Patent ID: 7784183
Filing Date: 2010-08-31
Classification: B23P,F01D,F05D,G05B,Y02T,Y10T

Abstract:
1. A manufacturing method comprising the following steps: (a) providing a component form and a component form data set comprising data for the component form for obtaining a processed component having three-dimensional internal structural characteristics; (b) providing at least a relevant portion of the component form data set (c) performing a first manufacturing step on the component form to provide a processed component, wherein the at least relevant portion of the component form data set is used to adjust the manner in which the first manufacturing step is performed; (d) analyzing the processed component to provide a processed component data set (e) combining the component form data set with the processed component data set to provide accumulated component data (f) performing a second manufacturing step on the processed component, wherein at least a relevant portion of accumulated component data is used to adjust the manner in which the second manufacturing step is performed; and (g) repeating steps (d) through (f) after step (f) one or more times until a final manufactured component is obtained, wherein the component form provided in step (a) is a turbine component form that includes internal three-dimensional structural characteristics and is a cast airfoil form comprising an airfoil having one or more internal cooling passages and a blank root portion extending from the airfoil, and wherein step (c) comprises forming a dovetail in the blank root portion to provide a dovetail-containing turbine component, wherein step (f) comprises drilling holes in the airfoil of the dovetail-containing turbine component of step (c) to connect the drilled holes to the one or more internal cooling passages to provide a drilled turbine component, and wherein step (g) is repeated so as to carryout the additional manufacturing step (h) which comprises applying a protective coating to one or more of the external surface of the airfoil and the internal surface of the airfoil of the drilled turbine component of step (g).