Abstract: A method for forming a fire shield for an aircraft engine includes forming a case template matching a case body of the fire shield. The case template has a first template side and a second template side. The method further includes forming a fire shield layer at the second template side by spraying a fire shield material at the second template side and attaching the fire shield layer to the case body.

Abstract: An apparatus is provided for a gas turbine engine. This apparatus includes a shroud, and the shroud includes a base and an abradable coating system. The base extends axially along and circumferentially about an axis. The base extends radially between a base inner side and a base outer side. The abradable coating system is bonded to and covers the base at the base inner side. The abradable coating system includes a plurality of protrusions and an elastomeric material. The protrusions are arranged circumferentially about the axis in a circumferentially extending array. Each of the protrusions projects in a radial inward direction away from the base inner side to a distal inner end. Each of the protrusions is configured from or otherwise includes an abradable material. The elastomeric material fills a gap between each circumferentially neighboring pair of the protrusions.

Abstract: A method of manufacturing a composite guide vane with a metallic leading edge includes receiving a layup of fiber-reinforced composite sheets of continuous, substantially parallel and non-interlaced fibers impregnated with a resin. A vane body is formed from the layup of sheets. The vane body includes a body mid portion for interacting with a fluid and a body end portion. The method includes applying a metallic sheath on part of the vane body. The metallic sheath defines a leading edge of the guide vane. The method includes overmolding a head or a foot of the guide vane onto part of the vane body and onto part of the metallic sheath.

Abstract: Composite guide vanes for gas turbine engines are described together with methods of manufacturing such composite guide vanes. A composite guide vane comprises a body having a longitudinal axis and including a composite laminate made of an assembly of layers of a first fibrous composite material. The composite laminate defines a mid portion of the body for interacting with a fluid and an end portion of the body disposed axially of the mid portion of the body. A composite insert is disposed inside the composite laminate and made of a second fibrous composite material. The composite insert extends axially from the end portion of the body to a second location in the mid portion of the body. A head or foot of the composite guide vane envelops the end portion of the body.

Abstract: Composite guide vanes for gas turbine engines are described together with methods of manufacturing such composite guide vanes. A composite guide vane comprises a body having a longitudinal axis and including a composite laminate made of an assembly of layers of a first fibrous composite material. The composite laminate defines a mid portion of the body for interacting with a fluid and an end portion of the body disposed axially of the mid portion of the body. A composite insert is disposed inside the composite laminate and made of a second fibrous composite material. The composite insert extends axially from the end portion of the body to a second location in the mid portion of the body. A head or foot of the composite guide vane envelops the end portion of the body.

Abstract: A method is provided for manufacturing an engine component. During this method, a preform engine component is provided that includes a substrate. The substrate includes a substrate surface and a plurality of apertures. Each of the apertures projects partially into the substrate from the substrate surface. A coating is formed on the substrate. The coating includes a base and a plurality of projections. The base covers the substrate surface. Each of the projections projects out from the base into and fills a respective one of the apertures. The forming of the coating includes electroless plating a coating material onto the substrate over the substrate surface and within the apertures.

Abstract: A method of manufacturing a composite guide vane with a metallic leading edge includes receiving a layup of fiber-reinforced composite sheets of continuous, substantially parallel and non-interlaced fibers impregnated with a resin. A vane body is formed from the layup of sheets. The vane body includes a body mid portion for interacting with a fluid and a body end portion. The method includes applying a metallic sheath on part of the vane body. The metallic sheath defines a leading edge of the guide vane. The method includes overmolding a head or a foot of the guide vane onto part of the vane body and onto part of the metallic sheath.

Abstract: A method of manufacturing a composite guide vane with a metallic leading edge includes receiving a layup of fiber-reinforced composite sheets of continuous, substantially parallel and non-interlaced fibers impregnated with a resin. A vane body is formed from the layup of sheets. The vane body includes a body mid portion for interacting with a fluid and a body end portion. The method includes applying a metallic sheath on part of the vane body. The metallic sheath defines a leading edge of the guide vane. The method includes overmolding a head or a foot of the guide vane onto part of the vane body and onto part of the metallic sheath.

Abstract: A method of manufacturing a composite guide vane with a metallic leading edge includes receiving a layup of fiber-reinforced composite sheets of continuous, substantially parallel and non-interlaced fibers impregnated with a resin. A vane body is formed from the layup of sheets. The vane body includes a body mid portion for interacting with a fluid and a body end portion. The method includes applying a metallic sheath on part of the vane body. The metallic sheath defines a leading edge of the guide vane. The method includes overmolding a head or a foot of the guide vane onto part of the vane body and onto part of the metallic sheath.

Abstract: A method of manufacturing a composite guide vane with a metallic leading edge includes receiving a layup of fiber-reinforced composite sheets of continuous, substantially parallel and non-interlaced fibers impregnated with a resin. A vane body is formed from the layup of sheets. The vane body includes a body mid portion for interacting with a fluid and a body end portion. The method includes applying a metallic sheath on part of the vane body. The metallic sheath defines a leading edge of the guide vane. The method includes overmolding a head or a foot of the guide vane onto part of the vane body and onto part of the metallic sheath.

Abstract: A method of manufacturing a composite guide vane with a metallic leading edge includes receiving a layup of fiber-reinforced composite sheets of continuous, substantially parallel and non-interlaced fibers impregnated with a resin. A vane body is formed from the layup of sheets. The vane body includes a body mid portion for interacting with a fluid and a body end portion. The method includes applying a metallic sheath on part of the vane body. The metallic sheath defines a leading edge of the guide vane. The method includes overmolding a head or a foot of the guide vane onto part of the vane body and onto part of the metallic sheath.

Abstract: Plated polymeric gas turbine engine parts and methods for fabricating lightweight plated polymeric gas turbine engine parts are disclosed. The parts include a polymeric substrate plated with one or more metal layers. The polymeric material of the polymeric substrate may be structurally reinforced with materials that may include carbon, metal, or glass. The polymeric substrate may also include a plurality of layers to form a composite layup structure.

Abstract: There is disclosed a shroud for a compressor stator, including: shroud segments extending circumferentially around an axis along portions of a circumference of the shroud. At least one of the shroud segments extending from a first lateral edge to a second lateral edge. The shroud segment has an inner face oriented toward the axis and an opposed outer face oriented away from the axis. At least one opening extends from the inner face to the outer face for receiving a vane of the compressor. A tab protrudes circumferentially from the second lateral edge and away from the first lateral edge. A slot extends circumferentially from the first lateral edge toward the second lateral edge. The tab is matingly received within a slot of an adjacent one of the shroud segments.

Abstract: A gas turbine engine assembly comprises a casing defining a gas path, the casing including a shroud having an annular body having a surface defining a portion of gas path, the shroud having slots configured for receiving inserted vanes. The slots are delimited substantially about their perimeter by respective flanges, the flanges radially offset from the shroud gas path surface so as to be disposed outside of said gas path, the flanges defined by opposed flange surfaces. Vanes received in the slots. Grommets engage the vanes at the slots. Inserts extend between the shroud and the grommets, the inserts having slots configured for engaging both of the opposed flanges, the inserts extending in a radial direction from at least the respective flange to an adjacent said shroud gas path surface to substantially matchingly mate with an inner surface the adjacent shroud gas path surface.

Abstract: Plated polymeric gas turbine engine parts and methods for fabricating lightweight plated polymeric gas turbine engine parts are disclosed. The parts include a polymeric substrate plated with one or more metal layers. The polymeric material of the polymeric substrate may be structurally reinforced with materials that may include carbon, metal, or glass. The polymeric substrate may also include a plurality of layers to form a composite layup structure.

Abstract: A gas turbine engine assembly comprises a casing defining a gas path, the casing including a shroud having an annular body having a surface defining a portion of gas path, the shroud having slots configured for receiving inserted vanes. The slots are delimited substantially about their perimeter by respective flanges, the flanges radially offset from the shroud gas path surface so as to be disposed outside of said gas path, the flanges defined by opposed flange surfaces. Vanes received in the slots. Grommets engage the vanes at the slots. Inserts extend between the shroud and the grommets, the inserts having slots configured for engaging both of the opposed flanges, the inserts extending in a radial direction from at least the respective flange to an adjacent said shroud gas path surface to substantially matchingly mate with an inner surface the adjacent shroud gas path surface.

Abstract: There is disclosed a shroud for a compressor stator, including: shroud segments extending circumferentially around an axis along portions of a circumference of the shroud. At least one of the shroud segments extending from a first lateral edge to a second lateral edge. The shroud segment has an inner face oriented toward the axis and an opposed outer face oriented away from the axis. At least one opening extends from the inner face to the outer face for receiving a vane of the compressor. A tab protrudes circumferentially from the second lateral edge and away from the first lateral edge. A slot extends circumferentially from the first lateral edge toward the second lateral edge. The tab is matingly received within a slot of an adjacent one of the shroud segments.

Abstract: A method of applying a nanocrystalline metal coating to a titanium or titanium alloy blade of a gas turbine engine is described. The method includes selecting an intermediate bond coat from the group consisting of nickel, nickel alloy, P, B, Tl and combinations thereof, and applying the intermediate bond coat to at least a portion of the blade. A nanocrystalline metal coating having an average grain size of between 10 nm and 500 nm is then applied to the portion of the blade overtop of the intermediate bond coat.

Abstract: A fan blade of a gas turbine engine is disclosed which is composed of an airfoil having a leading edge and a trailing edge, and a root with a platform and a blade fixing for engaging a fan hub. The fan blade is composed of a core substrate selected from the group consisting of composites and polymers, and an entirety of the airfoil and the root of the fan blade has a nanocrystalline metal outer layer thereon which forms an outer surface fully enveloping the fan blade. The nanocrystalline metal layer formed of a nanocrystalline metal coating has an average grain size of between 10 nm and 500 nm, and the nanocrystalline metal outer layer forms a structural element of the fan blade.

Abstract: The gas turbine engine vane assembly has a vane having an elongated airfoil body extending to a tip and a grommet disposed around the tip. An insert having a closed loop shape with an inner surface matingly shaped to receive the outer surface of the grommet, and an outer surface matingly shaped to be snugly received in the slot. A method of mounting such a vane assembly is also disclosed.