Abstract: A diaphragm assembly for use in pneumatic actuators uses two or more diaphragms, one nested inside of the other. Each of the diaphragms, when shaped, includes a fabric pattern. The fabric patterns on each of the diaphragms are aligned one with another upon installation into a pneumatic actuator.

Abstract: A low hysterisis fuel control valve for proportioning fuel being supplied to the combustor of the turbine engine into a first portion for delivery to primary fuel nozzles and a second portion for delivery to secondary fuel nozzles is provided. The valve includes a piston mounted within a linear ball bearing bushing. In response to fuel pressure, the piston is continuously operable between a first position where said no fuel flow to the fuel nozzles occurs, a second position where fuel flows to the primary nozzles and a third position where fuel flows to the secondary nozzles.

Abstract: A method for forming a thermally isolating gas turbine housing from the significantly high temperatures associated with the combustion gases flowing through the housing. A floating liner is positioned within the turbine housing with an outer baffle arranged about the floating liner and an inner baffle arranged within the floating liner. The inner and outer baffles are welled or brazed to the floating liner assembly to form a unitary assembly creating a single, continuous cooling passageway within the housing for collecting heat from adjacent the surfaces of the floating liner and expelling the heat into the combustion exhaust stream.

Abstract: A shaft coupling is made from carbon-carbon composite to achieve significantly higher temperature capability, combined with lubricity and high strength, allowing its use in hot, non-lubricated sections of gas turbine engines, where previously, these couplings could not be used. The coupler may be cylindrical for joining the facing ends of co-axial shafts is made from carbon-carbon composite with a female spline in a coupling bore and a male spline on the coupling outer surface. Variations of the torque carrying geometry include involute splines, circular splines, square drive, hex drives, serrations, or double-D drives. By fabricating the coupler from carbon-carbon (or carbon-graphite) composite, metallic shaft mating splines are provided with a coupler that has exceptionally high temperature capabilities (>2500 F.), high strength, and can be impregnated with graphite or other dry lubricants to reduce frictional heat generation and reduce spline wear.

Abstract: A system and method of using a variable geometry ejector for a bleed air system using integral bleed pressure feedback which utilizes a minimal amount of high-pressure air, thus improving the overall engine cycle performance and is easily adaptable to a multitude of different engine types. This is accomplished through the use of a variable ejector using downstream pressure feedback to control the flow and pressure.

Abstract: An air turbine starter system and air turbine starter valve that has a microvolume actuator to prevent the connected butterfly valve from opening too quickly. Air turbine starter valves can in some circumstances freeze shut, but may be opened by normal actuator operation. Such operation may open the valve too quickly due to stored potential energy. A sharp pressure transient may be inflicted upon the connected air turbine starter which can cause damage. The microvolume actuator air turbine starter system set forth herein allows generation of sufficient force to break ice and move the valve while minimizing stored potential energy that could open the valve too quickly.

Abstract: A turbofan engine throttle control system and method for eliminating dead bands in the throttle control by decreasing and increasing the fuel flow to the engine during transition from the scheduled core speed to scheduled fan speed of the engine to effect a smooth and continuous transition from the core speed to the fan speed and vice-versa. A signal is generated to open and close a valve system to augment and decrease the fuel flow in response to sensing different throttle lever angles.

Abstract: An air turbine starter valve able to open despite being frozen shut. Dual actuators apply sufficient torque upon an air turbine starter valve to overcome obstructions presented by frozen moisture. By applying separate and generally-aligned torques, the actuators are able to provide sufficient force to overcome the adhesion provided by frozen moisture between the valve plate and adjacent structures.

Abstract: A gearless electric thrust reverser actuator includes an electric motor that is coupled to a jack screw without any intervening gears. The actuator may additionally include all of the actuation and sensing components in a single actuation package. Thus, the actuator is relatively lightweight and compact.

Abstract: An apparatus and method that provides a flexible anisotropic support, which may accommodate open, closed, or re-circulating squeeze film damper in parallel, has improved internal rolling element clearances, limits maneuver and blade loss responses by limiting rotor excursion, and has a rotor centering feature. This is accomplished through the combination of beam and ring arrangement, which provides support anisotropy that produces beneficial cross-coupling stiffness for the support to control synchronous and non-synchronous vibration.

Abstract: An improved air turbine starter that includes fluid flow control devices. The devices may be check valves, for example normally open check valves. The check valves may be located in fluid flow paths between the starter and the gearbox to which it is mounted. The starter may also include a ring seal about the output shaft to restrict fluid flow over the shaft.

Abstract: An improved jet engine thrust reverser that includes a sensor to determined the rotational position of a motor. The system includes an actuator, a motor, motor position sensor, and an electronic control unit. The electronic control unit converts the rotational position of the motor to thrust reverser system using, for example, a summation algorithm and reset logic. The summation algorithm incrementally calculates absolute position of the thrust reverser from the sensed motor rotational position.

Abstract: An ion fusion formation (IFF) system uses a plasma welding torch to create ions that heat feedstock for application at a deposition point. A plasma welding torch may use argon gas or the like in order to provide extremely hot ions that impact or collide with the feedstock in order to melt it and enabling application of the melted feedstock to a deposition point on a workpiece. By positioning the workpiece, wire feeder, and/or welding torch, parts, devices, or components can be built in almost any three-dimensional shape. Parts can be manufactured in a “just-in-time fashion” with high precision and predictable performance.

Abstract: One or more stator seal assemblies are mounted in the housing of a rotating machine such as, for example, an air turbine starter for a gas turbine engine, and surround a rotating shaft. The seal assemblies each include a seal case and a seal. The seal has a face that engages an axial face of a face seal rotor to form a seal. One or more anti-rotation tabs in the seal case engage anti-rotation notches formed in the peripheral surface of the seal. The anti-rotation notches each include substantially arcuate sections formed in notch end surfaces. The arcuate sections increase the amount of wear in the notches that can be tolerated before a potential seal lock-up, thus increasing seal assembly lifetime.

Abstract: A joint assembly for coupling a ceramic member to a metal member is comprised of a ceramic shaft portion attached to the ceramic member; a slotted shrink fitter formed of a first metal and disposed around and in torque transmitting contact with the ceramic shaft portion to define a first interface surface therebetween; and a sleeve formed of a second metal disposed around and in torque transmitting contact with the shrink fitter to define a second interface surface therebetween. Either the shrink fitter or the sleeve attached to the metal member. The coefficient of thermal expansion of the second metal is relatively low compared to that of the first metal and the diameters of the first interface, (d1), and the second interface, (d2), are determined from the equation, d1/d2=(&agr;c−&agr;1)/(&agr;2−&agr;1) where &agr;c, &agr;1 and &agr;2 are the coefficients of thermal expansion of the ceramic, the first metal and the second metal respectively.

Abstract: A lower stress and higher service life curvic coupling design is disclosed for use on coupling mechanisms for assembly of components that comprise rotating elements, such as impellers, turbine wheels and couplings for gas turbine engines and other types of engines having highly stressed components. The curvic coupling design includes a compound fillet radius, comprised of a large and a small radius, located between the root and the pressure surface of all splined teeth on the torque transmitting coupling halves. The larger radius, with its lower stress concentration, is positioned in the root area where the background hoop stresses act, thereby resulting in a lower fillet peak stress value. The smaller radius smoothly connects the larger radius with the pressure surface, minimizing the penetration of the fillet surface towards the mating tooth, thereby allowing proper clearances to be maintained.

Abstract: An apparatus and method for testing the flow distribution through a turbine engine fuel manifold and one or more nozzles connected to the manifold. A plurality of individual fluid measurement vessels, at least one for each of the nozzles being tested, collects test fluid pumped through the manifold and the connected nozzles. The level in each of the measurement vessels is periodically sampled during the test. The test fluid flow rate through each of the nozzles is periodically determined based on the periodically sampled levels.

Abstract: A thrust reverser system that includes a pass-through torque activated brake assembly that limits the torque applied in portions of the thrust reverser system drive train. The brake assembly includes two plates that are coupled together with a torsion spring. When a predetermined torque is applied to the torsion spring, the torsion spring displaces the plates from one another. Balls that are positioned in cammed grooves in each of the plates causes the plates to translate away from one another and contact brake surfaces to thereby limit the torque in the drive train.

Abstract: A multi-pole high speed generator includes a rectifier module assembly that is dimensioned to be mounted within the hub of a high speed generator exciter armature includes a rectifier module assembly includes a substantially flat base that has a plurality of conductive circuit runs formed on it, and which is dimensioned to be mounted within a hub of the exciter. A first diode circuit, which includes an anode and a cathode, has its anode electrically coupled to a first of the plurality of conductive circuit runs. A second diode circuit, which also includes an anode and a cathode, has its cathode electrically coupled to a second of the plurality of conductive circuit runs. A conductive element electrically couples together the cathode of the first diode circuit and the anode of the second diode circuit.

Abstract: A composite face seal having an annular seal rotor with a metal base portion and a radially extending flange. The flange having first and second axially facing surfaces. A first ceramic ring is mounted to the first surface of the flange by a first braze joint and a second ceramic ring is mounted to the second surface of the flange by a second braze joint. The composite face seal assembly further includes an annular stator having an axially facing surface that sealingly engages an axially facing surface of one of the ceramic rings. Each of the braze joints may comprise a molybdenum ring disposed between two braze rings or, for thicker seal assemblies, molybdenum and nickel rings disposed between braze rings.