Bonding system for dual walled turbine components

A system comprising:

• a resistance welder;
• a cover sheet probe electrically coupled with the resistance welder, the cover sheet probe comprising a tip having a three dimensional (3D) contoured contacting area that follows a 3D contoured outer surface of a cover sheet of a dual wall structure;
• an inner pedestal probe electrically coupled with the resistance welder, the inner pedestal probe to electrically couple with the dual wall structure;
• and
• the resistance welder including a controller to control a supply of electric power to the cover sheet probe and control a pressing force of the tip of the cover sheet probe against the outer surface of the cover sheet, wherein the tip includes the 3D contoured contacting area to abut the 3D contoured outer surface of the cover sheet opposite an inner surface of the cover sheet, the inner surface abutting a pedestal included in the core, and the 3D contoured contacting area equal to or greater than a surface area of the pedestal contacting the inner surface of the cover sheet,
• wherein the pedestal is a plurality of pedestals, and the tip of the cover sheet probe comprises a corresponding plurality of tips, and wherein the 3D contoured surface of the tip of the cover sheet probe is configured to abut the corresponding 3D contoured outer surface of the cover sheet, wherein a pattern of the pedestals included in the core match a pattern of the 3D contoured contacting surfaces of the corresponding plurality of tips of the cover sheet probe tip such that each of the pedestals aligns with one of the corresponding plurality of tips to create a respective maximum temperature junction between the cover sheet and a respective pedestal.

A system comprising:

• a resistance welder;
• a cover sheet probe electrically coupled with the resistance welder, the cover sheet probe comprising a tip having a three dimensional (3D) contoured contacting area that follows a 3D contoured outer surface of a cover sheet of a dual wall structure;
• an inner pedestal probe electrically coupled with the resistance welder, the inner pedestal probe to electrically couple with the dual wall structure;
• and
• the resistance welder including a controller to control a supply of electric power to the cover sheet probe and control a pressing force of the tip of the cover sheet probe against the outer surface of the cover sheet, wherein the tip includes the 3D contoured contacting area to abut the 3D contoured outer surface of the cover sheet opposite an inner surface of the cover sheet, the inner surface abutting a pedestal included in the core, and the 3D contoured contacting area equal to or greater than a surface area of the pedestal contacting the inner surface of the cover sheet,
• wherein the pedestal is a plurality of pedestals, and the cover sheet probe comprises a plurality of cover sheet probes each with a corresponding tip, and wherein the tip of the cover sheet probe is configured to abut against the outer surface of the cover sheet, wherein a pattern of the pedestals included in the core match a pattern of the 3D contoured contacting surfaces of the corresponding tips of the coversheet probe such that each of the pedestals aligns with one of the corresponding tips to create a respective maximum temperature junction between the cover sheet and a respective pedestal.