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.

A manufacturing method is provided. During this method, a preform component is provided for a turbine engine. The preform component includes a substrate comprising electrically conductive material having an outer coating comprising non-electrically conductive material applied over a surface of the substrate. A preform aperture is formed in the preform component using an electrical discharge machining electrode. The preform aperture includes a meter section of a cooling aperture in the substrate. The preform aperture also includes a pilot hole in the outer coating. A diffuser section of the cooling aperture is formed in at least the outer coating using a second machining process.

A tool for validating a wire-electric-discharge-machining (wEDM) operation to be performed using a wEDM machine comprises a body including an engagement feature shaped to removably hold a validation coupon to be machined in the wEDM operation, the validation coupon sized larger than a size of a cut-out to be made in a part using the wEDM machine. A method of manufacturing the tool and a wEDM machine assembly are also provided.

A tool for validating a wire-electric-discharge-machining (wEDM) operation to be performed using a wEDM machine comprises a body including an engagement feature shaped to removably hold a validation coupon to be machined in the wEDM operation, the validation coupon sized larger than a size of a cut-out to be made in a part using the wEDM machine. A method of manufacturing the tool and a wEDM machine assembly are also provided.

A method of wire electric discharge machining (wEDM) a feature in a part includes using wEDM, cutting and detaching a slug from a portion of the part that is to be detached from the part to define the feature, and thereby defining a validation cut-out in the portion, and using wEDM, cutting and detaching the portion having the validation cut-out from the part and thereby defining the feature.

The production of a device for holding one or more electrodes for electrical discharge machining, comprising a body having a rectilinear portion in which at least one first duct is provided for the passage of one or more electrode(s). The body further has an integral curved portion in which (at least) one second curved dielectric fluid supply duct is provided and in which is provided a curved extension of said at least one first duct. The curved extension and the second curved duct are made of ceramic, with an inner mean roughness of: Ra<2 μm.

The production of a device for holding one or more electrodes for electrical discharge machining, comprising a body having a rectilinear portion in which at least one first duct is provided for the passage of one or more electrode(s). The body further has an integral curved portion in which (at least) one second curved dielectric fluid supply duct is provided and in which is provided a curved extension of said at least one first duct. The curved extension and the second curved duct are made of ceramic, with an inner mean roughness of: Ra<2 μm.

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.

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.

An electrolyte for electrochemical machining of a γ-γ′ nickel-based superalloy includes NaNO.sub.3 at a content of between 10 and 50% by weight relative to the total weight of the electrolyte; an additive chosen from KBr, NaBr, KI, NaI and mixtures thereof, in an additive/NaNO.sub.3 molar ratio of between 1 and 15; optionally an ethylenediaminetetraacetic acid-based complexing agent at a content of between 1 and 5% by weight relative to the total weight of the electrolyte at a pH of between 6 and 12; optionally an anionic surfactant at a content of between 1 and 5% by weight relative to the total weight of the electrolyte; optionally NaOH to obtain the appropriate pH; and an aqueous solvent.