Abstract: A fuel injector is provided for a gas turbine engine. The fuel injector includes a fuel conduit and a cooling fluid circuit through a strut. A gas turbine engine is provided that includes a multiple of fuel injectors in communication with a combustor and a cooling system in communication with each of the multiple of fuel injectors.

Abstract: A method for abrasive flow machining includes moving an abrasive media through a high-aspect passage of a workpiece. Local pressure of the abrasive media is increased at target abrasion surfaces of the high-aspect passage using a passage geometry that is configured to direct flow of the abrasive media into the target abrasion surfaces such that the target abrasion surfaces are preferentially polished by the abrasive media over other, non-targeted surfaces of the high-aspect passage at which the flow of the abrasive media is not directed into.

Abstract: An additively manufactured component includes a planar sheet and a coating applied to the planar sheet to form the component. The component is configured for attachment to a non-planar surface of a workpiece.

Abstract: A rotating tool system attachment on the spindle of a computer numerical control (“CNC”) machine includes a rotating assembly mounted on a static assembly. The rotating assembly provides a continuous supply of a wire material for deposition on a substrate during an additive manufacturing process. The rotating assembly includes a material supply housing a feedstock of wire mounted on a rotating spindle and a wire feeder configured to draw the wire from the wire supply and provide the wire for application during the additive manufacturing process. The tool system can be attached to the spindle of CNC machine to provide additive manufacturing capabilities to the CNC machine.

Abstract: An example method of mounting a first component to a second component includes receiving at least a fastening assembly within an aperture established in the first component, the fastening assembly coupled to the second component via a linking member, positioning a felt metal material between the fastening assembly and the first component, securing the fastening assembly, and compressing the felt metal material during the securing.

Abstract: A method for abrasive flow machining includes moving an abrasive media through a high-aspect passage of a workpiece. Local pressure of the abrasive media is increased at target abrasion surfaces of the high-aspect passage using a passage geometry that is configured to direct flow of the abrasive media into the target abrasion surfaces such that the target abrasion surfaces are preferentially polished by the abrasive media over other, non-targeted surfaces of the high-aspect passage at which the flow of the abrasive media is not directed into.

Abstract: A method of joining polymer components includes additively manufacturing first and second mating features on first and second polymer components such that a mechanical lock is created through undercut geometric features of an adhesive material when the polymer components are joined. Adhesive is added between the mating components to strengthen the joint.

Abstract: A thermal energy exchange system for cooling air of a gas turbine engine includes a heat exchanger located at a diffuser of the gas turbine engine. The diffuser is positioned axially between a compressor and a combustor of the gas turbine engine. A fuel source is operably connected to the heat exchanger to direct a flow of fuel through the heat exchanger via a fuel pipe and toward a fuel nozzle of the combustor. An airflow inlet directs a cooling airflow through the heat exchanger to reduce an airflow temperature via thermal energy exchange between the cooling airflow and the flow of fuel. An airflow outlet directs the cooling airflow from the heat exchanger toward one or more of components of the turbine to cool the one or more components.

Abstract: A component includes an additively manufactured component with an internal passage; and an additively manufactured elongated member within the internal passage. A method of additively manufacturing a component including additively manufacturing a component with an internal passage; and additively manufacturing an elongated member within the internal passage concurrent with additively manufacturing the component.

Abstract: A method of monitoring the residual stress in surface and near surface regions of a component includes identifying predetermined locations on the surface of a component that are expected to experience high stress during normal operating conditions of the component. Marker particles are introduced into the component during additive manufacture of the component at the predetermined locations. Then, the residual stress of the component is measured at a location corresponding with the marker material using x-ray techniques.

Abstract: An apparatus includes first, second, and third layers. The first layer includes a plurality of flanges. The second layer includes a deformable membrane. The second layer is connected to the first layer along a first major surface of the deformable membrane. The third layer is connected to the second layer along a second major surface of the deformable membrane opposite the first major surface. The third layer includes a first series of internal structures.

Abstract: An embodiment of a fitting assembly includes a fitting having at least a solid outer body, a pass-through bore, and at least one undercut region. The pass-through bore is defined by at least one pass-through bore wall, extending longitudinally through a length of the outer body from a first end to a second end. The at least one undercut region is formed into the at least one pass-through bore wall, and includes at least one expansion bearing surface disposed radially outward of at least one contraction bearing surface.

Abstract: A method of monitoring the residual stress in surface and near surface regions of a component includes identifying predetermined locations on the surface of a component that are expected to experience high stress during normal operating conditions of the component. Marker particles are introduced into the component during additive manufacture of the component at the predetermined locations. Then, the residual stress of the component is measured at a location corresponding with the marker material using x-ray techniques.

Abstract: A fuel/oil manifold includes first and second manifold flanges and a manifold tube. The first and second manifold flanges are located in non-parallel planes with respect to one another. The manifold tube is connected at a first end to the first manifold flange and at a second end to the second manifold flange and includes at least one turn between the first and the second end that includes a non-zero tube bend radius defined as the ratio of a turn radius to a diameter of the manifold tube.

Abstract: A method includes building a tubular object by a layer-by-layer additive manufacturing process. A structure integrally connected to the tubular object for supporting a portion of the tubular object is formed during building of the tubular object. The structure provides vibration dampening, heat shielding, heat transfer, stiffening, energy absorption, or mounting after the tubular object is built.

Abstract: A method for smoothing surface roughness within an internal passageway is disclosed. In various embodiments, the method comprises developing a first sphere progression through a length of the internal passageway, each sphere within the first sphere progression having a first sphere diameter greater than or equal to a diameter of the internal passageway; and developing a second sphere progression through the length of the internal passageway, each sphere within the second sphere progression having a second sphere diameter greater than the first sphere diameter, whereby the inner surface of the internal passageway is smoothed, first by the first sphere progression and then by the second sphere progression.

Abstract: A method for smoothing surface roughness within a passageway is disclosed. In various embodiments, the method comprises flowing an abrasive media through the passageway and positioning a mandrel within the passageway, the mandrel being sized to create a gap between an outer surface of the mandrel and an inner surface of the passageway, wherein the abrasive media is caused to flow through the gap, abrading the inner surface of the passageway.

Abstract: An insert apparatus for protecting a curved inner surface within a passageway from abrasion during an abrasive machining operation is disclosed. In various embodiments, the insert apparatus includes a shield having a shell shaped to match a curved portion of the curved inner surface of the passageway and a shaft having a first end connected to the shell and a second end connected to a member configured to maintain the shaft within the passageway and the shell positioned against the curved inner surface during the abrasive machining operation.

Abstract: A cluster-tool assembly for abrasive flow machining a plurality of airfoils is disclosed. The cluster-tool assembly comprises an airfoil cluster, the airfoil cluster including a supporting rail and the plurality of airfoils spaced about the supporting rail, and a sacrificial tool unitarily formed with the airfoil cluster, the sacrificial tool including a body and a plurality of prongs extending from the body.

Abstract: An electrochemical machining system comprises a component having a passage, the passage has an opening and an internal surface formed along the passage, a conductive wire has insulation covering portions of the conductive wire forming gaps having exposed wire; the conductive wire is inserted in the passage; a power source is coupled to the component and the conductive wire forms an electrical circuit, wherein the component comprises an anode and the conductive wire comprises a cathode; and an electrolyte within the passage contacting the internal surface and the exposed wire, wherein the electrolyte comprises a charge-carrying liquid configured to complete the electrical circuit between the cathode and anode.