Abstract: The present invention generally relates to an external cylindrical or conic section shaped fixture which is tightly fit around the same shaped workpiece prior to expansion forming to a final dimension. During expansion forming, the external fixture is also deformed and is therefore designed for one-time use. The external cylindrical or conic section shaped fixture of the present invention is particularly useful for expansion forming of workpieces which contain brazed lap joints. The external fixture restrains, out-of-plane joint rotation and reduces the stress concentrations existing near the lap joints. Additionally, the external fixture provides additional load carrying capability to allow better load distribution during expansion forming. No change is required to the expansion forming machinery or the inner expander dies (jaws) with use of the present invention.

Abstract: Disclosed is a single-cast, thin wall structure capable of withstanding impinging gases at temperatures of 4300° F. and higher, and method of making the same.

Abstract: Disclosed is an integral single-cast multi wall structure including a very thin wall and a second thin wall. There is a passageway interposed between the pair of walls of the structure, and a high thermal conductivity member extends into said passageways and thermally couples the walls. The high thermal conductivity member increases the heat transfer between the walls of the structure. The present invention further includes a method for casting an integral structure having very thin walls that utilizes the high thermally conductive member in the casting process to hold the pattern and cores in alignment.

Abstract: An improved cobalt-base braze alloy composition and method for diffusion brazing are provided for use in repairing superalloy articles, such as gas turbine engines, power generation turbines, refinery equipment, and heat exchangers. The improved cobalt-base braze alloy composition includes nickel; at least one element selected from the group of rhenium, palladium, platinum, ruthenium, and iridium; at least one element selected from the group of boron and silicon; and the remaining balance consists of cobalt. This composition may also include aluminum and/or one or more rare earth/lanthanide series elements, and the composition may be combined with one or more powdered base metal superalloy compositions to form an improved diffusion braze alloy mixture. In the improved method for repairing superalloy articles, the foregoing mixture is applied to a region of the superalloy article to be repaired.

Abstract: A gear reduction gearbox connected to a gas turbine engine to reduce the shaft speed and increase the output torque. In one form of the present invention an input shaft and an output shaft are rotatable within a mechanical housing. A face gear set connects between the shafts for changing the speed of the output shaft relative to the input shaft. The present invention, in one embodiment includes load sharing wherein a plurality of pinion gear assemblies distribute the load transmitted through the gearbox.

Abstract: A lightweight high temperature multiproperty rotor disk and method of manufacture for use in a gas turbine engine. The rotor disk of a nickel super alloy and having a plurality of lightweight high temperature single crystal blade attachment lugs bonded thereto. The single crystal high temperature rotor blade attachment lugs being cast in a substantially rectangular shape and bonded to the circumference of the disk. A method of manufacturing the rotor includes positioning the plurality of single crystal attachment lugs on a positioning ring that has locating nests formed thereon. Subsequently, the rotor disk is placed within the bonding ring and a restraining ring is placed around the entire subassembly. Upon subjecting the assembly to high temperature the rotor disk, having a coefficient of thermal expansion greater than the coefficient of thermal expansion of the restraining member, forces the components into a mating relationship.

Abstract: The present invention provides a brazing fixture and method of using the fixture which allows the brazing of a joint in an oxide-dispersion-strengthened (ODS) high temperature alloy workpiece where stresses in the workpiece operate to open the joint during the brazing process. The fixture is formed from the same ODS alloy as the workpiece, such that the fixture exhibits the same coefficient of thermal expansion as the workpiece. This allows maximization of surface area contact between the fixture and the workpiece during the brazing operation in order to force the workpiece to maintain its design dimensions and to prevent the joint from opening. The fixture includes a cavity preventing fixture/workpiece contact in the area of the braze to help control thermal lag in the area of the joint.

Abstract: A single-cast, thin wall structure capable of withstanding impinging gases at temperatures of 4300.degree. F. and higher, and method of making the same.

Abstract: Disclosed is an integral single-cast multi wall structure including a very thin wall and a second thin wall. There is a passageway interposed between the pair of walls of the structure, and a high thermal conductivity member extends into said passageways and thermally couples the walls. The high thermal conductivity member increases the heat transfer between the walls of the structure. The present invention further includes a method for casting an integral structure having very thin walls that utilizes the high thermally conductive member in the casting process to hold the pattern and cores in alignment.

Abstract: A wave rotor apparatus and method of using the transient gas dynamic processes within the wave rotor to accomplish an engine topping cycle. In one form of the present invention the wave rotor is a five port device. Working fluid from the highest pressure outlet port is routed to a port adjacent to and preceding an inlet port admitting air from the compressor. In a preferred form of the present invention there are two port sequences disposed along the circumference of the wave rotor apparatus.

Abstract: A lightweight high temperature rotor blade attachment structure for use in a gas turbine engine. The lightweight high temperature rotor blade attachment lug being cast of a single crystal alloy and the lug is then bonded to a conventional nickel based wheel. A circular arc firtree is utilized to connect the insertable turbine blade between a pair of circumferentially spaced lugs that have been bonded to the turbine disk. In an alternate form of the present invention the attachment lug includes an internal cooling passage for receiving cooling fluid from a compressor. More particularly, the present invention discloses a single crystal attachment lug that is bonded to a powdered metal nickel alloy rotor disk and includes internal cooling passages, and in one form is designed for use with turbine blades that do not have a platform.

Abstract: A lightweight high temperature rotor blade attachment structure for use in a gas turbine engine. The lightweight high temperature rotor blade attachment lug being cast of a single crystal alloy and the lug is then bonded to a conventional nickel based wheel. A circular arc firtree is utilized to connect the insertable turbine blade between a pair of circumferentially spaced lugs that have been bonded to the turbine disk. In an alternate form of the present invention the attachment lug includes an internal cooling passage for receiving cooling fluid from a compressor. More particularly, the present invention discloses a single crystal attachment lug that is bonded to a powdered metal nickel alloy rotor disk and includes internal cooling passages, and in one form is designed for use with turbine blades that do not have a platform.

Abstract: A carbon seal contaminant barrier system for a gas turbine engine including a lip seal for wiping the surface of a rotating seal runner, and a baffle spaced from the rotating seal runner to prevent the impingement of the contaminants on the lip seal. The lip seal and the baffle are spaced axially and cooperate to minimize the contaminants passed to a carbon sealing system. The circumferential carbon sealing ring having a plurality of passages therethrough for delivering pressurized gas adjacent the carbon sealing ring. The pressurized gas being utilized to reduce the drag on the lip seal and to reduce the migration of contaminants onto the carbon seal. The barrier system being utilized to reduce the contamination of the carbon seal and prevent the inherent leakages associated therewith and the potential contamination of the environmental system of the aircraft.

Abstract: The present invention relates generally to a low emission can-annular combustion system for an industrial gas turbine engine to satisfy increasingly stringent environmental requirements. The combustion system of the present invention employs a dual mode combustion technique to meet engine operability requirements and high power emission targets without the use of combustor diluent injection or post combustor exhaust treatment. A lean premix combustion mode is utilized to minimize primary zone combustion temperatures and limit the oxide of nitrogen production during high power engine operation. A pilot-starting auxiliary fueling system is utilized to augment the main premix fueling system. The lean premix combustion mode is enabled by a lean premix dome having a fixed axial swirler with radial fuel pathways connecting to a circumferential main fuel manifold for distributing the fuel more uniformly across the flow path.

Abstract: Disclosed is an integral single-cast multi wall structure including a very thin wall and a second thin wall. There is a passageway interposed between the pair of walls of the structure, and a high thermal conductivity member extends into said passageways and thermally couples the walls. The high thermal conductivity member increases the heat transfer between the walls of the structure. The present invention further includes a method for casting an integral structure having very thin walls that utilizes the high thermally conductive member in the casting process to hold the pattern and cores in alignment.

Abstract: The present invention relates generally to a low emission can-annular combustion system for an industrial gas turbine engine to satisfy increasingly stringent environmental requirements. The combustion system of the present invention employs a dual mode combustion technique to meet engine operability requirements and high power emission targets without the use of combustor diluent injection or post combustor exhaust treatment. A lean premix combustion mode is utilized to minimize primary zone combustion temperatures and limit the oxide of nitrogen production during high power engine operation. A pilot-starting auxiliary fueling system is utilized to augment the main premix fueling system. The lean premix combustion mode is enabled by a lean premix dome having a fixed axial swirler with radial fuel pathways connecting to a circumferential main fuel manifold for distributing the fuel more uniformly across the flow path.

Abstract: A thrust vectoring system comprising a working fluid source mounted to an aircraft, and a vectoring nozzle connected to the working fluid source which has an extendable conduit defining a passage from an inlet to an outlet. The passage is adjustable so that the direction of the working fluid exiting the outlet is different than the working fluid entering the inlet when the conduit of the vectoring nozzle is extended. This conduit provides a way to change the direction of working fluid exiting the nozzle and correspondingly change the thrust vector of the aircraft. A directing member such as a guide vane or door is mounted to the conduit adjacent the outlet to further direct the working fluid exiting the outlet. Directing members provide a way to refine the thrust vector without changing the extension of the segmented conduit. Another aspect of the present invention is to provide an adapter to connect the vectoring nozzle to a working fluid source with an annular outlet.

Abstract: The present invention contemplates a hybrid magnetic bearing thrust disk. In one embodiment the hydrid magnetic bearing thrust disk comprises a high magnetic permeable portion that is supported by a high specific strength circumferential ring. The high specific strength circumferential ring resisting the dynamic loads applied to the hydrid thrust disk.

Abstract: A high performance hybrid shaft for use in applications where high stiffness, high temperature capacity and lightweight are important. In one form of the present invention the hybrid shaft is formed of a titanium alloy outer tube having in it's interior a gamma titanium aluminide alloy powder metal that is metallurgically bonded to the outer tube. The gamma titanium aluminide alloy powder metal has a room temperature modulus of elasticity greater than the modulus of elasticity of the titanium alloy tube. The hybrid shaft has a modulus of elasticity greater than modulus of elasticity of the titanium alloy tube, and a density equivalent to that of the titanium alloy tube. The wear resistant capability of the shaft is increased at local regions by surface modification treatment such as plasma ion nitrating or by affixing at the ends of the tube a hardened steel fitting.

Abstract: A lightweight high temperature rotor blade attachment structure for use in a gas turbine engine. The lightweight high temperature rotor blade attachment lug being cast of a single crystal alloy and the lug is then bonded to a conventional nickel based wheel. A circular arc firtree is utilized to connect the insertable turbine blade between a pair of circumferentially spaced lugs that have been bonded to the turbine disk. In an alternate form of the present invention the attachment lug includes an internal cooling passage for receiving cooling fluid from a compressor. More particularly, the present invention discloses a single crystal attachment lug that is bonded to a powdered metal nickel alloy rotor disk and includes internal cooling passages, and in one form is designed for use with turbine blades that do not have a platform.