Abstract: An apparatus and method for a mandrel used during an electroforming process. The mandrel is formed of a structural wax and includes a metallic layer utilized to formulate a metal component. During the electroforming process, the mandrel is actively cooled utilizing a closed loop. The closed loop includes the mandrel and a heat exchanger through which a coolant flows.

Abstract: A system is configured for machining a workpiece (100), the workpiece includes an interior surface (110) that defines an internal passage (112). The system includes an electrode (116) located within the internal passage and electrically isolated from the workpiece, an electrolyte supply, a power supply, and a remover. The electrolyte supply is configured for circulating an electrolyte in a gap between the electrode and the workpiece. The power supply is configured for applying a voltage between the electrode and the workpiece to facilitate smoothing the interior surface. The remover is configured for completely removing the electrode from within the internal passage after smoothing the interior surface.

Abstract: An apparatus and method for a mandrel used during an electroforming process. The mandrel is formed of a structural wax and includes a metallic layer utilized to formulate a metal component. During the electroforming process, the mandrel is actively cooled utilizing a closed loop. The closed loop includes the mandrel and a heat exchanger through which a coolant flows.

Abstract: A system includes a magnetic material supply for regulating a magnetic material flow rate of a magnetic material and a binder material supply for regulating a binder material flow rate of a binder material. A nozzle is configured for depositing a deposition mixture of the magnetic material and the binder material on a surface and a preheater is configured to preheat the deposition mixture before depositing on the surface. A controller is in operative communication with the magnetic material supply, the binder material supply, and the preheater. The controller is configured to receive an inductor core design file that represents a geometry and a magnetic permeability distribution of an inductor core, move the nozzle to one or more deposition locations, and adjust the magnetic material flow rate to the binder material flow rate to achieve a deposition mixture having a desired magnetic permeability at the deposition locations.

Abstract: A fan casing assembly, connection assembly and method for moving a fan casing cooler. The fan casing assembly for the turbine engine can include an annular fan casing with a peripheral wall having a flow path defined through the casing. A fan casing cooler can mount along the peripheral wall in order to confront a cooling fluid flow within the flow path in order to cool a fluid through the fan casing cooler.

Abstract: A method for fabricating aircraft engine external target parts including complex geometries utilizes reusable reconfigurable shape memory polymer and conformable woven braided carbon fiber sleeves. The method includes providing a tubular three-dimensional reusable shape memory polymer mandrel assembly designed for a target part, and heating the shape memory polymer mandrel.

Abstract: A strengthened component includes a sacrificial material mold of the component having an outer surface, an insert having an inner surface and an outer surface opposite and spaced from the inner surface such that the strengthening insert inner surface abuts the mold outer surface, and a metallic layer deposited over the exposed mold outer surface and the exposed strengthening insert outer surface, where the sacrificial material mold is removed from the strengthened component.

Abstract: A manufacturing process for making aircraft engine parts utilizes reusable reconfigurable smart memory polymer mandrel tooling, low temperature metal deposition, and composite part lay-up with resin coated conformable braided carbon fiber sleeves, to fabricate both metal internal engine parts and non-metal external parts for turbine engines.

Abstract: A component can be formed having an integral monolithic body. The integral monolithic body can be formed utilizing electroforming processes such as electrodeposition of metal alloys. The electroformed monolithic body can be formed utilizing multiple anodes powered by multiple power sources. The monolithic body can have differing local material properties determined during formation of the component.

Abstract: A method of forming a strengthened component includes forming a sacrificial material into a mold of the component having an outer surface, disposing an insert having an inner surface and an outer surface opposite and spaced from the inner surface such that the strengthening insert inner surface abuts the mold outer surface, forming the component by way of electrodisposition of a metallic layer over the exposed mold outer surface and the exposed strengthening insert outer surface, and removing the sacrificial material from the component.

Abstract: An apparatus and method of forming a heat exchanger including a thermally compliant material and geometry with a core having a first set of flow passages and a second set of flow passages passing through the core. A first manifold of high temperature and strength material defines a fluid inlet for the first set of flow passages and a second manifold of high temperature and strength material defines a fluid inlet for the second set of flow passages. At least one of the first and second manifolds can include an in-situ compliant portion to provide for compliance during thermal expansion of the heat exchanger.

Abstract: A duct for a turbine engine, such as a gas turbine engine, can be utilized to carry a fluid from one portion of the engine to another. The duct can include a metallic tubular element having one of a varying wall thickness, a varying cross section, or a tight bend. Such a duct can be formed utilizing additive manufacturing or metal deposition on an additively manufactured mandrel.

Abstract: A tunable compliant mount structure for an engine such as a turbine engine can include a fluid conduit coupled to a fan casing by a connector. At a junction between the connector and the fluid conduit, a compliant mount structure can provide compliance and can be tuned to operate under variable stresses at the junction. The compliant mount structure can include a set of nested convolutions to provide compliance. The geometry of the convolutions can be used to tune the compliance, stiffness, or directionality. The tunable compliant attachment structure provides for additive in-situ manufacturing at the fluid conduit.

Abstract: The embodiments disclosed herein relate generally to magnetic resonance imaging systems and, more specifically, to the manufacturing of a gradient coil assembly for magnetic resonance imaging (MRI) systems. For example, in one embodiment, a method of manufacturing a gradient coil assembly for a magnetic resonance imaging system includes depositing a first layer comprising a base material onto a surface to form a substrate and depositing a second layer onto the first layer. The second layer may enable bonding between a conductor material and the substrate. The method also includes depositing a third layer onto the second layer using a consolidation process. The consolidation process uses the conductor material to form at least a portion of a gradient coil.

Abstract: The present disclosure discloses a method of manufacturing a structure with a wall, comprising manufacturing a structure with a wall by using additive manufacturing technology, and dissolving a surface of the wall for reducing thickness of the wall.

Abstract: A core includes a first layer, a second layer, and a third layer. The first layer has a first surface, a second surface, and a first recessed pattern extending from the second surface of the first layer toward the first surface of the first layer. The second layer has a third surface, a fourth surface, a second recessed pattern extending from the third surface of the second layer toward the fourth surface of the second layer, and a third recessed pattern extending from the fourth surface of the second layer toward the third surface of the second layer. The third layer has a fifth surface, a sixth surface, and a fourth recessed pattern extending from the fifth surface of the third layer toward the sixth surface of the third layer. The second layer is disposed between the first and third layers such that the second surface of the first layer faces the third surface of the second layer and the fourth surface of the second layer faces the fifth surface of the third layer.

Abstract: The present disclosure discloses a method of manufacturing a structure with a wall, comprising manufacturing a structure with a wall by using additive manufacturing technology, and dissolving a surface of the wall for reducing thickness of the wall.

Abstract: A valve and a heat exchanger apparatus for a gas turbine engine include a valve body having a valve seat and an actuation component including a plate formed from a set of metal layers and responsive to a change in at least one of a thermal condition and a pressure exerted thereon such that the plate moves and the valve moves between an opened and a closed position where a portion of the plate engages with the valve seat.

Abstract: A method of manufacturing an inductor core includes controlling a flow of magnetic material and a flow of binder material to a nozzle such that the flow magnetic material merges with the flow of binder material at a focal point of a preheater, preheating the magnetic material and the binder material by energizing the preheater, mixing the magnetic material and the binder material according to a ratio based on a magnetic permeability distribution of the inductor core, and depositing the magnetic material and the binder material on a surface to form the inductor core having three layers with recessed patterns defined between the layers for receiving a coil.

Abstract: An apparatus and method of forming a heat exchanger including a thermally compliant material and geometry with a core having a first set of flow passages and a second set of flow passages passing through the core. A first manifold of high temperature and strength material defines a fluid inlet for the first set of flow passages and a second manifold of high temperature and strength material defines a fluid inlet for the second set of flow passages. At least one of the first and second manifolds can include an in-situ compliant portion to provide for compliance during thermal expansion of the heat exchanger.