Abstract: A turbine blade includes an airfoil that has a tip region that extends from the leading edge toward the trailing edge, and the tip region is bounded by a wall that extends at a positive angle. The leading edge has a leading edge cooling circuit that is defined from the platform to a tip flag channel, and the leading edge cooling circuit is in fluid communication with the tip flag channel. The pressure side includes at least one tip dust hole defined through the wall proximate the pressure side, and the at least one tip dust hole has an inlet and an outlet. The airfoil has at least one rib defined on the wall that extends at a second angle, and the at least one rib merges with at least one flow scoop to direct the particles and a portion of the cooling fluid into the inlet.

Abstract: Disclosed is a tangential on-board injector (TOBI) system that includes an annulus and a plurality of cooling airflow passages disposed about the annulus. Each cooling airflow passage of the plurality of cooling airflow passages includes an inlet opening having a polygonal inlet cross-section, the inlet opening having an inlet cross-sectional area. Each cooling airflow passage of the plurality of cooling airflow passages further includes an outlet opening having an outlet cross-section and an outlet cross-sectional area. The inlet cross-sectional area is greater in magnitude than the outlet cross-sectional area. Also disclosed are additive manufacturing methods for manufacturing the tangential on-board injector system and gas turbine engines that incorporate the tangential on-board injector system.

Abstract: Methods for processing bonded dual alloy rotors are provided. In one embodiment, the method includes obtaining a bonded dual alloy rotor including rotor blades bonded to a hub disk. The rotor blades and hub disk are composed of different alloys. A minimum processing temperature (TDISK_PROCESS_MIN) for the hub disk and a maximum critical temperature for the rotor blades (TBLADE_MAX) is established such that TBLADE_MAX is less than TDIsK_PROCESS_MIN. A differential heat treatment process is then performed during which the hub disk is heated to processing temperatures equal to or greater than TDISK_PROCESS_MIN, while at least a volumetric majority of each of the rotor blades is maintained at temperatures below TBLADE_MAX. Such a targeted differential heat treatment process enables desired metallurgical properties (e.g., precipitate hardening) to be created within the hub disk, while preserving the high temperature properties of the rotor blades and any blade coating present thereon.

Abstract: A heat exchanger includes a plurality of interconnected separator members that respectively include a first surface and an opposite second surface. The separator members respectively include an array of wave features. Also, the separator members are stacked and disposed in an alternating arrangement with the first surfaces of adjacent separator members facing each other and attached at the respective wave features, and with the second surfaces of adjacent separator members facing each other and attached at the respective wave features. The heat exchanger also includes a plurality of first flow passages for first fluid flow and second flow passages for second fluid flow. The second fluid and the first fluid are configured to exchange heat through the separator members.

Abstract: An airfoil for a gas turbine engine includes a first side wall; a second side wall joined to the first side wall at a leading edge and a trailing edge; and an internal cooling system arranged within the first and second side walls configured to direct cooling air through and out of the airfoil. The internal cooling system has a first cooling circuit that includes an acceleration channel generally extending in a radial outward direction. A first section of the acceleration channel decreases in cross-sectional area along the radial outward direction such that the cooling air is accelerated through the first section of the acceleration channel. The first cooling circuit further includes a trailing edge chamber fluidly coupled to receive at least a portion of the cooling air from the acceleration channel and extending generally in a chordwise aft direction from the acceleration channel to the trailing edge.

Abstract: Methods for processing bonded dual alloy rotors are provided. In one embodiment, the method includes obtaining a bonded dual alloy rotor including rotor blades bonded to a hub disk. The rotor blades and hub disk are composed of different alloys. A minimum processing temperature (TDISK_PROCESS_MIN) for the hub disk and a maximum critical temperature for the rotor blades (TBLADE_MAX) is established such that TBLADE_MAX is less than TDISK_PROCESS_MIN. A differential heat treatment process is then performed during which the hub disk is heated to processing temperatures equal to or greater than TDISK_PROCESS_MIN, while at least a volumetric majority of each of the rotor blades is maintained at temperatures below TBLADE_MAX. Such a targeted differential heat treatment process enables desired metallurgical properties (e.g., precipitate hardening) to be created within the hub disk, while preserving the high temperature properties of the rotor blades and any blade coating present thereon.

Abstract: A heat exchanger includes a plurality of interconnected separator members that respectively include a first surface and an opposite second surface. The separator members respectively include an array of wave features. Also, the separator members are stacked and disposed in an alternating arrangement with the first surfaces of adjacent separator members facing each other and attached at the respective wave features, and with the second surfaces of adjacent separator members facing each other and attached at the respective wave features. The heat exchanger also includes a plurality of first flow passages for first fluid flow and second flow passages for second fluid flow. The second fluid and the first fluid are configured to exchange heat through the separator members.

Abstract: A turbine blade includes an airfoil that has a tip region that extends from the leading edge toward the trailing edge, and the tip region is bounded by a wall that extends at a positive angle. The leading edge has a leading edge cooling circuit that is defined from the platform to a tip flag channel, and the leading edge cooling circuit is in fluid communication with the tip flag channel. The pressure side includes at least one tip dust hole defined through the wall proximate the pressure side, and the at least one tip dust hole has an inlet and an outlet. The airfoil has at least one rib defined on the wall that extends at a second angle, and the at least one rib merges with at least one flow scoop to direct the particles and a portion of the cooling fluid into the inlet.

Abstract: A turbine vane includes an airfoil that extends from an inner diameter to an outer diameter, and from a leading edge to a trailing edge. The turbine vane includes an inner platform coupled to the airfoil at the inner diameter. The turbine vane includes a cooling system defined in the airfoil including a first conduit in proximity to the leading edge to cool the leading edge and a second conduit to cool the trailing edge. The first conduit has an inlet at the outer diameter to receive a cooling fluid and an outlet portion that is defined at least partially through the inner platform. The first conduit includes a plurality of cooling features that extend between a first surface and a second surface of the first conduit, and the first surface of the first conduit is opposite the leading edge.

Abstract: A heat exchanger includes a separator member that divides a first flow passage from a second flow passage. The heat exchanger also includes a plurality of first hollow members that extend across the first flow passage at respective non-orthogonal angles. The plurality of first hollow members are fluidly connected to the second flow passage. Moreover, the heat exchanger includes a plurality of second hollow members that extend across the second flow passage at respective non-orthogonal angles. The plurality of second hollow members are fluidly connected to the first flow passage.

Abstract: A heat exchanger includes a separator member that divides a first flow passage from a second flow passage. The heat exchanger also includes a plurality of first hollow members that extend across the first flow passage at respective non-orthogonal angles. The plurality of first hollow members are fluidly connected to the second flow passage. Moreover, the heat exchanger includes a plurality of second hollow members that extend across the second flow passage at respective non-orthogonal angles. The plurality of second hollow members are fluidly connected to the first flow passage.

Abstract: Methods for manufacturing an article include providing a three-dimensional computer model of the article and providing a metal alloy in powdered form. The metal alloy is a titanium aluminide alloy. The powdered form includes a grain size range of about 5 to about 20 microns and a d50 grain size average of about 10 to about 14 microns. The methods further include, at a binder jet printing apparatus, supplying the metal alloy and loading the three-dimensional model, and, using the binder jet printing apparatus, manufacturing the article in accordance with the loaded three-dimensional model in a layer-by-layer manner with the supplied metal alloy. A liquid binder is applied at each layer, and each layer has a thickness of about 10 to about 150 microns. The methods avoid remelting of the metal alloy and avoid metal alloy cooling rates of greater than about 100 ° F. per minute.

Abstract: Methods for manufacturing an article include providing a three-dimensional computer model of the article and providing a metal alloy in powdered form. The metal alloy is a gamma prime precipitation hardened nickel-based superalloy. The powdered form includes a grain size range of about 5 to about 22 microns and a d50 grain size average of about 10 to about 13 microns. The methods further include, at a binder jet printing apparatus, supplying the metal alloy and loading the three-dimensional model, and, using the binder jet printing apparatus, manufacturing the article in accordance with the loaded three-dimensional model in a layer-by-layer manner with the supplied metal alloy. A liquid binder is applied at each layer, and each layer has a thickness of about 10 to about 150 microns. The methods avoid remelting of the metal alloy and avoid metal alloy cooling rates of greater than about 100° F. per minute.

Abstract: Methods for processing bonded dual alloy rotors are provided. In one embodiment, the method includes obtaining a bonded dual alloy rotor including rotor blades bonded to a hub disk. The rotor blades and hub disk are composed of different alloys. A minimum processing temperature (TDISK_PROCESS_MIN) for the hub disk and a maximum critical temperature for the rotor blades (TBLADE_MAX) is established such that TBLADE_MAX is less than TDISK_PROCESS_MIN. A differential heat treatment process is then performed during which the hub disk is heated to processing temperatures equal to or greater than TDISK_PROCESS_MIN, while at least a volumetric majority of each of the rotor blades is maintained at temperatures below TBLADE_MAX. Such a targeted differential heat treatment process enables desired metallurgical properties (e.g., precipitate hardening) to be created within the hub disk, while preserving the high temperature properties of the rotor blades and any blade coating present thereon.

Abstract: Methods for manufacturing an article include providing a three-dimensional computer model of the article and providing a metal alloy in powdered form. The metal alloy is a nickel-chromium-tungsten-molybdenum alloy. The powdered form includes a grain size range of about 5 to about 22 microns and a d50 grain size average of about 10 to about 13 microns. The methods further include, at a binder jet printing apparatus, supplying the metal alloy and loading the three-dimensional model, and, using the binder jet printing apparatus, manufacturing the article in accordance with the loaded three-dimensional model in a layer-by-layer manner with the supplied metal alloy. A liquid binder is applied at each layer, and each layer has a thickness of about 10 to about 150 microns. The methods avoid remelting of the metal alloy and avoid metal alloy cooling rates of greater than about 100° F. per minute.

Abstract: An airfoil for a gas turbine engine includes a first side wall; a second side wall joined to the first side wall at a leading edge and a trailing edge; and an internal cooling system arranged within the first and second side walls configured to direct cooling air through and out of the airfoil. The internal cooling system has a first cooling circuit that includes an acceleration channel generally extending in a radial outward direction. A first section of the acceleration channel decreases in cross-sectional area along the radial outward direction such that the cooling air is accelerated through the first section of the acceleration channel. The first cooling circuit further includes a trailing edge chamber fluidly coupled to receive at least a portion of the cooling air from the acceleration channel and extending generally in a chordwise aft direction from the acceleration channel to the trailing edge.

Abstract: An apparatus including a housing, an electrical conductor, and a suction control valve. The housing forms a handle and a shaft. The housing defines a suction channel from a distal end of the shaft. The electrical conductor extends to the distal end of the shaft. The suction control valve is connected to the suction channel at the handle. The suction control valve includes a valve body having a first channel and a second channel connected to the first channel, where the first channel forms a portion of the suction channel; and a valve barrel rotatably connected to the valve body. The valve barrel includes a rotatable ring extending around the handle and forming a portion of the housing. The ring includes an orifice configured to be rotated into and out of registration with an end of the second channel as the ring is rotated about the valve body.

Abstract: A method for manufacturing a metallic article includes providing or obtaining a metallic material in powder form, using an additive manufacturing process, building the metallic article from the powder-form metallic material, layer-by-layer, in a build direction, wherein as a result of the additive manufacturing process, the metallic article comprises columnar grain structures oriented in the build direction, and conveying the metallic article through a gradient furnace in a direction of conveyance from a first area of the gradient furnace to a second area of the gradient furnace to increase a size of the columnar grain structures in the metallic article. The metallic article is conveyed through the gradient furnace in an orientation such that the columnar structures oriented in the build direction are substantially parallel to the direction of conveyance.

Abstract: A heat exchanger includes a plurality of interconnected separator members that respectively include a first surface and an opposite second surface. The separator members respectively include an array of wave features. Also, the separator members are stacked and disposed in an alternating arrangement with the first surfaces of adjacent separator members facing each other and attached at the respective wave features, and with the second surfaces of adjacent separator members facing each other and attached at the respective wave features. The heat exchanger also includes a plurality of first flow passages for first fluid flow and second flow passages for second fluid flow. The second fluid and the first fluid are configured to exchange heat through the separator members.

Abstract: A heat exchanger includes a separator member that divides a first flow passage from a second flow passage. The heat exchanger also includes a plurality of first hollow members that extend across the first flow passage at respective non-orthogonal angles. The plurality of first hollow members are fluidly connected to the second flow passage. Moreover, the heat exchanger includes a plurality of second hollow members that extend across the second flow passage at respective non-orthogonal angles. The plurality of second hollow members are fluidly connected to the first flow passage.