Abstract: A method of manufacturing and measuring the geometry of at least a part of a component, and a method of manufacturing a component, both include providing a powder layer to a melt region; selectively melting the powder layer using an energy source, the melted powder subsequently solidifying to form a solid layer; scanning the melt region, including the solid layer, using a scanning electron beam; detecting backscattered electrons resulting from the interaction of the scanning electron beam with the melt region; determining the geometry of the solid layer from the detected backscattered electrons; and storing data relating to the determined geometry of the solid layer. The methods may also include adjusting parameters of the steps of providing a powder layer and/or selectively melting the powder layer to avoid future recurring errors, or generating a virtual 3-D model of the manufactured component, using the stored data.

Abstract: This invention relates to an electrical system for an aircraft, comprising: a first main generator connected to at least one load via a first bus; a second main generator connected to at least one load via a second bus; a first and a second auxiliary generator associated with the first and second buses, the auxiliary generators being driven by a common prime mover.

Abstract: A method for the manufacture of a blisk drum is described. Disc forging for inertia welding together are provided with sacrificial material whose shape and position is selectively provided such that, on completion of the inertia welding process, integral blades can be fashioned from the sacrificial material. Other components such as buckets and balancing lands may also be provided from the sacrificial material.

Abstract: A method for sentencing a manufactured component as a pass or fail is described. The method involves zoning a two-dimensional image of the component, weighting individual zones according to their importance in the load bearing function and comparing overall weighted dimensions against those of a pre-defined compliant component design. By considering the internal and external dimensions and offsetting variations between zones, a more accurate assessment of compliance can be achieved. It is envisaged that components which might otherwise have been rejected and scrapped may be accepted resulting in material and cost savings.

Abstract: A method for welding together pieces which form a curved or angled end product using a friction welding process. The method includes: providing first and second pieces which together define the end product geometry, each piece including an end product geometry portion and a sacrificial weld portion, the sacrificial weld portion forming a dog-leg relative to the end product geometry portion and terminating in a planar weld interface surface. The pieces are arranged with their planar weld interface surfaces together at a weld surface interface and the sacrificial weld portions in coaxial alignment. Mechanical friction is applied between the planar weld interface surfaces sufficient to plastically deform the sacrificial weld portions. An axial force is applied along the co-axis of the sacrificial weld portions sufficient to upset the sacrificial weld portions and bring together the end product geometry portions. The sacrificial geometry portions are removed to provide the end product.

Abstract: The present invention provides a pipe for transferring powder material from a reservoir to a container e.g. prior to hot isostatic pressing. The pipe comprises a continuous outer wall and a concentric continuous inner wall enclosed within and spaced from the outer wall. The spacing between the inner and outer walls defines a flow channel extending from an inlet to an outlet. The radial cross sectional area of the outlet is greater than the cross sectional area of the inlet.

Abstract: A fan blade is provided with an aerofoil portion for which, at radii between 20% and 40% of the blade span, the location of the position of maximum thickness along the camber line is at less than a defined percentage of the total length of the camber line. For all cross-sections through the aerofoil portion at radii greater than 70% of the blade span, the location of the position of maximum thickness along the camber line is at more than a defined percentage of the total length of the camber line. The geometry of the fan blade may result in a lower susceptibility to flutter.

Abstract: Described is a turbine arrangement of a gas turbine engine, the turbine comprising: a rotor comprising a disc which incorporates a plurality of circumferentially spaced turbine blades, each blade having an aerofoil extending for a platform and a root portion securing the blade to the disc, a lock plate located at an axial end of the root portion of the blade, the lock plate comprising: a plate body having an inward facing surface which is located adjacent the blade root and an outward facing surface, radially inner and outer edge portions, and first and second circumferential edges; a head located at the radially outer edge portion of the plate body; a foot portion located at the radially inner portion of the plate body; a projection extending from the outwardly facing surface away from the turbine blade root in use, the projection being located adjacent to the foot portion, wherein the foot portion and head portion are located within slots provided at least partially by the disc and turbine blade respectivel

Abstract: An abradable sealing element is positioned radially outwardly of a plurality of aerofoil blades of a gas turbine engine. The abradable sealing element comprises a radially inwardly facing surface region and a plurality of cooling holes. The radially inwardly facing surface region comprises a wall structure, with the wall structure having one or more radially inwardly projecting walls formed by additive layer, powder fed, laser weld deposition. Each of the inwardly projecting walls is continuous and defines a plurality of repeating units arranged circumferentially around the radially inwardly facing surface region, each repeating unit is open at a radially inwardly facing side of the sealing element, and each repeating unit comprises a plurality of curved portions forming a multi-lobed profile shape. Each cooling hole is provided in the radially inwardly facing surface region at a position within the multi-lobed profile shape.

Abstract: A fan blade is provided with an aerofoil portion for which, for cross-sections through the aerofoil portion at radii between 15% and 25% of the blade span from the root radius, the average leading edge thickness is greater than the leading edge thickness at the tip. The geometry of the fan blade may result in a lower susceptibility to flutter.

Abstract: A fan blade for a gas turbine engine is provided with forward axial lean. The fan blade may have a substantially straight leading edge. The geometry of the fan blade results in a lower susceptibility to flutter, thereby allowing a gas turbine engine comprising such a fan blade to operate over a wider range of operating conditions.

Abstract: There is disclosed a stator vane section for a gas turbine engine. The stator vane comprises an aerofoil, a first platform at a radial end of the aerofoil, a cooling chamber within the aerofoil and a guide duct within the cooling chamber. An impingement chamber is defined between the first platform and a perforated impingement plate provided on the first platform to receive cooling air through the impingement plate. The guide duct is coupled to the first platform so that a collecting chamber extending around the guide duct is defined between the guide duct and the first platform and the collecting chamber is configured to receive cooling air from the impingement chamber via a plurality of collecting channels, and is configured to direct cooling air to the cooling chamber.

Abstract: A fluid transfer coupling comprises a first shaft assembly a second shaft assembly, and a seal assembly. The first shaft assembly comprises a first shaft and an annular fin attached to the first shaft, the annular fin having one or more internal passages extending therethrough. Each internal passage connects a centre portion of the first shaft to a radially outwardly facing side of the annular fin. The second shaft assembly comprises a second shaft and an annular trough extending radially outwardly of the second shaft.

Abstract: A fan blade for a gas turbine engine is arranged such that for any two points on its leading edge that are in the radially outer 40% of the blade span and are radially separated by at least 5% of the blade span, the radially outer of the two points is axially forward of the radially inner point. The radius of the leading edge of a given fan blade at the hub divided by the radius of the leading edge of the fan blade at the tip is less than or equal to 0.3. Such an arrangement may result in an improved operability range.

Abstract: A method of shear forming a component comprises the steps of: (i) providing a pre-formed metallic sheet blank, the sheet blank having a first surface and an opposite second surface, the perpendicular separation between the first surface and the second surface defining a thickness of the sheet blank; (ii) applying a surface modification process to the first surface of the sheet blank to reduce a surface roughness of the first surface to a first predetermined roughness value; (iii) positioning the second surface of the sheet blank against a mandrel; and (iv) applying a roller to the first surface of the sheet blank in a shear forming operation to form the sheet blank into the component.

Abstract: A method of manufacturing a component includes providing a powder layer; scanning the powder layer using an electron beam; detecting back scattered electrons produced by the interaction of the electron beam with the powder layer; identifying, from the detected back scattered electrons, any defects in the powder layer; selectively melting at least a part of the powder layer so as to generate a solid layer; and repeating these steps at least once so as to build up a shape corresponding to the component. The method may also includes steps of making a decision about whether to remove any identified defects in the powder layer, and adjusting one or more parameters of the step of providing a powder and/or adjusting one or more parameters of the selective melting step so as to avoid future recurring defects at that position based on stored data relating to the scanned powder layer.

Abstract: A marine propulsor comprises: a stationary part and a movable part which is movable relative to the stationary part; and a wireless communication system, comprising at least one transmitter which is disposed in the movable part and is configured to transmit an electromagnetic data signal and at least one receiver which is disposed in the stationary part and is configured to receive the electromagnetic data signal. The wireless communication system includes a diversity scheme for mitigating multipath distortion of the electromagnetic data signal between the at least one transmitter and the at least one receiver.

Abstract: A gas turbine engine having a fan and a bypass duct for discharging airflow from the fan to generate engine thrust. The bypass duct includes a first component and a second component each having a gas washed surface, the first component being positioned adjacent the second component with a gap therebetween. A sealing strip is positioned in the gap between the first component and the second component distal to the gas washed surfaces of the first and second components. A sealant is positioned between the first and second component proximal to the gas washed surfaces of the first and second components, so as to seal the gap between the first component and the second component from airflow through the bypass duct.

Abstract: A friction welding process includes: providing a first workpiece having a first weld surface, and a second workpiece having a second weld surface; aligning the workpieces with the weld surfaces facing each other, moving one workpiece relative to the other workpiece, and engaging the first and second weld surfaces such that the movement raises the temperature at the weld surfaces to create a weld interface; and ceasing the movement and allowing the weld interface to cool to weld the workpieces together at the interface. The first workpiece has a plurality of flash removal channels formed in and/or adjacent to the first weld surface. The channels provide pathways for ejection of material from the weld interface during welding.

Abstract: A power electronics module is provided having one or more power converter semiconductor components. The power electronics module further has a substrate having a first surface to which the one or more components are mounted, and having an opposing second surface from which project a plurality of heat transfer formations for enhancing heat transfer from the substrate. The power electronics module further has a coolant housing which sealingly connects to the substrate to form a void over the heat transfer formations of the second surface. The coolant housing has an inlet for directing a flow of an electrically insulating coolant into the void and an outlet for removing the coolant flow from the void, whereby heat generated during operation of the one or more components is transferred into the coolant flow via the substrate.