Abstract: A bladed disk for a gas turbine engine is provided. The bladed disk includes a rotor disk, a plurality of rotor blades, and an interlocking transition zone. The rotor disk includes a plurality of fused layers of a first material formed via additive manufacturing and defines an outer rim. The plurality of rotor blades includes a plurality of fused layers of a second material formed via additive manufacturing. The interlocking transition zone includes a plurality of projections alternately extending from the outer rim of the rotor disk and the plurality of rotor blades, respectively, to undetachably couple the rotor disk and the plurality of rotor blades.

Abstract: Methods for repairing surface of a metal substrate are provided, which can include preparing the surface of the metal substrate for repair; melt attaching a base layer onto the surface of the metal substrate; fusing a plurality of first layers of a first material via additive manufacturing to the base coating; forming an interlocking transition zone via additive manufacturing from the first material and a second material; and fusing a plurality of second layers of the second material via additive manufacturing on the interlocking transition zone. The interlocking transition zone can have a plurality of projections alternately extending from the plurality of first layers and the plurality of second layers, respectively, to undetachably couple the plurality of first layers to the plurality of second layers. A repaired metal substrate is also provided.

Abstract: A gas turbine engine fuel nozzle apparatus includes: an annular outer body, the outer body extending parallel to a centerline axis, and having a generally cylindrical exterior surface extending between forward and aft ends, and having a plurality of openings passing through the exterior surface; an annular main injection ring disposed inside the outer body, the main injection ring including an annular array of fuel posts extending radially outward therefrom; a main fuel gallery extending within the main injection ring in a circumferential direction; a plurality of main fuel orifices, each main fuel orifice communicating with the main fuel gallery and extending through one of the fuel posts; and a suspension structure connecting the main injection ring to the outer body, the suspension structure configured to substantially rigidly locate the position of the main ring in axial and lateral directions while permitting controlled deflection in a radial direction.

Abstract: A gas turbine engine fuel nozzle apparatus includes: an annular outer body, the outer body extending parallel to a centerline axis, and having a generally cylindrical exterior surface extending between forward and aft ends, and having a plurality of openings passing through the exterior surface; an annular main injection ring disposed inside the outer body, the main injection ring including an annular array of fuel posts extending radially outward therefrom; a main fuel gallery extending within the main injection ring in a circumferential direction; a plurality of main fuel orifices, each main fuel orifice communicating with the main fuel gallery and extending through one of the fuel posts; and a suspension structure connecting the main injection ring to the outer body, the suspension structure configured to substantially rigidly locate the position of the main ring in axial and lateral directions while permitting controlled deflection in a radial direction.

Abstract: A process of producing a metallic component having a desired shape that includes at least one nonuniform section, as well as metallic components produced by such a process. The process uses a composition containing a mixture of a polymeric binder and a metal powder that includes particles of an alloy having a reactive element that renders the alloy uncastable. The composition is metal injection molded to yield a green compact having a shape corresponding to the shape of the metallic component, including its at least one nonuniform section. A majority of the binder is then removed from the green compact, and then the green compact is sintered to remove a remainder of the binder and fuse particles of the metal powder together to form the metallic component and the nonuniform section thereof.