Abstract: A repaired turbine housing for use in an air cycle machine including a journal bearing bore having an inlet, an outlet, and an inner diameter of about 2.580±0.001 inches (6.553±0.003 centimeters). The repaired turbine housing including a cylindrical insert secured within the journal bearing bore. The cylindrical insert having a first end, a second end, an inner surface, a step located at the first end, and an outer surface with an outer diameter that provides a diametric interference with the inner diameter of the journal bearing bore. The diametric interference being between about 0.000-0.003 inches (0.000-0.008 centimeters). The cylindrical insert being inserted into the inlet of the journal bearing bore up to the step. The step has an outer diameter greater than the outer diameter of the cylindrical insert. The inner surface of the cylindrical insert includes at least one selected inner diameter.

Abstract: A turbine housing for a two-wheel air cycle machine includes a first side of the turbine housing, a second side of the turbine housing, a central axis, an outer housing portion, an inner housing portion, a plurality of struts between the inner housing portion and the outer housing portion and a plurality of cooling slots between the plurality of supports. The outer housing portion includes an inner surface, an outer surface, a cooling inlet extending from the outer surface of the outer housing portion and a cooling outlet opposite the cooling inlet and extending from the outer surface of the outer housing portion. The inner housing portion includes a thrust bearing support surface substantially parallel to the second side of the turbine housing and a journal bearing bore extending between the first side of the turbine housing and the thrust bearing support surface.

Abstract: A bearing housing includes an inner housing portion centered on a central axis and an outer housing portion centered on the central axis. The inner housing portion has a first end and a second end positioned axially away from the first end. The outer housing portion has a first end and a second end positioned axially away from the first end. A disk portion connects the second end of the outer housing portion to the second end of the inner housing portion The outer housing portion includes a radially outer surface having a diameter Doh1, a radially inner surface having a diameter Doh2, and a shoulder on the first end of the outer housing portion and having a radially outer surface with a diameter Ds. Diameter Ds is smaller than the diameter Doh1 and larger than the diameter Doh2.

Abstract: A turbine housing for a two-wheel air cycle machine includes a first side of the turbine housing, a second side of the turbine housing, a central axis, an outer housing portion, an inner housing portion, a plurality of struts between the inner housing portion and the outer housing portion and a plurality of cooling slots between the plurality of supports. The outer housing portion includes an inner surface, an outer surface, a cooling inlet extending from the outer surface of the outer housing portion and a cooling outlet opposite the cooling inlet and extending from the outer surface of the outer housing portion. The inner housing portion includes a thrust bearing support surface substantially parallel to the second side of the turbine housing and a journal bearing bore extending between the first side of the turbine housing and the thrust bearing support surface.

Abstract: A method of installing a diffuser in an air cycle machine includes placing a first housing on a shaft, placing a seal plate on the shaft, and placing a diffuser on the shaft. Next, the diffuser and the seal plate are aligned with an alignment tool. The alignment tool has a first annular surface to align with a radially outer surface of the seal plate and a second annular surface to align with an annular flange on the diffuser. Finally, the diffuser is fastened to the seal plate and the alignment tool is removed from the diffuser and the seal plate.

Abstract: A repaired turbine housing for use in an air cycle machine including a journal bearing bore having an inlet, an outlet, and an inner diameter of about 2.580±0.001 inches (6.553±0.003 centimeters). The repaired turbine housing including a cylindrical insert secured within the journal bearing bore. The cylindrical insert having a first end, a second end, an inner surface, a step located at the first end, and an outer surface with an outer diameter that provides a diametric interference with the inner diameter of the journal bearing bore. The diametric interference being between about 0.000-0.003 inches (0.000-0.008 centimeters). The cylindrical insert being inserted into the inlet of the journal bearing bore up to the step. The step has an outer diameter greater than the outer diameter of the cylindrical insert. The inner surface of the cylindrical insert includes at least one selected inner diameter.

Abstract: A bearing housing includes an inner housing portion centered on a central axis and an outer housing portion centered on the central axis. The inner housing portion has a first end and a second end positioned axially away from the first end. The outer housing portion has a first end and a second end positioned axially away from the first end. A disk portion connects the second end of the outer housing portion to the second end of the inner housing portion The outer housing portion includes a radially outer surface having a diameter Doh1, a radially inner surface having a diameter Doh2, and a shoulder on the first end of the outer housing portion and having a radially outer surface with a diameter Ds. Diameter Ds is smaller than the diameter Doh1 and larger than the diameter Doh2.

Abstract: A method for repairing a turbine housing of an air cycle machine that includes removing damaged material from a journal bearing bore of the turbine housing and forming the journal bearing bore. Next, the inner diameter of the journal bearing bore is determined and a cylindrical insert is formed. The cylindrical insert includes a first end, a second end, an inner surface, a step located at the first end, and an outer surface with an outer diameter that provides a diametric interference with the inner diameter of the journal bearing bore. The second end of the cylindrical insert is inserted into an inlet of the journal bearing bore up to the step. The cylindrical insert is secured to the turbine housing and both are stress relieved by heating. Following the stress relief, the inner surface of the cylindrical insert is formed and seal grooves are formed on the inner surface.

Abstract: A ground connect duct includes a ground connect flange with an inner diameter and an outer diameter, wherein the inner diameter is between 7.000 inches and 9.000 inches and the outer diameter is between 9.000 inches and 11.000 inches, a V-band flange, and a duct body with the inner diameter, wherein the duct body is coupled to the ground connect flange and the V-band flange to have an overall length between 6.261 inches and 8.261 inches and to dispose the V-band flange at an angle between 6.000 degrees and 8.000 degrees relative to the ground connect flange.

Abstract: A method for repairing an air cycle machine compressor housing includes removing a journal bearing support sleeve in an air cycle machine compressor housing, positioning a cylindrical insert within the air cycle machine compressor housing, wherein the cylindrical insert has an outer diameter greater than an outer diameter of at least one portion of the removed journal bearing support sleeve, an inner diameter less than an inner diameter of at least one portion of the removed journal bearing support sleeve, and a length greater than a length of the removed journal bearing support sleeve, welding the cylindrical insert to the air cycle machine compressor housing, and machining the welded cylindrical insert to form a replacement journal bearing support sleeve.

Abstract: A method for repairing a cabin air compressor outlet housing includes removing a journal bearing support sleeve in a cabin air compressor outlet housing, positioning a cylindrical insert within the cabin air compressor outlet housing, wherein the cylindrical insert has an outer diameter greater than an outer diameter of at least one portion of the removed journal bearing support sleeve, an inner diameter less than an inner diameter of at least one portion of the removed journal bearing support sleeve, and a length greater than a length of the removed journal bearing support sleeve, welding the cylindrical insert to the cabin air compressor outlet housing, and machining the welded cylindrical insert to form a replacement journal bearing support sleeve.

Abstract: A cabin supply duct of an air conditioning and temperature control system including a first tubular body having an inlet, an outlet, an inner surface, an outer surface, and a longitudinal axis. A diameter of the inner surface at the first inlet being about 8.404±0.002 inches (21.346±0.005 centimeters). A second tubular body having an inlet, an outlet, an inner surface, an outer surface, and a longitudinal axis. A diameter of the outer surface of the second tubular body at the inlet being about 8.641±0.015 inches (21.948±0.038 centimeters). The inner surface of the second tubular body being fluidly connected to the inner surface of the first tubular body at the outlet of the second tubular body. The longitudinal axis of the first tubular body being perpendicular to the longitudinal axis of the second tubular body.

Abstract: A vane for a variable diffuser includes a body with an inlet end and an outlet end, a leading surface extending from the inlet end to the outlet end, a trailing surface opposite the leading surface and extending from the inlet end to the outlet end, a first surface extending from the inlet end to the outlet end, and a second surface opposite the first surface and extending from the inlet end to the outlet end. The vane further includes a first cavity on the first surface of the vane adjacent the inlet end, a second cavity on the first surface of the vane adjacent the outlet end, a third cavity on the second surface of the vane adjacent the inlet end, and a fourth cavity on the second surface of the vane adjacent the outlet end.

Abstract: A method for repairing a turbine housing of an air cycle machine is provided. The method comprises: removing damaged material from a journal bearing bore of the turbine housing; forming the journal bearing bore to an inner diameter of about 2.580±0.001 inches (6.553±0.003 centimeters). The journal bearing bore having an inlet and an outlet. The method also comprises determining the inner diameter of the journal bearing bore; and forming a cylindrical insert having a first end, a second end, an inner surface, a step located at the first end, and an outer surface with an outer diameter that provides a diametric interference with the inner diameter of the journal bearing bore. The diametric interference being between about 0.000-0.003 inches (0.000-0.008 centimeters). The method further comprises inserting the second end of the cylindrical insert into the inlet of the journal bearing bore up to the step.

Abstract: A method for repairing a cabin air compressor outlet housing includes removing a journal bearing support sleeve in a cabin air compressor outlet housing, positioning a cylindrical insert within the cabin air compressor outlet housing, wherein the cylindrical insert has an outer diameter greater than an outer diameter of at least one portion of the removed journal bearing support sleeve, an inner diameter less than an inner diameter of at least one portion of the removed journal bearing support sleeve, and a length greater than a length of the removed journal bearing support sleeve, welding the cylindrical insert to the cabin air compressor outlet housing, and machining the welded cylindrical insert to form a replacement journal bearing support sleeve.

Abstract: A method for repairing an air cycle machine compressor housing includes removing a journal bearing support sleeve in an air cycle machine compressor housing, positioning a cylindrical insert within the air cycle machine compressor housing, wherein the cylindrical insert has an outer diameter greater than an outer diameter of at least one portion of the removed journal bearing support sleeve, an inner diameter less than an inner diameter of at least one portion of the removed journal bearing support sleeve, and a length greater than a length of the removed journal bearing support sleeve, welding the cylindrical insert to the air cycle machine compressor housing, and machining the welded cylindrical insert to form a replacement journal bearing support sleeve.

Abstract: A cabin supply duct of an air conditioning and temperature control system including a first tubular body having an inlet, an outlet, an inner surface, an outer surface, and a longitudinal axis. A diameter of the inner surface at the first inlet being about 8.404±0.002 inches (21.346±0.005 centimeters). A second tubular body having an inlet, an outlet, an inner surface, an outer surface, and a longitudinal axis. A diameter of the outer surface of the second tubular body at the inlet being about 8.641±0.015 inches (21.948±0.038 centimeters). The inner surface of the second tubular body being fluidly connected to the inner surface of the first tubular body at the outlet of the second tubular body. The longitudinal axis of the first tubular body being perpendicular to the longitudinal axis of the second tubular body.

Abstract: A cabin supply duct of an air conditioning and temperature control system including a first tubular body having an inlet, an outlet, an inner surface, an outer surface, and a longitudinal axis. The first tubular body having a bead around the circumference of the first tubular body located proximate to the outlet. A second tubular body having an inlet, an outlet, an inner surface, an outer surface, and a longitudinal axis. The inner surface of the second tubular body being fluidly connected to the inner surface of the first tubular body at the outlet of the second tubular body. The longitudinal axis of the first tubular body being perpendicular to the longitudinal axis of the second tubular body.

Abstract: A ground connect duct includes a ground connect flange with an inner diameter and an outer diameter, wherein the inner diameter is between 7.000 inches and 9.000 inches and the outer diameter is between 9.000 inches and 11.000 inches, a V-band flange, and a duct body with the inner diameter, wherein the duct body is coupled to the ground connect flange and the V-band flange to have an overall length between 6.261 inches and 8.261 inches and to dispose the V-band flange at an angle between 6.000 degrees and 8.000 degrees relative to the ground connect flange.

Abstract: A ram air fan inlet shroud for a ram air fan assembly is provided. The ram air fan inlet shroud includes a shroud portion extending outwardly from a conical portion. The conical portion provides a transition between a central portion and an inner ram air fan hub interface portion. The conical portion includes a plurality of inner cooling slots having a slot arc length and spaced apart by a slot spacing angle. A ratio of the slot spacing angle to the slot arc length is between about 1.24 and 1.4. The ram air fan inlet shroud also includes a recessed portion located between the inner ram air fan hub interface portion and an outer ram air fan hub interface portion. The recessed portion includes a plurality of outer cooling holes.