Abstract: Disclosed is a method of making an integrally bladed rotor. According to the method, a rotor disk comprising a radially outer rim surface is provided. A portion of the disk outer rim surface is removed, leaving a protrusion on the rotor disk outer rim surface. The disk with material removed is subjected to thermal processing. A blade comprising an airfoil and a base is positioned such that a base surface is in contact with the protrusion, and heat, pressure, and motion are applied between the blade and the disk to friction weld the base surface to the protrusion.

Abstract: A method of forming an airfoil includes placing a material onto a die that is heated to a predetermined temperature to pre-heat the material to a first temperature, while the die is in an open position. The method further includes closing the die at a predetermined rate and holding the die in a closed position for a predetermined period of time at a first force. The method still further includes removing the part from the die, cooling the die, placing the part onto the die, and closing the die at a second force.

Abstract: Disclosed is a method of making an integrally bladed rotor. According to the method, a titanium alloy rotor disk with 15-50% by volume of primary alpha grains with a grain size less than 10 ?m and secondary alpha grains comprising widmanstatten grains with a grain size less than 1.0 ?m is subjected to thermal processing. After thermal processing, a blade having an airfoil and a base is positioned such that a base surface is in contact with an outer rim surface of the disk. Heat, pressure, and motion are applied between the blade and the disk to friction weld the base surface to the disk outer rim surface.

Abstract: Disclosed is a method of making an integrally bladed rotor. According to the method, a titanium alloy rotor disk with 15-50% by volume of primary alpha grains with a grain size less than 10 ?m and secondary alpha grains comprising widmanstatten grains with a grain size less than 1.0 ?m is subjected to thermal processing. After thermal processing, a blade having an airfoil and a base is positioned such that a base surface is in contact with an outer rim surface of the disk. Heat, pressure, and motion are applied between the blade and the disk to friction weld the base surface to the disk outer rim surface.

Abstract: Disclosed is a method of making an integrally bladed rotor. According to the method, a rotor disk comprising a radially outer rim surface is provided. A portion of the disk outer rim surface is removed, leaving a protrusion on the rotor disk outer rim surface. The disk with material removed is subjected to thermal processing. A blade comprising an airfoil and a base is positioned such that a base surface is in contact with the protrusion, and heat, pressure, and motion are applied between the blade and the disk to friction weld the base surface to the protrusion.

Abstract: An estimated force applied by a milling tool at a surface point of a component is determined during milling operations of the component. An estimated deflection of the component associated with the estimated force is determined using the estimated force and a compliance tensor of the component corresponding to the surface point of the component. The estimated deflection of the component is compared to one or more deflection criteria. A feed rate of the milling tool is adjusted during the milling operations of the component based on results of the comparing.

Abstract: A method of forming an airfoil includes placing a material onto a die that is heated to a predetermined temperature to pre-heat the material to a first temperature, while the die is in an open position. The method further includes closing the die at a predetermined rate and holding the die in a closed position for a predetermined period of time at a first force. The method still further includes removing the part from the die, cooling the die, placing the part onto the die, and closing the die at a second force.