Machined film holes

1. A component comprising a set of thin film cooling holes formed therein,

wherein each of the thin film cooling holes provides a passage between a first surface of the component and a second surface of the component, and

wherein each of the thin film cooling holes includes:

a smooth transition between the first surface of the component and the surface the passage;

a progressively steeper flow path relative to the first surface of the component and between the smooth transition and the second surface of the component;

a lip opposing the smooth transition at the interface between the first surface of the component and the passage; and

an edge break at the lip on the first surface of the component.

2. The component of claim 1 , wherein each of the thin film cooling holes forms a Coanda ramp that provides the smooth transition and the progressively steeper flow path.

3. The component of claim 1 , wherein each of the thin film cooling holes further includes a straight section between the progressively steeper flow path and the second surface of the component.

4. The component of claim 3 , wherein for each of the thin film cooling holes, the smooth transition is a first smooth transition, wherein each of the thin film cooling holes further includes a second smooth transition between the progressively steeper flow path and the straight section.

5. The component of claim 3 , wherein for each of the thin film cooling holes, the straight section is at an angle of less than 75 degrees relative to the second surface of the component.

6. The component of claim 1 , wherein for each of the thin film cooling holes, the smooth transition between the first surface of the component and the surface the passage is wider than the most narrow width of the passage, wherein for each of the thin film cooling holes, the progressively steeper flow path progressively narrows from the width of the smooth transition to the most narrow width of the passage.

7. The component of claim 6 , wherein for each of the thin film cooling holes, the smooth transition between the first surface of the component and the surface the passage forms at least two separate flow channels separated by one or more dividers within the progressively steeper flow path.

8. The component of claim 7 , wherein for each of the thin film cooling holes, wherein the dividers become progressively less pronounced between the smooth transition and the most narrow width of the passage.

9. A component comprising a set of thin film cooling holes formed therein,

wherein each of the thin film cooling holes provides a passage between a first surface of the component and a second surface of the component,

wherein the passage enters the first surface of the component at a non-perpendicular angle to form an overhang over the passage at a lip on one side of the interface between the passage and the first surface of the component, and

wherein the passage includes an edge break at the overhang on the first surface of the component.

10. The component of claim 9 , wherein the edge break functions to dull the transition between the passage and the first surface of the component to limit stress concentrations at the lip.

11. The component of claim 9 , wherein for each of the thin film cooling holes, the component forms an overhang over the passage at the lip on the first surface of the component.

12. The component of claim 9 , wherein for each of the thin film cooling holes, the non-perpendicular angle less than 75 degrees relative to the first surface of the component.

13. The component of claim 9 , wherein each of the thin film cooling holes includes a smooth transition between the first surface of the component and the surface the passage, the smooth transition opposing the lip at the interface between the first surface of the component and the passage.

14. The component of claim 13 , wherein for each of the thin film cooling holes, the smooth transition between the first surface of the component and the surface the passage forms at least two separate flow channels separated by one or more dividers.

15. A method of manufacturing an array of thin film cooling holes in a component, the method comprising:

inspecting the component to obtain a component surface data set;

determining machining paths for each of the thin film cooling holes in the array of thin film cooling holes based on the component surface data set; and

for each of the thin film cooling holes, machining a passage between a first surface of the component and a second surface of the component,

wherein machining the passage includes:

machining a smooth transition between the first surface of the component and the surface the passage,

machining a progressively steeper flow path relative to the first surface of the component and between the smooth transition and the second surface of the component, and

machining an edge break at a lip opposing the smooth transition at the interface between the first surface of the component and the passage.

16. The method of claim 15 , wherein determining machining paths for each of the thin film cooling holes in the array of thin film cooling holes based on the component surface data set comprises:

accessing a design surface data set;

creating a new surface data set based on the design surface data set and the component surface data set, the new surface data set approximating the design surface data set while accounting for variation between a component specified by the design surface data set and the component surface data set; and

generating machining paths for each of the thin film cooling holes based on the new surface data set.

17. The method of claim 16 , further including determining a degree of variation in response to the new surface data set and the design surface data set and predicting a quality outcome in response to the degree of variation.

18. The method of claim 15 , further including securing the component in a fixture and obtaining the component surface data set of the component in relation to the fixture.

19. The method of claim 18 , further including determining a hole location in response to the component surface data set of the component in relation to the fixture, wherein machining the passage further includes machining the component in response to the machining path and the hole location.