps of enlarging the existing hole, placing a rivet into the enlarged hole, welding the rivet into place, and grinding the rivet to be flush with the surface of the turbine component.

A combustion cylinder mounting method, wherein a preparation step, a first contact maintenance step, a second contact maintenance step, and a combustion cylinder fixing step are executed. In the preparation step, a combustion cylinder mounting jig equipped with a spacer portion capable of maintaining a predetermined spacing between a first combustion cylinder and a second combustion cylinder adjacent to each other in the circumferential direction is prepared. In the first contact maintenance step, the spacer portion is brought into contact with the first combustion cylinder attached to the stationary portion of a casing. In the second contact maintenance step, the second combustion cylinder is brought into contact with the spacer portion. In the combustion cylinder fixing step, the second combustion cylinder is attached to the stationary portion while the first combustion cylinder and the second combustion cylinder are in contact with the spacer portion.

A system for forming a nozzle inlet of a nozzle includes a nozzle body and an electro-chemical machining (ECM) assembly. The nozzle body includes an external surface. The nozzle body forms a nozzle orifice and a manifold passage. The nozzle orifice extends through the nozzle body between and to a nozzle inlet and a nozzle outlet. The nozzle inlet is disposed at the manifold passage. The nozzle outlet is disposed at the external surface. The ECM assembly is installed on the nozzle body. The ECM assembly includes a machining tool and a flexible line. The machining tool is disposed at the nozzle inlet. The flexible line is attached to the machining tool. The flexible line extends through the nozzle outlet from the machining tool to an exterior of the nozzle body.

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 the step or process of additively manufacturing 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 such that a geometry of the component-defining surface region is transferred to the body layer. The tooling structure is chemically dissolved, thermally decomposed, or otherwise 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. In certain implementations, the method may further include the step or process of depositing an electrically-conductive base coat over the component-defining surface region of the tooling structure for usage in the subsequently-performed electroforming process.

An insertion tool is provided for an engine defining an access opening and including a component defining at least in part a cavity. The insertion tool includes: an insertion tool arm having a plurality of segments, the insertion tool arm configured for insertion through the access opening into the cavity and the plurality of segments configured to be in a fixed position relative to one another within the cavity; and a base coupled to the insertion tool arm and configured to be positioned outside the cavity and to move the insertion tool arm along at least two degrees of freedom.

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 insertion tool is provided for an engine defining an access opening and including a component defining at least in part a cavity. The insertion tool includes: an insertion tool arm having a plurality of segments, the insertion tool arm configured for insertion through the access opening into the cavity and the plurality of segments configured to be in a fixed position relative to one another within the cavity; and a base coupled to the insertion tool arm and configured to be positioned outside the cavity and to move the insertion tool arm along at least two degrees of freedom.