Patent Description:
A gas turbine engine includes various fluid cooled components such as turbine blades and turbine vanes. Such fluid cooled components may include one or more cooling apertures extending through a sidewall of the respective component. Various methods are known in the art for forming cooling apertures. While these known cooling aperture formation methods have various benefits, there is still room in the art form improvement. <CIT>, <CIT>, <CIT>, <CIT> and <CIT> disclose arrangements of the prior art. <CIT> discloses a manufacturing method for a turbine engine vane having a substrate and an outer coating. The diffusion portion of a cooling passage is cast together with the vane without a metering portion. The metering portion is then formed by a machining process to complete the cooling passage. A nest key adjacent the diffuser section is used as a locating feature to ensure that the metering portion is properly aligned with the diffusion portion.

According to the invention, a manufacturing method for a component of a turbine engine with the features of claim <NUM> is provided during which a preform component for a turbine engine is provided. The preform component includes a substrate and a locating feature at an exterior surface of the substrate. An outer coating is applied over the substrate. The outer coating covers the locating feature. At least a portion of the preform component and the outer coating are scanned with an imaging system to provide scan data indicative of a location of the locating feature. A cooling aperture is formed in the substrate and the outer coating based on the scan data.

The locating feature may be configured as or otherwise include an indentation in the exterior surface of the substrate.

The locating feature may be configured as or otherwise include a protrusion projecting out from the exterior surface of the substrate.

The locating feature may be removed during the forming of the cooling aperture.

The imaging system may be configured as or otherwise include a microwave imaging system.

The method may also include applying an inner coating onto the substrate. The outer coating may be applied onto the inner coating.

The cooling aperture may include a meter section and a diffuser section.

The cooling aperture may include a first section and a second section. The forming of the cooling aperture may include: forming the first section in at least the exterior (e.g. outer) coating using a first machining process; and forming the second section in the substrate using a second machining process that is different than the first machining process.

The method may also include forming a second locating feature at an end of the first section. The second section may be formed based on a location of the second locating feature.

The second locating feature may be formed during the forming of the first section.

The substrate may be configured from or otherwise include metal.

The outer coating may be configured from or otherwise include ceramic.

The cooling aperture may be configured as a single lobed diffuser section.

The cooling aperture may be configured as a multi-lobed diffuser section.

The preform component may be configured as or otherwise include a preform of an airfoil for the turbine engine.

The preform component may be configured as or otherwise include a preform of a flowpath wall for the turbine engine.

The present invention includes methods for manufacturing fluid cooled components of a gas turbine engine. For ease of description, the turbine engine may be described below as a turbofan turbine engine. The present invention, however, is not limited to such an exemplary gas turbine engine. The turbine engine, for example, may alternatively be configured as a turbojet turbine engine, a turboprop turbine engine, a turboshaft turbine engine, a propfan turbine engine, a pusher fan turbine engine or an auxiliary power unit (APU) turbine engine. The turbine engine may be configured as a geared turbine engine or a direct drive turbine engine. The present invention is also not limited to aircraft applications. The turbine engine, for example, may alternatively be configured as a ground-based industrial turbine engine for power generation, or any other type of turbine engine which utilizes fluid cooled components.

<FIG> is a side cutaway illustration of the turbofan turbine engine <NUM>. This turbine engine <NUM> extends along an axial centerline <NUM> between a forward, upstream airflow inlet <NUM> and an aft, downstream airflow exhaust <NUM>. The turbine engine <NUM> includes a fan section <NUM>, a compressor section <NUM>, a combustor section <NUM>, a turbine section <NUM> and an exhaust section <NUM> (partially shown in <FIG>). The compressor section <NUM> includes a low pressure compressor (LPC) section 29A and a high pressure compressor (HPC) section 29B. The turbine section <NUM> includes a high pressure turbine (HPT) section 31A and a low pressure turbine (LPT) section 31B.

The engine sections <NUM>-<NUM> are arranged sequentially along the axial centerline <NUM> within an engine housing <NUM>. This engine housing <NUM> includes an inner case <NUM> (e.g., a core case) and an outer case <NUM> (e.g., a fan case). The inner case <NUM> may house one or more of the engine sections 29A-31B; e.g., an engine core. The outer case <NUM> may house at least the fan section <NUM>.

Each of the engine sections <NUM>, 29A, 29B, 31A and 31B includes a respective rotor <NUM>-<NUM>. Each of these rotors <NUM>-<NUM> includes a plurality of rotor blades arranged circumferentially around and connected to one or more respective rotor disks. The rotor blades, for example, may be formed integral with or mechanically fastened, welded, brazed, adhered and/or otherwise attached to the respective rotor disk(s).

The fan rotor <NUM> is connected to a gear train <NUM>, for example, through a fan shaft <NUM>. The gear train <NUM> and the LPC rotor <NUM> are connected to and driven by the LPT rotor <NUM> through a low speed shaft <NUM>. The HPC rotor <NUM> is connected to and driven by the HPT rotor <NUM> through a high speed shaft <NUM>. The shafts <NUM>-<NUM> are rotatably supported by a plurality of bearings <NUM>; e.g., rolling element and/or thrust bearings. Each of these bearings <NUM> is connected to the engine housing <NUM> by at least one stationary structure such as, for example, an annular support strut.

During operation, air enters the turbine engine <NUM> through the airflow inlet <NUM>. This air is directed through the fan section <NUM> and into a core flowpath <NUM> and a bypass flowpath <NUM>. The core flowpath <NUM> extends sequentially through the engine sections 29A-<NUM>. The air within the core flowpath <NUM> may be referred to as "core air". The bypass flowpath <NUM> extends through a bypass duct, which bypasses the engine core. The air within the bypass flowpath <NUM> may be referred to as "bypass air".

The core air is compressed by the LPC rotor <NUM> and the HPC rotor <NUM> and directed into a combustion chamber <NUM> of a combustor in the combustor section <NUM>. This fuel air mixture is ignited and combustion products thereof flow through and sequentially cause the HPT rotor <NUM> and the LPT rotor <NUM> to rotate. The rotation of the HPT rotor <NUM> and the LPT rotor <NUM> respectively drive rotation of the HPC rotor <NUM> and the LPC rotor <NUM> and, thus, compression of the air received from a core airflow inlet. The rotation of the LPT rotor <NUM> also drives rotation of the fan rotor <NUM>, which propels bypass air through and out of the bypass flowpath <NUM>.

The turbine engine <NUM> includes a plurality of fluid cooled components (e.g., 60AH; generally referred to as "<NUM>") arranged within, for example, the combustor section <NUM>, the turbine section <NUM> and/or the exhaust section <NUM>. Examples of these fluid cooled components <NUM> include airfoils such as, but not limited to, a rotor blade airfoil (e.g., 60A, 60D) and a stator vane airfoil (e.g., 60B, 60C, <NUM>). Other examples of the fluid cooled components <NUM> include flowpath walls such as, but not limited to, a combustor wall (e.g., 60F), an exhaust duct wall (e.g., 60E), a shroud or other flowpath wall (e.g., <NUM>), a rotor blade platform and a stator vane platform. Of course, various other fluid cooled components may be included in the turbine engine <NUM>, and the present disclosure is not limited to any particular types or configurations thereof.

<FIG> illustrates a portion of one of the fluid cooled components <NUM> within the turbine engine <NUM>. This fluid cooled component <NUM> has a component wall <NUM> (e.g., a sidewall or an endwall) configured with one or more cooling apertures <NUM>.

Referring to <FIG>, the component wall <NUM> has a thickness <NUM> that extends vertically (e.g., along a z-axis) between and to a first surface <NUM> and a second surface <NUM>. The component first surface <NUM> may be configured as an interior and/or a cold side surface of the component wall <NUM>. The component first surface <NUM>, for example, may at least partially form a peripheral boundary of a cooling fluid volume <NUM> (e.g., a cavity or a passage) along the component wall <NUM>. The component first surface <NUM> may thereby be subject to relatively cool fluid (e.g., cooling air) supplied to the cooling fluid volume <NUM>. This cooling fluid volume <NUM> may be an internal volume formed within the fluid cooled component <NUM> where, for example, the component is an airfoil. Alternatively, the cooling fluid volume <NUM> may be an external volume formed external to the fluid cooled component <NUM> where, for example, the component is a flowpath wall. The component second surface <NUM> may be configured as an exterior and/or a hot side surface of the component wall <NUM>. The component second surface <NUM>, for example, may at least partially form a peripheral boundary of a portion of, for example, the core flowpath <NUM> along the component wall <NUM>. The component second surface <NUM> may thereby be subject to relative hot fluid (e.g., combustion products) flowing through the core flowpath <NUM> within, for example, one of the engine sections <NUM>-<NUM> of <FIG>.

The component wall <NUM> of <FIG> includes a component substrate <NUM> and one or more external component coatings <NUM> and <NUM>. The component substrate <NUM> at least partially or completely forms and carries the component first surface <NUM>. The component substrate <NUM> has a thickness <NUM> that extends vertically (e.g., along the z-axis) between and to the component first surface <NUM> and a second surface <NUM> of the component substrate <NUM>. This substrate second surface <NUM> may be configured as an exterior surface of the component substrate <NUM> prior to being (e.g., partially or completely) covered by the one or more component coatings <NUM> and <NUM>. The substrate thickness <NUM> may be greater than one-half (<NUM>/<NUM>) of the wall thickness <NUM>. The substrate thickness <NUM>, for example, may be between two-third (<NUM>/<NUM>) and four-fifths (<NUM>/<NUM>) of the wall thickness <NUM>.

The component substrate <NUM> is constructed from substrate material <NUM>. This substrate material <NUM> may be an electrically conductive material. The substrate material <NUM>, for example, may be or otherwise include metal. Examples of the metal include, but are not limited to, nickel (Ni), titanium (Ti), aluminum (Al), chromium (Cr), cobalt (Co), and alloys thereof. The metal, for example, may be a nickel or cobalt based superalloy such as, but not limited to, PWA <NUM> or PWA <NUM>.

The inner coating <NUM> may be configured as a bond coating between the component substrate <NUM> and the outer coating <NUM>. The inner coating <NUM> of <FIG> is bonded (e.g., directly) to the substrate second surface <NUM>. The inner coating <NUM> at least partially or completely covers the substrate second surface <NUM> (e.g., along an x-y plane of <FIG>). The inner coating <NUM> has a thickness <NUM> that extends vertically (e.g., along the z-axis) between and to component substrate <NUM> and the outer coating <NUM>. This inner coating thickness <NUM> may be less than one-seventh (<NUM>/<NUM>) of the wall thickness <NUM>. The inner coating thickness <NUM>, for example, may be between one-eighth (<NUM>/<NUM>) and one-fortieth (<NUM>/<NUM>) of the wall thickness <NUM>.

The inner coating <NUM> is constructed from inner coating material <NUM>. This inner coating material <NUM> may be an electrically conductive material. The inner coating material <NUM>, for example, may be or otherwise include metal. Examples of the metal include, but are not limited to, MCrAlY and MAlCrX, where "M" is nickel (Ni), cobalt (Co), iron (Fe) or any combination thereof, and where "Y" or "X" is hafnium (Hf), yttrium (Y), silicon (Si) or any combination thereof. The MCrAlY and MAlCrX may be further modified with strengthening elements such as, but not limited to, tantalum (Ta), rhenium (Re), tungsten (W), molybdenum (Mo) or any combination thereof. An example of the MCrAlY is PWA <NUM>.

The inner coating <NUM> may be formed from a single layer of the inner coating material <NUM>. The inner coating <NUM> may alternatively be formed from a plurality of layers of the inner coating material <NUM>, where the inner coating material <NUM> within each of those inner coating layers may be the same as one another or different from one another.

The outer coating <NUM> may be configured as a protective coating for the component substrate <NUM> and, more generally, the fluid cooled component <NUM>. The outer coating <NUM>, for example, may be configured as a thermal barrier layer and/or an environmental layer. The outer coating <NUM> at least partially or completely forms and carries the component second surface <NUM>. The outer coating <NUM> of <FIG> is bonded (e.g., directly) to a second (e.g., exterior) surface <NUM> of the inner coating <NUM>. The outer coating <NUM> at least partially or completely covers the inner coating second surface <NUM> as well as the underlying substrate second surface <NUM> (e.g., along an x-y plane of <FIG>). The outer coating <NUM> has a thickness <NUM> that extends vertically (e.g., along the z-axis) between and to the inner coating <NUM> and the component second surface <NUM>. This outer coating thickness <NUM> may be less than one-half (<NUM>/<NUM>) of the wall thickness <NUM>. The outer coating thickness <NUM>, for example, may be between one-third (<NUM>/<NUM>) and one-eighth (<NUM>/<NUM>) of the wall thickness <NUM>. The outer coating thickness <NUM>, however, may be greater than the inner coating thickness <NUM>.

The outer coating <NUM> is constructed from outer coating material <NUM>. This outer coating material <NUM> may be a non-electrically conductive material. The outer coating material <NUM>, for example, may be or otherwise include ceramic. Examples of the ceramic include, but are not limited to, yttria stabilized zirconia (YSZ) and gadolinium zirconate (GdZ). The outer coating material <NUM> of the present invention is not limited to non-electrically conductive materials. In other embodiments, for example, the outer coating material <NUM> may be an electrically conductive material; e.g., metal.

The outer coating <NUM> may be formed from a single layer of the outer coating material <NUM>. The outer coating <NUM> may alternatively be formed from a plurality of layers of the outer coating material <NUM>, where the outer coating material <NUM> within each of those outer coating layers may be the same as one another or different from one another. For example, the outer coating <NUM> may include a thin interior layer of the YSZ and a thicker exterior later of the GdZ.

Each of the cooling apertures <NUM> extends along a respective longitudinal centerline <NUM> between and to an inlet <NUM> of the respective cooling aperture <NUM> and an outlet <NUM> of the respective cooling aperture <NUM>. The cooling aperture inlet <NUM> of <FIG> is located in the component first surface <NUM>. The cooling aperture inlet <NUM> thereby fluidly couples its respective cooling aperture <NUM> with the cooling fluid volume <NUM> along the component first surface <NUM>. The cooling aperture outlet <NUM> of <FIG> is located in the component second surface <NUM>. The cooling aperture outlet <NUM> thereby fluidly couples its respective cooling aperture <NUM> with the core flowpath <NUM> along the component second surface <NUM>.

Each of the cooling apertures <NUM> may include a meter section <NUM> and a diffuser section <NUM>. The meter section <NUM> is disposed at (e.g., on, adjacent or proximate) the cooling aperture inlet <NUM>. The meter section <NUM> is configured to meter (e.g., regulate) a flow of cooling fluid flowing from the cooling fluid volume <NUM>, through the substrate material <NUM>, to the diffuser section <NUM>. The diffuser section <NUM> is disposed at the cooling aperture outlet <NUM>. The diffuser section <NUM> is configured to diffuse the cooling fluid exhausted (e.g., directed out) from the cooling aperture outlet <NUM> into, for example, a film for cooling a downstream portion of the component second surface <NUM>.

The meter section <NUM> of <FIG> extends longitudinally along the longitudinal centerline <NUM> within (e.g., partially into) the component substrate <NUM>. More particularly, the meter section <NUM> extends longitudinally along a meter segment <NUM> of the longitudinal centerline <NUM> (e.g., a centerline of the meter section <NUM>) from the cooling aperture inlet <NUM> to an outlet <NUM> of the meter section <NUM>. The meter section outlet <NUM> of <FIG> is disposed vertically within the component substrate <NUM> intermediately between the component first surface <NUM> and the substrate second surface <NUM>. The meter section outlet <NUM> of <FIG> is thereby vertically recessed into the component substrate <NUM> by a vertical distance <NUM> (e.g., along the z-axis).

The longitudinal centerline <NUM> and its (e.g., entire) meter segment <NUM> of <FIG> are angularly offset from the component first surface <NUM> by an included angle <NUM>. This meter segment angle <NUM> may be an acute angle. The meter segment angle <NUM>, for example, may be between ten degrees (<NUM>°) and eighty degrees (<NUM>°); e.g., between twenty degrees (<NUM>°) and thirty degrees (<NUM>°).

The meter section <NUM> has a longitudinal length <NUM> measured along the meter segment <NUM> between the cooling aperture inlet <NUM> and the meter section outlet <NUM>. The meter section <NUM> has a lateral width <NUM> (e.g., diameter) measured along a line perpendicular to the meter section <NUM> of the longitudinal centerline <NUM>. The meter section lateral width <NUM> may be different (e.g., smaller or larger) than or equal to the meter section longitudinal length <NUM>.

The meter section <NUM> has a cross-sectional geometry when viewed, for example, in a plane perpendicular to its meter segment <NUM> (or the x-y plane). This meter section cross-sectional geometry may be uniform along the longitudinal length <NUM> of the meter section <NUM>. Referring to <FIG>, the meter section cross-sectional geometry may be circular, oval, elliptical or otherwise annular in shape. The present invention, however, is not limited to such exemplary annular shapes.

The diffuser section <NUM> of <FIG> extends longitudinally along the longitudinal centerline <NUM> out of the component substrate <NUM>, through the inner coating <NUM> and the outer coating <NUM>. More particularly, the diffuser section <NUM> of <FIG> extends longitudinally along a diffuser segment <NUM> of the longitudinal centerline <NUM> (e.g., a centerline of the diffuser section <NUM>) from an inlet <NUM> of the diffuser section <NUM> (here, the same as the meter section outlet <NUM>), through the materials <NUM>, <NUM> and <NUM>, to the cooling aperture outlet <NUM>. The diffuser section inlet <NUM> of <FIG> is disposed vertically within the component substrate <NUM> intermediately between the component first surface <NUM> and the substrate second surface <NUM>. The diffuser section inlet <NUM> of <FIG> is thereby vertically recessed into the component substrate <NUM> by the vertical distance <NUM> (e.g., along the z-axis).

The longitudinal centerline <NUM> and its (e.g., entire) diffuser segment <NUM> of <FIG> are angularly offset from the component second surface <NUM> by an included angle <NUM>. This diffuser segment angle <NUM> may be an acute angle. The diffuser segment angle <NUM>, for example, may be between twenty degrees (<NUM>°) and eighty degrees (<NUM>°); e.g., between thirty-five degrees (<NUM>°) and fifty-five degrees (<NUM>°). The diffuser segment angle <NUM> of <FIG> is different (e.g., less) than the meter segment angle <NUM>. The diffuser segment <NUM> may thereby be angularly offset from the meter segment <NUM>.

The diffuser section <NUM> has a longitudinal length <NUM> measured along the diffuser segment <NUM> between the diffuser section inlet <NUM> and the cooling aperture outlet <NUM>. This diffuser section longitudinal length <NUM> may be equal to or different (e.g., less or greater) than the meter section longitudinal length <NUM>. The diffuser section <NUM> has a lateral width <NUM>, <NUM> (see <FIG>) measured along a respective line perpendicular to the diffuser segment <NUM> of the longitudinal centerline <NUM>. The diffuser section lateral width <NUM>, <NUM> may be different (e.g., smaller or larger) than or equal to the diffuser section longitudinal length <NUM>. The diffuser section lateral width <NUM>, <NUM> of <FIG> and <FIG> at the interface <NUM> between the diffuser section <NUM> and the meter section <NUM> is equal to the meter section lateral width <NUM>. However, the diffuser section lateral width <NUM>, <NUM> of <FIG> and <FIG> at other locations along the longitudinal centerline <NUM> may be greater than meter section lateral width <NUM>. More particularly, the diffuser section <NUM> laterally diverges as the diffuser section <NUM> projects longitudinally away from the meter section <NUM> towards or to the cooling aperture outlet <NUM>.

The diffuser section <NUM> has a cross-sectional geometry when viewed, for example, in a plane perpendicular to its diffuser segment <NUM>. This diffuser section cross-sectional geometry changes as the diffuser section <NUM> projects longitudinally away from the meter section <NUM>, sequentially through the materials <NUM>, <NUM> and <NUM> of <FIG>, to the cooling aperture outlet <NUM>.

Referring to <FIG>, the cooling aperture outlet <NUM> may have a complex cross-sectional geometry when viewed, for example, a plane parallel with the component second surface <NUM> (e.g., the x-y plane). This outlet cross-sectional geometry may include a (e.g., curved or straight) leading edge section <NUM>, a (e.g., curved or straight) trailing edge section <NUM> and opposing (e.g., curved or straight) sidewall sections 136A and 136B (generally referred to as "<NUM>"). Each of the sidewall sections <NUM> extends between and to respective ends of the leading and the trailing edge sections <NUM> and <NUM>. A lateral width of the leading edge section <NUM> may be different (e.g., smaller) than a lateral width of the trailing edge section <NUM>. The sidewall sections <NUM> may thereby generally laterally diverge away from one another as the sidewall sections <NUM> extend from the leading edge section <NUM> to the trailing edge section <NUM>.

In some embodiments, referring to <FIG>, the diffuser section <NUM> may be configured as a single lobe diffuser section. In other embodiments, referring to <FIG>, the diffuser section <NUM> may be configured as a multi-lobe diffuser section. Various other single lobe and multi-lobe diffuser sections for cooling apertures <NUM> are known in the art, and the present invention disclosure is not limited to any particular ones thereof. Further details on various multi-lobe diffuser sections can be found in <CIT>.

<FIG> is a flow diagram of a method <NUM> for manufacturing a fluid cooled component. For ease of description, the method <NUM> is described below with reference to the fluid cooled component <NUM> described above. The method <NUM> of the present invention, however, is not limited to manufacturing such an exemplary fluid cooled component.

In step <NUM>, a preform substrate <NUM>' is provided. Referring to <FIG>, the preform substrate <NUM>' may generally have the configuration (e.g., shape, size, etc.) of the substrate for the fluid cooled component <NUM> to be formed (e.g., see <FIG>). The preform substrate <NUM>' of <FIG>, however, does not include any holes therein for forming the cooling apertures <NUM>.

In step <NUM>, an external locating feature <NUM> is provided. Referring to <FIG>, this external locating feature <NUM> is configured with the preform substrate <NUM>' at (e.g., on, adjacent or proximate) its second surface <NUM>. This external locating feature <NUM> is configured for locating the to-be-formed cooling aperture <NUM> (see <FIG>) as described below in further detail.

The external locating feature <NUM> may be arranged at a location where the longitudinal centerline <NUM> and its diffuser segment <NUM> are to intersect a plane of the second surface <NUM>. The external locating feature <NUM>, for example, may be arranged such that a center of the external locating feature <NUM> is coincident with the longitudinal centerline <NUM> and its diffuser segment <NUM> of the to-be-formed cooling aperture <NUM> (see <FIG>).

Referring to <FIG>, the external locating feature <NUM> may be configured with a footprint <NUM> (e.g., an outline / a perimeter) that fits (e.g., completely) within a footprint <NUM> (e.g., an outline / a perimeter) of the to-be-formed cooling aperture <NUM> and its diffuser section <NUM> (e.g., see <FIG>), where the footprints <NUM> and <NUM> are viewed in a common plane; e.g., the x-y plane or a plane perpendicular to the longitudinal centerline <NUM> at the second surface <NUM>. The external locating feature <NUM> may thereby be sized smaller than the to-be-formed cooling aperture <NUM> such that, for example, formation of the cooling aperture <NUM> may (e.g., completely) remove the external locating feature <NUM>. The present invention, however, is not limited to such an exemplary relationship.

Referring to <FIG>, the external locating feature <NUM> may be configured as a negative feature. The external locating feature <NUM> of <FIG>, for example, is configured as or otherwise includes an indentation <NUM> in the second surface <NUM> of the preform substrate <NUM>'. Examples of the indentation <NUM> include, but are not limited to, a dimple, a groove, a channel, a recess, a depression, a blind aperture and an etching. The indentation <NUM> of <FIG> extends vertically (e.g., along the z-axis) into the preform substrate <NUM>' from the second surface <NUM> to an indentation end <NUM>. The indentation <NUM> of <FIG> extends laterally (e.g., along the x-y plane) between opposing indentation sides <NUM>. While the external locating feature <NUM> of <FIG> is shown as a single indentation <NUM>, the present invention is not limited thereto. For example, in other embodiments, the external locating feature <NUM> may include a plurality of the indentations <NUM>; e.g., a cluster of indentations.

Referring to <FIG>, the external locating feature <NUM> may be configured as a positive feature. The external locating feature <NUM> of <FIG>, for example, is configured as or otherwise includes a protrusion <NUM> out from the second surface <NUM> of the preform substrate <NUM>'. Examples of the protrusion <NUM> include, but are not limited to, a bump, a pedestal, a column, a mound, a rib and a hemisphere. The protrusion <NUM> of <FIG> projects vertically (e.g., along the z-axis) out from the second surface <NUM> to a protrusion distal end <NUM>. The protrusion <NUM> of <FIG> extends laterally (e.g., along the x-y plane) between opposing protrusion sides <NUM>. While the external locating feature <NUM> of <FIG> is shown as a single protrusion <NUM>, the present invention is not limited thereto. For example, in other embodiments, the external locating feature <NUM> may include a plurality of the protrusions <NUM>; e.g., a cluster of protrusions. It is also contemplated the external locating feature <NUM> includes a combination of one or more of the protrusions <NUM> with one or more of the indentations <NUM>.

Referring to <FIG>, the footprint <NUM> of the external locating feature <NUM> may have various shapes. For example, referring to <FIG>, the external locating feature footprint <NUM> may be curved; e.g., circular (see <FIG>) or oval (see <FIG>). Referring to <FIG>, the external locating feature footprint <NUM> may be polygonal; e.g., rectangular (see <FIG>), triangular (see <FIG>) or cross / X shaped (see <FIG>). Referring to <FIG>, the external locating feature footprint <NUM> may be splined (e.g., amorphous) shaped. The present invention, however, is not limited to the foregoing exemplary external locating feature footprint shapes.

The external locating feature <NUM> may be formed using various formation techniques. Examples of these formation techniques include, but are not limited to, machining, etching, additive manufacturing, depositing, coating and welding.

In step <NUM>, a preform inner coating <NUM>' is applied to the preform substrate <NUM>'. For example, referring to <FIG>, the inner coating material <NUM> may be applied (e.g., deposited) onto the second surface <NUM> of the preform substrate <NUM>'. This inner coating material <NUM> may cover and/or otherwise visually obscure the external locating feature <NUM> at the outer surface <NUM> of the preform substrate <NUM>'.

The inner coating material <NUM> may be applied using various different inner coating application techniques. Examples of the inner coating application techniques include, but are not limited to, a physical vapor deposition (PVD) process, chemical vapor deposition (CVD) process, a plating process, and a thermal spray process (e.g., a plasma spray (PS) process, a high velocity oxygen fuel (HVOF) process, high velocity air fuel (HVAF) process, a wire spray process or a combustion spray process). The inner coating application may be performed via a non-line-of-sight (NLOS) coating process or a direct-line-of-sight (DLOS) coating process. The preform inner coating <NUM>' of <FIG> may generally have the configuration of the inner coating <NUM> for the fluid cooled component <NUM> to be formed (e.g., see <FIG>). The preform inner coating <NUM>' of <FIG>, however, does not include any holes for forming the cooling apertures <NUM>.

In step <NUM>, a preform outer coating <NUM>' is applied to the preform inner coating <NUM>'. For example, referring to <FIG>, the outer coating material <NUM> may be applied (e.g., deposited) onto the second surface <NUM> of the preform inner coating <NUM>'. This outer coating material <NUM> covers the external locating feature <NUM> at the outer surface <NUM> of the preform substrate <NUM>'.

The outer coating material <NUM> may be applied using various different outer coating application techniques. Examples of the outer coating application techniques include, but are not limited to, a physical vapor deposition (PVD) process (e.g., an electron-beam PVD process), chemical vapor deposition (CVD) process, a thermal spray process (e.g., a plasma spray (PS) process, a high velocity oxygen fuel (HVOF) process, high velocity air fuel (HVAF) process, a wire spray process or a combustion spray process). The outer coating application may be performed via a non-line-of-sight (NLOS) coating process or a direct-line-of-sight (DLOS) coating process. The preform outer coating <NUM>' of <FIG> may generally have the configuration of the outer coating <NUM> for the fluid cooled component <NUM> to be formed (e.g., see <FIG>). The preform outer coating <NUM>' of <FIG>, however, does not include any holes for forming the cooling apertures <NUM>.

The combination of the preform substrate <NUM>', the preform inner coating <NUM>' and the preform outer coating <NUM>' provides a preform component <NUM>'. This preform component <NUM>' of <FIG> may generally have the configuration of the fluid cooled component <NUM> to be formed (e.g., see <FIG>). The preform component <NUM>' of <FIG>, however, does not include any holes for forming the cooling apertures <NUM>.

The thickness <NUM> (see <FIG>) of the inner coating material <NUM> applied during the step <NUM> and/or the thickness <NUM> (see <FIG>) of the outer coating material <NUM> applied during the step <NUM> may fluctuate within an acceptable tolerance range; e.g., along the x-y plane. These fluctuations may provide the preform component <NUM>' with a slightly different exterior surface topology than expected. Therefore, if the cooling aperture <NUM> was formed at a location in the preform component <NUM>' solely based on the appearance of the exterior surface topology of the preform component <NUM>', then the cooling aperture <NUM> may (or may not) be slightly laterally offset from its intended (e.g., design) location. The method <NUM> of the present invention prevents or reduces such cooling aperture location deviation by identifying a location of the to-be-formed cooling aperture <NUM> based on at least an actual location of the external locating feature <NUM>.

In step <NUM>, at least a portion of the preform component <NUM>' is scanned with a non-contact, non-destructive imaging system <NUM>. Referring to <FIG>, this imaging system <NUM> may be configured as a microwave imaging system.

The imaging system <NUM> of <FIG> may include a microwave transceiver <NUM> (or a transmitter and a receiver). This transceiver <NUM> (or the transmitter) is configured to direct (e.g., transmit) microwaves into the preform component <NUM>' from the exterior of the preform component <NUM>'. These microwaves include electromagnetic waves with a predetermined frequency (or frequency range) within a microwave frequency ban of three-hundred mega-Hertz (<NUM>) and three-hundred giga-Hertz (<NUM>). The specific frequency (or frequency range) may be selected / tuned based on the material composition of the preform component <NUM>' and/or the specific geometric configuration of the external locating feature <NUM>. For example, the microwaves may be selected to travel through portions (certain component materials) of the preform component <NUM>'. However, the microwaves may be selected to reflect against other portions (certain component materials) of the preform component <NUM>'. The microwaves may also or alternatively be selected to reflect against certain geometric features; e.g., surfaces, etc. At least some of the reflected microwaves may travel back to and may be received by the transceiver <NUM> (or the receiver). The transceiver <NUM> may output information associated with the reflected microwaves as scan data - imaging system output data.

The scan data is indicative of a location of the locating feature <NUM> and may be indicative of an internal structure of the scanned portion of the preform component <NUM>'. The scan data, for example, may be used to provide a feature map of the internal structure of the scanned portion of the preform component <NUM>'. This feature map may include location and/or dimensional information for the external locating feature <NUM>. The feature map may also or alternatively include locations and/or dimensional information for one or more of the coatings <NUM>' and <NUM>' and/or the preform substrate <NUM>'. With this information, a processing system <NUM> (e.g., a computer system) may determine a location and/or an orientation of the external locating feature <NUM>, or at least a portion thereof, relative to the preform component <NUM>' and/or a coordinate system. The external locating feature <NUM> may thereby provide / correlate with a datum in the scan data.

In step <NUM>, the diffuser section <NUM> of a respective cooling aperture <NUM> is formed in the preform component <NUM>' using the scan data as shown, for example, in <FIG>. For example, since the preform substrate <NUM>' and the external locating feature <NUM> (see <FIG>) may be completely covered or otherwise visually obscured by one or more of the external coatings <NUM>', <NUM>', the scan data and the external locating feature location and/or orientation information determined therefrom may be used to locate a position of where and/or an orientation of how the diffuser section <NUM> should be formed in the preform component <NUM>'. The diffuser section <NUM> may then be formed at this location / orientation such that the diffuser section <NUM> is located, for example, as specified in a design specification.

A portion of the outer coating material <NUM>, a portion of the inner coating material <NUM> and a portion of the underlying substrate material <NUM> is machined away (from the exterior of the preform component <NUM>') to provide the respective diffuser section <NUM> of <FIG>. The diffuser section <NUM> may be formed in the various materials of the preform component <NUM>' using a diffuser section machining process. This diffuser section machining process is selected to form the diffuser section <NUM> in the various different electrically conductive and non-electrically conductive materials in the preform component <NUM>'. The diffuser section machining process is also selected to provide the diffuser section <NUM> with a precise finish geometry. Examples of the diffuser section machining process include, but are not limited to, a laser machining (e.g., ablation) process, a water-jet guided laser (WJGL) machining process, an abrasive water jet (AWJ) machining process, an electron beam machining process, and a mechanical drilling process.

The meter section <NUM> of the respective cooling aperture <NUM> may be subsequently formed using a different machining process than the machining process used to form the diffuser section <NUM>. In such embodiments, when two (or more) different machining processes are used to form different portions / sections of the same cooling aperture <NUM>, one tool is moved away and another tool is positioned in its place. The swapping of the tools may open the manufacturing process up to slight lateral misalignments due to, for example, tool manipulator tolerances. To prevent or reduce a magnitude of such lateral misalignment between the diffuser section <NUM> and the meter section <NUM> for example, the method <NUM> of the present invention may utilize another locating feature for the forming of the meter section <NUM>.

In step <NUM>, an internal locating feature <NUM> is provided. Referring to <FIG>, this internal locating feature <NUM> is configured with the preform substrate <NUM>' at (e.g., on, adjacent or proximate) an end <NUM> of the diffuser section <NUM>. This internal locating feature <NUM> is configured for locating the to-be-formed meter section <NUM> (see <FIG>) as described below in further detail.

The internal locating feature <NUM> may be arranged at a location where the longitudinal centerline <NUM> and its meter segment <NUM> are to intersect a plane of the interface <NUM>. The internal locating feature <NUM>, for example, may be arranged such that a center of the internal locating feature <NUM> is coincident with the longitudinal centerline <NUM> and its meter segment <NUM> of the to-be-formed meter section <NUM> (see <FIG>).

Referring to <FIG>, the internal locating feature <NUM> may be configured with a footprint <NUM> (e.g., an outline / a perimeter) that fits (e.g., completely) within a footprint <NUM> (e.g., an outline / a perimeter) of the to-be-formed meter section <NUM> (see <FIG>), where the footprints <NUM> and <NUM> are viewed in a common plane; e.g., the x-y plane or a plane perpendicular to the longitudinal centerline <NUM> at the interface <NUM>. The internal locating feature <NUM> may thereby be sized smaller than the to-be-formed meter section <NUM> such that, for example, formation of the meter section <NUM> may (e.g., completely) remove the internal locating feature <NUM>. The present invention, however, is not limited to such an exemplary relationship.

Referring to <FIG>, the internal locating feature <NUM> may be configured as a negative feature. The internal locating feature <NUM> of <FIG>, for example, is configured as or otherwise includes an indentation <NUM> in the end <NUM> of the diffuser section <NUM>. Examples of the indentation <NUM> include, but are not limited to, a dimple, a groove, a channel, a recess, a depression, a blind aperture and an etching. The indentation <NUM> of <FIG> extends longitudinally along the longitudinal centerline <NUM> into the preform substrate <NUM>' from the diffuser section end <NUM> to an indentation end <NUM>. The indentation <NUM> of <FIG> extends within the preform substrate <NUM>' between opposing indentation sides <NUM>. While the internal locating feature <NUM> of <FIG> is shown as a single indentation <NUM>, the present invention is not limited thereto. For example, in other embodiments, the internal locating feature <NUM> may include a plurality of the indentations <NUM>; e.g., a cluster of indentations.

Referring to <FIG>, the internal locating feature <NUM> may be configured as a positive feature. The internal locating feature <NUM> of <FIG>, for example, is configured as or otherwise includes a protrusion <NUM> out from the diffuser section end <NUM>. Examples of the protrusion <NUM> include, but are not limited to, a bump, a pedestal, a column, a mound, a rib and a hemisphere. The protrusion <NUM> of <FIG> projects longitudinally along the longitudinal centerline <NUM> out from the diffuser section end <NUM> to a protrusion distal end <NUM>. The protrusion <NUM> of <FIG> extends within the preform substrate <NUM>' between opposing protrusion sides <NUM>. While the internal locating feature <NUM> of <FIG> is shown as a single protrusion <NUM>, the present invention is not limited thereto. For example, in other embodiments, the internal locating feature <NUM> may include a plurality of the protrusions <NUM>; e.g., a cluster of protrusions. It is also contemplated the internal locating feature <NUM> includes a combination of one or more of the protrusions <NUM> with one or more of the indentations <NUM>.

Referring to <FIG>, the footprint <NUM> of the internal locating feature <NUM> may have various shapes. For example, referring to <FIG>, the internal locating feature footprint <NUM> may be curved; e.g., circular (see <FIG>) or oval (see <FIG>). Referring to <FIG>, the internal locating feature footprint <NUM> may be polygonal; e.g., rectangular (see <FIG>), triangular (see <FIG>) or cross / X shaped (see <FIG>). Referring to <FIG>, the internal locating feature footprint <NUM> may be splined (e.g., amorphous) shaped. The present invention, however, is not limited to the foregoing exemplary internal locating feature footprint shapes.

The internal locating feature <NUM> may be formed using various formation techniques. Examples of these formation techniques include, but are not limited to, machining, etching, additive manufacturing, depositing, coating and welding. For example, the internal locating feature <NUM> may be formed at the diffuser section end <NUM> during (e.g., near an end of) the formation of the diffuser section <NUM> during the step <NUM>.

In step <NUM>, at least an end portion of the diffuser section <NUM> is scanned with a non-contact, non-destructive imaging system <NUM>. Referring to <FIG>, this imaging system <NUM> may be different than the imaging system <NUM> of <FIG> discussed above. For example, the imaging system <NUM> of <FIG> may be configured as an optical imaging system with an optical sensor <NUM>. However, in other embodiments, the imaging system <NUM> of <FIG> and the imaging system <NUM> of <FIG> may be the same.

The imaging system <NUM> of <FIG> is operated to provide scan data. The scan data may be indicative of a visible structure of the scanned portion of the preform component <NUM>'; e.g., the diffuser section <NUM>. The scan data, for example, may be used to provide a feature map of the structure of the scanned portion of the preform component <NUM>'. This feature map may include location and/or dimensional information for the internal locating feature <NUM>. The feature map may also or alternatively include locations and/or dimensional information for other features / elements of the preform substrate <NUM>'. With this information, a processing system <NUM> may determine a location and/or an orientation of the internal locating feature <NUM>, or at least a portion thereof, relative to the preform component <NUM>' and/or a coordinate system. The internal locating feature <NUM> may thereby provide / correlate with a datum in the scan data.

In step <NUM>, the meter section <NUM> of the respective cooling aperture <NUM> is formed in the preform component <NUM>' using the scan data as shown, for example, in <FIG>. For example, the scan data and the internal locating feature location and/or orientation information determined therefrom may be used to locate a position of where and/or an orientation of how the meter section <NUM> should be formed in the preform component <NUM>'. The meter section <NUM> may then be formed at this location / orientation such that the meter section <NUM> is located, for example, as specified in a design specification and aligned with the diffuser section <NUM>.

A portion of the substrate material <NUM> is machined away (from the exterior of the preform component <NUM>') to provide the respective meter section <NUM>. The meter section <NUM> may be formed in the (e.g., electrically conductive, metal) substrate material <NUM> using a meter section machining process. This meter section machining process is selected to quickly, precisely and efficiently form the meter section <NUM> in the electrically conductive, metal substrate material <NUM>. The meter section machining process, for example, may be an electrical discharge machining (EDM) process. The present invention, however, is not limited to such an exemplary meter section machining process. The meter section <NUM>, for example, may also or alternatively be formed using one or more other machining processes such as, but not limited to, a laser machining (e.g., ablation) process, a water-jet guided laser (WJGL) machining process, an abrasive water jet (AWJ) machining process, an electron beam machining process, and a mechanical drilling process.

The method <NUM> is described above as using different machining processes for forming the diffuser section <NUM> and the meter section <NUM>. However, in other embodiments, one machining process may be used for machining through at least one of the coating materials (e.g., <NUM>), and the other machining process may be used for machining through the remaining material (e.g., <NUM> and <NUM>). In still other embodiments, the entire cooling aperture <NUM> may be formed using a common machining process (e.g., a laser machining process, etc.) and in a single forming step. In other embodiments, the method <NUM> may be performed without utilizing and scanning for the internal locating feature <NUM>. A start location for formation of the meter section <NUM>, for example, may be determined using another technique, or formed with the diffuser section <NUM> via a common machining process.

For ease of description, the method <NUM> is described above with respect to formation of a single cooling aperture <NUM> of the fluid cooled component <NUM>. However, the fluid cooled component <NUM> may be formed with multiple of the cooling apertures <NUM>, for example, by repeating the steps <NUM> and <NUM>. For example, the step <NUM> may be repeated multiple times to form diffuser sections <NUM> for multiple cooling apertures <NUM>. The step <NUM> may then be repeated multiple times to form meter sections <NUM> for the multiple cooling apertures <NUM>.

The method <NUM> is described above with reference to a microwave imaging system and an optical imaging system. The present invention, however, is not limited to such exemplary imaging systems. For example, the scanning step <NUM> may also or alternatively be performed by other non-contact, non-destructive imaging systems such as, but not limited to, a micro computed tomography (micro-CT) imaging system, a terahertz imaging system, a flash thermography system, etc..

Claim 1:
A manufacturing method for a component of a turbine engine, comprising:
providing (<NUM>, <NUM>) a preform component (<NUM>') for the turbine engine, the preform component including a substrate (<NUM>') and a locating feature (<NUM>) at an exterior surface (<NUM>) of the substrate (<NUM>');
applying (<NUM>) an outer coating (<NUM>') over the substrate (<NUM>'), wherein the outer coating (<NUM>') covers the locating feature (<NUM>);
scanning (<NUM>) at least a portion of the preform component (<NUM>') and the outer coating (<NUM>') with an imaging system (<NUM>) to provide scan data indicative of a location of the locating feature (<NUM>); and
forming a cooling aperture (<NUM>) in the substrate (<NUM>') and the outer coating (<NUM>') based on the scan data.