A method of forming an airfoil includes placing a material onto a die that is heated to a predetermined temperature to pre-heat the material to a first temperature, while the die is in an open position. The method further includes closing the die at a predetermined rate and holding the die in a closed position for a predetermined period of time at a first force. The method still further includes removing the part from the die, cooling the die, placing the part onto the die, and closing the die at a second force.

A method of forming an airfoil includes placing a material onto a die that is heated to a predetermined temperature to pre-heat the material to a first temperature, while the die is in an open position. The method further includes closing the die at a predetermined rate and holding the die in a closed position for a predetermined period of time at a first force. The method still further includes removing the part from the die, cooling the die, placing the part onto the die, and closing the die at a second force.

An airfoil surface includes a first titanium portion, a second titanium portion, an aluminum alloy braze disposed there between, and a titanium coating covering the aluminum alloy braze, at least part of the first titanium portion and at least part of the second titanium portion.

An airfoil surface includes a first titanium portion, a second titanium portion, an aluminum alloy braze disposed there between, and a titanium coating covering the aluminum alloy braze, at least part of the first titanium portion and at least part of the second titanium portion.

A method of forming an airfoil includes placing a material onto a die that is heated to a predetermined temperature to pre-heat the material to a first temperature, while the die is in an open position. The method further includes closing the die at a predetermined rate and holding the die in a closed position for a predetermined period of time at a first force. The method still further includes removing the part from the die, cooling the die, placing the part onto the die, and closing the die at a second force.

A method of forming an airfoil includes placing a material onto a die that is heated to a predetermined temperature to pre-heat the material to a first temperature, while the die is in an open position. The method further includes closing the die at a predetermined rate and holding the die in a closed position for a predetermined period of time at a first force. The method still further includes removing the part from the die, cooling the die, placing the part onto the die, and closing the die at a second force.

An airfoil surface includes a first titanium portion, a second titanium portion, an aluminum alloy braze disposed there between, and a titanium coating covering the aluminum alloy braze, at least part of the first titanium portion and at least part of the second titanium portion.

An embodiment of a tool assembly includes a hub connected to a distal end of a spring-loaded shaft assembly disposed along a first axis. An upper hub portion is adjacent to the distal end of the spring-loaded shaft assembly aligned with the first axis, and a lower hub portion extends along a second axis, forming a nonzero angle relative to the first axis. A roller disk is joined to the lower portion of the hub, and is rotatable about the second axis parallel to the second portion of the hub. A load cell is disposed along the first axis between a proximal end of the shaft and the roller disk, and is adapted to measure a downward force applied along the shaft assembly.

An embodiment of a tool assembly includes a hub connected to a distal end of a spring-loaded shaft assembly disposed along a first axis. An upper hub portion is adjacent to the distal end of the spring-loaded shaft assembly aligned with the first axis, and a lower hub portion extends along a second axis, forming a nonzero angle relative to the first axis. A roller disk is joined to the lower portion of the hub, and is rotatable about the second axis parallel to the second portion of the hub. A load cell is disposed along the first axis between a proximal end of the shaft and the roller disk, and is adapted to measure a downward force applied along the shaft assembly.

An embodiment of a tool assembly includes a robotic assembly, a tool mount, and a non-axisymmetric deep rolling tool. The robotic assembly includes a plurality of linear arms connected in series between a base end and a working end. Adjacent ones of the plurality of arms are connected via a corresponding plurality of multi-axis joints such that the working end is articulated by movement of one or more of the plurality of arms relative to one or more of the plurality of multi-axis joints. The tool mount is connected to one of the linear arms or one of the multi-axis joints at the working end of the robotic assembly. The non-axisymmetric deep rolling tool is connected to the tool mount, and includes a spring-loaded shaft assembly disposed along a first axis. A hub has an upper hub portion adjacent to the distal end of the spring-loaded shaft assembly aligned with the first axis, and a lower hub portion extending along a second axis, forming a nonzero angle relative to the first axis. A roller disk is joined to the lower portion of the hub and is rotatable about the second axis parallel to the second portion of the hub.