Abstract: A method for modeling additive manufacturing of a part, includes (i) constructing a model for estimating output of a simulated additive manufacturing process based upon part design, energy equation and at least one additional relationship selected from the group consisting of phase field equation, concentration equation and stress equation; (ii) entering process operating parameters into the model to produce an output; (iii) comparing the output to acceptance criteria to determine whether the output is acceptable or unacceptable; (iv) for acceptable output, adding operating parameters which resulted in the acceptable output to a process map for additive manufacturing the part; and (v) repeating steps (ii) through (iv) for different operating parameters until the process map is complete.

Abstract: A tandem tip blade includes a main blade body, a front blade and a rear blade. The front blade extends from a main body end. Each of a front blade pressure and a front blade suction side extends between a front blade leading edge and a front blade trailing edge and a front blade tip extending from the front blade pressure side to the front blade suction side. The rear blade extends from the main body end. Each of a rear blade pressure side and a rear blade suction side extends between a rear blade leading edge and a rear blade trailing edge, and a rear blade tip extending from the rear blade pressure side to the rear blade suction side.

Abstract: A fuel deoxygenation system has a deoxygenator, an ultrasound transducer, and a control. The ultrasonic transducer is operable to direct ultrasonic waves into a flow passage for a fuel connected to the deoxygenator. A gas turbine engine and a method are also disclosed.

Abstract: A method includes accessing a first model defining a shape of a part. The shape of the part is segregated into a plurality of predefined shapes selected from a library of predefined shapes. The predefined models for each of plurality of predefined shapes are assembled into a second model defining the shape of the part. The part is additively manufactured according to the second model.

Abstract: An environmental barrier coating deposited onto a substrate by cold spraying has a microstructure having a porosity that increases through a thickness dimension extending from the substrate toward an outer layer. A process for forming an environmental barrier coating includes sequentially depositing a plurality of layers of solid powder onto a substrate by cold spraying and heat treating the plurality of layers.

Abstract: In accordance with at least one aspect of this disclosure, a structure can include a first body formed from a first material, and a second body disposed on or embedded within the first body. The second body includes a shape memory alloy configured to provide a first stress to the first body in a first state and a second stress to the first body in a second state. The shape memory alloy is configured to transition from the first and second state as a function of an applied activation energy.

Abstract: According to one embodiment of this disclosure, a coating includes a plurality of elongated reinforcing materials. The coating includes a bond coat in which a first portion of a first elongated reinforcing material is embedded. The coating further includes a ceramic coat adjacent the bond coat in which a second portion of the first elongated reinforcing material is embedded.

Abstract: An additive manufacturing system utilizing an epitaxy process, and method of manufacture, utilizes a heating source and a cooling source to control thermal gradients and a solidification rate of each slice of a workpiece manufactured from a seed having a directional grain microstructure. An energy gun is utilized to melt selected regions of each successive layer of a plurality layers of a powder in a powder bed to successively form each solidified slice of the workpiece.

Abstract: A system and method for prognostic health monitoring of thermal barrier coatings is provided. The system may comprise monitoring a thermal barrier coated gas turbine engine component, and measuring the infrared radiation emitting from the component. The measured thermal radiation data may be analyzed and compared to known material thermal radiation data in order to determine the health of the thermal barrier coating. The compiled comparison results may be compared against a historical statistical study to then determine the overall health of the thermal barrier coating. The system may comprise generating a health monitoring alert in response to the health of the thermal barrier coating indicating an imminent failure.

Abstract: A fan blade includes a blade body and a shape memory alloy actuator. The blade body has a pressure side disposed opposite a suction side. Each of the pressure side and the suction side extends radially from a root towards a tip and extends axially from a leading edge towards a trailing edge. The blade body defines a passageway that is disposed between the pressure side and the suction side. The shape memory alloy actuator is received within the passageway and is operatively connected to the blade body.

Abstract: A workpiece manufactured from an additive manufacturing system (AMS) having a particle separator and a method of operating includes modeling the workpiece into layers and modeling the layers into a plurality of regions. The AMS then deposits one of a plurality of particle types into a respective one of the plurality of regions. In this way, the surface finishes of the component may be controlled and material densities from one region to the next and from one layer to the next are also controlled.

Abstract: A feedstock for a cold spray process includes a plurality of globule bodies. The globule bodies include a plurality of discrete particles bonded to one another to define porous globule bodies. The bonds between the particles are of sufficient strength such that the globule bodies can retain both the body integrity as well as the body shape when the body experiences acceleration from a conveying gas in a cold spray technique. Methods of making the feedstock and globule bodies are also described.

Abstract: A structure includes a substrate, and a thermal barrier coating comprising a base material and one or more reflective layers disposed in the base material, each reflective layer having a plurality of reflective particulates. The structure can be a turbine blade, for example.

Abstract: A feedstock for a cold spray process includes a plurality of globule bodies. The globule bodies include a plurality of discrete particles bonded to one another to define porous globule bodies. The bonds between the particles are of sufficient strength such that the globule bodies can retain both the body integrity as well as the body shape when the body experiences acceleration from a conveying gas in a cold spray technique. Methods of making the feedstock and globule bodies are also described.

Abstract: A hybrid airfoil according to an exemplary aspect of the present disclosure includes, among other things, a leading edge portion made of a first material, a trailing edge portion made of a second material, and an intermediate portion between the leading edge portion and the trailing edge portion made of a non-metallic material. A rib is disposed between the leading edge portion and the intermediate portion. A protrusion of one of the rib and the intermediate portion is received within a pocket of the other of the rib and the intermediate portion.

Abstract: A tandem tip blade includes a main blade body, a front blade and a rear blade. The front blade extends from a main body end. Each of a front blade pressure and a front blade suction side extends between a front blade leading edge and a front blade trailing edge and a front blade tip extending from the front blade pressure side to the front blade suction side. The rear blade extends from the main body end. Each of a rear blade pressure side and a rear blade suction side extends between a rear blade leading edge and a rear blade trailing edge, and a rear blade tip extending from the rear blade pressure side to the rear blade suction side.

Abstract: A system and method for prognostic health monitoring of thermal barrier coatings is provided. The system may comprise monitoring a thermal barrier coated gas turbine engine component, and measuring the infrared radiation emitting from the component. The measured thermal radiation data may be analyzed and compared to known material thermal radiation data in order to determine the health of the thermal barrier coating. The compiled comparison results may be compared against a historical statistical study to then determine the overall health of the thermal barrier coating. The system may comprise generating a health monitoring alert in response to the health of the thermal barrier coating indicating an imminent failure.

Abstract: There is a gear set. The gear set has a) a first gear having a first surface and b) an intermeshing second gear having a second surface. The first and second surfaces each, independently, have an isotropic arithmetic mean roughness, Ra, of about 0.0762 micrometers/3 microinches or less and are lubricated. There is also a method for increasing the contact surface-fatigue life of a gear set.

Abstract: A vane structure includes a baffle movably mounted within an aperture, the baffle movable to control a cooling flow between a first cooling cavity and a second cooling cavity.

Abstract: A vane structure includes a baffle movably mounted within an aperture, the baffle movable to control a cooling flow between a first cooling cavity and a second cooling cavity.