Abstract: One example aspect of the present disclosure is directed to a method for enhancing a maintenance operation routine. The method includes receiving, at one or more processors, engine history data. The method includes comparing, at the one or more processors, the received engine history data to expected engine history data. The method includes determining, at the one or more processors, an expected effectiveness of a plurality of maintenance operation types based on the comparison. The method includes selecting, at the one or more processors, one of the plurality of maintenance operation types based on the determinations. The method includes transmitting, at the one or more processors, a signal indicative of a notification of the selected maintenance operation type.

Abstract: An additively manufactured fastener and a method of manufacturing the same are provided. The fastener includes a shank defining an internal passageway and a head defining a distribution plenum in fluid communication with the internal passageway. The head further defines a cooling face defining a plurality of cooling holes for receiving a flow of cooling air from the internal passageway and the distribution plenum. In addition, an impingement baffle is positioned in the distribution plenum and defines impingement holes for directing the flow of cooling air onto the cooling face.

Abstract: A system and method for cleaning an installed gas turbine engine is provided. The system may include a controller on an engine core, wherein the engine core defines a primary gas path and includes at least one airfoil extending into the primary gas path. The method may include initiating a cleaning program and directing a cleaning fluid toward the engine core in response to the initiation of the cleaning program. The method may further include initiating delivery of the cleaning fluid as a non-vaporized liquid within the primary gas path to the engine core.

Abstract: A rotor blade formed via additive manufacturing is provided. The rotor blade includes an airfoil and a coupled component. The airfoil includes a plurality of fused layers of a first material formed via additive manufacturing and defines a leading edge and a tip at a distal end. The coupled component includes a plurality of fused layers of a second material formed via additive manufacturing. An interlocking transition zone includes a plurality of projections alternately extending from the airfoil and the coupled component, respectively, to undetachably couple the airfoil and the coupled component.

Abstract: An apparatus for manufacturing an axi-symmetric part. The apparatus includes a vessel configured to contain the powder. The vessel is also configured to receive a part such that at least a portion of the part contacts the powder contained within the vessel. A first energy source is configured to generate a first beam of energy. The first beam of energy is configured to melt the powder at a first predetermined location such that the melted powder fuses to the part.

Abstract: Turbine nozzles are provided for gas turbine engines. The turbine nozzle includes an arcuate inner band; an arcuate outer band; and a nozzle vane disposed between the arcuate inner band and the arcuate outer band. The radially inner end of the nozzle vane is attached to the arcuate inner band through an interlocking transition zone including a plurality of projections alternately extending from the radially inner end of the nozzle vane and the arcuate inner band, respectively, to undetachably couple the nozzle vane and the arcuate inner band. Optionally, the radially outer end of each nozzle vane is also attached to the arcuate outer band through an interlocking transition zone.

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: An additively manufactured fastener and a method of manufacturing the same are provided. The fastener includes a shank defining an internal passageway and a head defining a distribution plenum in fluid communication with the internal passageway. The head further defines a cooling face defining a plurality of cooling holes for receiving a flow of cooling air from the internal passageway and the distribution plenum. In addition, an impingement baffle is positioned in the distribution plenum and defines impingement holes for directing the flow of cooling air onto the cooling face.

Abstract: A system includes an image capture device within an existing aircraft shell having a turbine or a rotary wing, the image capture device including an optical assembly having a field of view directed towards at least one of the turbine, the rotary wing, and a surface of the aircraft shell, the image capture device configured to capture an image of radiant flux, and an image analysis unit in communication with the image capture device to analyze the captured radiant flux image to determine a particulate matter concentration in a debris suspension cloud. The system can also include a quantizer unit to quantize an electrical signal from the image capture device, the electrical signal proportional to an intensity of the radiant flux, and an integrator unit to obtain an about continuous value of the radiant flux intensity. A method to implement the system and a non-transitory computer-readable medium are also disclosed.

Abstract: One example aspect of the present disclosure is directed to a method for enhancing a maintenance operation routine. The method includes receiving, at one or more processors, engine history data. The method includes comparing, at the one or more processors, the received engine history data to expected engine history data. The method includes determining, at the one or more processors, an expected effectiveness of a plurality of maintenance operation types based on the comparison. The method includes selecting, at the one or more processors, one of the plurality of maintenance operation types based on the determinations. The method includes transmitting, at the one or more processors, a signal indicative of a notification of the selected maintenance operation type.

Abstract: A method of joining two components using additive manufacturing is provided. The method includes forming a first component made of a first material; forming an interlocking transition zone from the first material and a second material; and forming a second component made of the second material. The interlocking transition zone includes a plurality of projections alternately extending from the first component and the second component, respectively, to undetachably couple the first component and the second component.

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: An apparatus for manufacturing an axi-symmetric part. The apparatus includes a vessel configured to contain the powder. The vessel is also configured to receive a part such that at least a portion of the part contacts the powder contained within the vessel. A first energy source is configured to generate a first beam of energy. The first beam of energy is configured to melt the powder at a first predetermined location such that the melted powder fuses to the part.

Abstract: The present invention relates to a ceramic or metallic component including a first region having a first porosity ranging between 1 and 30%. The component includes a second region having a second porosity that is less than the first porosity. The component includes at least one graded transition between the first and second regions.

Abstract: A system and method for cleaning an installed gas turbine engine is provided. The system may include a controller on an engine core, wherein the engine core defines a primary gas path and includes at least one airfoil extending into the primary gas path. The method may include initiating a cleaning program and directing a cleaning fluid toward the engine core in response to the initiation of the cleaning program. The method may further include initiating delivery of the cleaning fluid as a non-vaporized liquid within the primary gas path to the engine core.

Abstract: The present disclosure is directed to a method for cleaning gas turbine engine components using an acoustic emitter. More specifically, in one embodiment, the method includes positioning the acoustic emitter at a cleaning location of a component of the gas turbine engine. For example, the cleaning location is typically characterized by having a build-up of foulants on a surface thereof. Thus, the method includes emitting, via the acoustic emitter, acoustic waves at a predetermined frequency towards the cleaning location of the component so as to disperse the foulants.

Abstract: Turbine nozzles are provided for gas turbine engines. The turbine nozzle includes an arcuate inner band; an arcuate outer band; and a nozzle vane disposed between the arcuate inner band and the arcuate outer band. The radially inner end of the nozzle vane is attached to the arcuate inner band through an interlocking transition zone comprising a plurality of projections alternately extending from the radially inner end of the nozzle vane and the arcuate inner band, respectively, to undetachably couple the nozzle vane and the arcuate inner band. Optionally, the radially outer end of each nozzle vane is also attached to the arcuate outer band through an interlocking transition zone.

Abstract: A rotor blade formed via additive manufacturing is provided. The rotor blade includes an airfoil and a coupled component. The airfoil includes a plurality of fused layers of a first material formed via additive manufacturing and defines a leading edge and a tip at a distal end. The coupled component includes a plurality of fused layers of a second material formed via additive manufacturing. An interlocking transition zone includes a plurality of projections alternately extending from the airfoil and the coupled component, respectively, to undetachably couple the airfoil and the coupled component.

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: A method of joining two components using additive manufacturing is provided. The method includes forming a first component made of a first material; forming an interlocking transition zone from the first material and a second material; and forming a second component made of the second material. The interlocking transition zone includes a plurality of projections alternately extending from the first component and the second component, respectively, to undetachably couple the first component and the second component.