Abstract: A method is provided for assembling a shaft having a metal matrix composite mid shaft and monolithic high strength alloy forward and aft shafts. The forward and aft shafts are each inertia friction welded to separate annular transition pieces which include a barrier layer operative to prevent the formation of intermetallic compounds. Special tooling is used to avoid applying shear stresses to the transition piece during welding. The welded forward and aft subassemblies are subsequently heat treated before inertia friction welding them to the mid shaft.

Abstract: A method is provided for assembling a shaft having a metal matrix composite mid shaft and monolithic high strength alloy forward and aft shafts. The forward and aft shafts are each inertia friction welded to separate annular transition pieces which include a barrier layer operative to prevent the formation of intermetallic compounds. Special tooling is used to avoid applying shear stresses to the transition piece during welding. The welded forward and aft subassemblies are subsequently heat treated before inertia friction welding them to the mid shaft.

Abstract: A method for manufacturing a rotor shaft includes fabricating a first shaft portion that extends axially from a first end to a second end, fabricating a second shaft portion that extends axially from a first end to a second end, and coupling the second shaft portion to the first shaft portion with an explosive bonded joint such that the second shaft portion is aligned substantially concentrically with respect to the first shaft portion, and such that the bonded joint extends obliquely with respect to a centerline axis of symmetry of the rotor shaft.

Abstract: A method for manufacturing a rotor shaft includes fabricating a first shaft portion that extends axially from a first end to a second end, fabricating a second shaft portion that extends axially from a first end to a second end, and coupling the second shaft portion to the first shaft portion with an explosive bonded joint such that the second shaft portion is aligned substantially concentrically with respect to the first shaft portion, and such that the bonded joint extends obliquely with respect to a centerline axis of symmetry of the rotor shaft.

Abstract: A method is provided for assembling a shaft having a metal matrix composite mid shaft and monolithic high strength alloy forward and aft shafts. The forward and aft shafts are each inertia friction welded to separate annular transition pieces which include a barrier layer operative to prevent the formation of intermetallic compounds. Special tooling is used to avoid applying shear stresses to the transition piece during welding. The welded forward and aft subassemblies are subsequently heat treated before inertia friction welding them to the mid shaft.

Abstract: A mechanical coupling to transfer torque between cooperating rotatable members each of substantially circular cross section and aligned along an axis of rotation comprises first and second members including, respectively, first and second surface portions in juxtaposition across an interface. Each surface portion includes a plurality of spaced apart teeth mechanically interlocking at the interface. The first surface portion comprises a fiber reinforced material including fibers oriented within about 45°, on either side, of an axis of rotation. Provided is a clamp to hold the first and second surface portions together at the interface.