Abstract: A method of manufacturing turbine engine casings having at least one boss includes, in one exemplary embodiment, forming an engine casing having an outer wall, machining a tapered opening through the casing outer wall, and machining a tapered portion in a metal plug where the tapered portion is sized to mate with the tapered opening in the casing outer wall. The method also includes inserting the metal plug into the tapered opening in the casing outer wall, and welding the metal plug to the casing.

Abstract: Friction welding systems and methods including a welding arrangement configured to impart kinetic friction between at least one surface of a first workpiece and at least one surface of a second workpiece to form a weld, a force providing mechanism arranged and disposed for applying a force to one or both of the first workpiece and the second workpiece, and a sensor arranged and disposed to measure a parameter of the welding arrangement, wherein an amount of vibration is determinable from the measured parameter.

Abstract: Friction welding systems and methods including a welding arrangement configured to impart kinetic friction between at least one surface of a first workpiece and at least one surface of a second workpiece to form a weld, a force providing mechanism arranged and disposed for applying a force to one or both of the first workpiece and the second workpiece, and a sensor arranged and disposed to measure a parameter of the welding arrangement, wherein an amount of vibration is determinable from the measured parameter.

Abstract: A method for fabricating a rotor assembly for a turbine, the turbine including a central rotational axis is provided. The method includes forging a first rotor component from a first material, separately forging a second rotor component from a second material, and coupling the second rotor component to the first rotor component at a location radially inward of the first rotor component. The second rotor component is coupled to the first rotor component in at least one axial-circumferential plane that is at least one of substantially parallel and obliquely oriented with respect to the central rotational axis.

Abstract: Friction welding systems and methods including a welding arrangement configured to impart kinetic friction between at least one surface of a first workpiece and at least one surface of a second workpiece to form a weld, a force providing mechanism arranged and disposed for applying a force to one or both of the first workpiece and the second workpiece, and a sensor arranged and disposed to measure a parameter of the welding arrangement, wherein an amount of vibration is determinable from the measured parameter.

Abstract: A method and apparatus for fabricating a workpiece is provided. The method includes applying a predetermined axial force to a tool, translating the axial force into a radial force in the workpiece using the tool, and generating a hoop stress in the work piece sufficient to relieve residual stress in the workpiece.

Abstract: A method for fabricating a rotor assembly for a turbine, the turbine including a central rotational axis is provided. The method includes forging a first rotor component from a first material, separately forging a second rotor component from a second material, and coupling the second rotor component to the first rotor component at a location radially inward of the first rotor component. The second rotor component is coupled to the first rotor component in at least one axial-circumferential plane that is at least one of substantially parallel and obliquely oriented with respect to the central rotational axis.

Abstract: A centering and holding fixture includes a base, a piston disposed within a piston chamber at least partially located within the base, and a radially flexible ring connected to the piston by force transmission apparatus operable to contract and expand the radially flexible ring by upward and downward motions respectively of the piston. The flexible ring may be slotted and may include alternating inwardly and outwardly extending radial slots extending axially through the flexible ring and extending radially inwardly and radially outwardly from radially outer and inner surfaces of the flexible ring respectively to axial stress relief holes extending axially through the flexible ring. The apparatus may further be operable to contract the radially flexible ring when the piston chamber is pressurized and to expand it when the piston chamber is depressurized. Spring loaded clamps mounted to the base may be used to secure a workpiece to the holding fixture.

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 rotor assembly of an axial flow turbine engine has a bladed ring including a ring, and a plurality of turbine blades affixed to the ring and extending radially outwardly from the ring. There is a solid state weld joint between a central disk hub and the ring of the bladed ring. In one approach, the rotor assembly is prepared by bonding the plurality of turbine blades to the coarse-grain ring so that the turbine blades extend outwardly from the ring, providing the fine-grain central disk hub, and solid-state inertia welding the central disk hub and the ring of the bladed ring at a solid state weld joint.

Abstract: A rotor assembly of an axial flow turbine engine has a bladed ring including a ring, and a plurality of turbine blades affixed to the ring and extending radially outwardly from the ring. There is a solid state weld joint between a central disk hub and the ring of the bladed ring. In one approach, the rotor assembly is prepared by bonding the plurality of turbine blades to the coarse-grain ring so that the turbine blades extend outwardly from the ring, providing the fine-grain central disk hub, and solid-state inertia welding the central disk hub and the ring of the bladed ring at a solid state weld joint.

Abstract: A damper for reducing vibration in a least a portion of a component during inertia welding. The damper includes a generally annular body having a spiral slot formed therein.

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 damper for reducing vibration in a least a portion of a component during inertia welding. The damper includes a generally annular body having a spiral slot formed therein.

Abstract: A method for manufacturing an integrally bladed rotor includes fixturing a plurality of blade blanks having radially inwardly facing blade conical surfaces into a segmented blade ring assembly circumscribed around an axis. A rotor ring having a radially outwardly facing ring conical surface circumscribed around the axis is rotated to a contact speed. The rotor ring is fictionally engaged under an axially applied weld load with the blade ring assembly to effect a conical inertia weld along the mating blade conical surfaces and ring conical surface. The integrally bladed rotor includes a plurality of airfoils circumferentially distributed about and integral with a rim. The airfoils extend radially outwardly from respective airfoil bases on a radially outer flowpath surface of the rim to airfoil tips. A conical inertia weld is located between the airfoil tips and a radially inwardly facing rim surface of the rim.

Abstract: A method for manufacturing an integrally bladed rotor includes fixturing a plurality of blade blanks having radially inwardly facing blade conical surfaces into a segmented blade ring assembly circumscribed around an axis. A rotor ring having a radially outwardly facing ring conical surface circumscribed around the axis is rotated to a contact speed. The rotor ring is fictionally engaged under an axially applied weld load with the blade ring assembly to effect a conical inertia weld along the mating blade conical surfaces and ring conical surface. The integrally bladed rotor includes a plurality of airfoils circumferentially distributed about and integral with a rim. The airfoils extend radially outwardly from respective airfoil bases on a radially outer flowpath surface of the rim to airfoil tips. A conical inertia weld is located between the airfoil tips and a radially inwardly facing rim surface of the rim.

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.