Abstract: A variable diffuser includes a backing plate, a shroud, a diffuser body between the backing plate and the shroud, a plurality of passages through the diffuser body, and a valve adjacent to the shroud and the diffuser body. The valve movably occludes a portion of the plurality of passages.

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 variable channel diffuser includes a shroud, a backing plate, a channel plate adjacent to the backing plate, a floor plate adjacent to the shroud, standoffs formed on the floor plate, and recessed areas formed in the channel plate. The channel plate is between the shroud and the backing plate. The floor plate is between the shroud and the channel plate and is movable relative to the channel plate. The standoffs and the recessed areas define channels for fluid flow. Each channel has an area which is variable through movement of the floor plate relative to the channel plate.

Abstract: A variable vaneless diffuser includes a shroud, a backing plate, a divider plate adjacent to the backing plate, a floor plate adjacent to the shroud, a plurality of standoffs formed on the divider plate, and a plurality of clearance slots formed in the floor plate. The divider plate is between the shroud and the backing plate. The floor plate is between the shroud and the divider plate and is movable relative to the divider plate. The plurality of standoffs and the plurality of clearance slots define a flow path for fluid flow. The flow path has an area which is variable through movement of the floor plate relative to the divider plate.

Abstract: A seal plate for a rotary machine includes a hub centered on a central axis of the rotary machine, a disk portion extending radially outwards from the hub, and a variable lattice structure in an interior of the seal plate. The variable lattice structure includes a first region of the seal plate having a first lattice structure, and a second region of the seal plate having a second lattice structure. The second lattice structure of the second region is denser than the first lattice structure of the first region. The second region is a deflection region, a stress region, or an energy containment region of the seal plate.

Abstract: A compressor includes a rotor driven by a shaft and configured to compress air and a motor for driving the shaft. At least one bearing facilitates rotation of the shaft. A motor cooling loop is configured to provide motor cooling air to the motor. A bearing cooling loop is configured to provide bearing cooling air to the at least one bearing. A bearing support is configured to support the least one bearing, the bearing support includes an opening. A duct is configured to communicate air from the opening to an inlet of the compressor. A method for cooling a compressor is also disclosed.

Abstract: A seal plate for a rotary machine includes a hub centered on a central axis of the rotary machine, a disk portion extending radially outwards from the hub, and a variable lattice structure in an interior of the seal plate. The variable lattice structure includes a first region of the seal plate having a first lattice structure, and a second region of the seal plate having a second lattice structure. The second lattice structure of the second region is denser than the first lattice structure of the first region. The second region is a deflection region, a stress region, or an energy containment region of the seal plate.

Abstract: An air cycle machine includes an air inlet connected to an air cycle compressor. Air downstream of the air cycle compressor is connected to be delivered across a first turbine. The air cycle compressor is driven by the first turbine through a shaft. Air downstream of the first turbine is connected to a second turbine. The second turbine is connected to deliver air downstream. The second turbine is connected with a second shaft to drive a fan rotor. The fan rotor delivers a source of air across a primary heat exchanger positioned between the inlet and the air cycle compressor. The air cycle compressor and the first turbine are formed of a metal. The second turbine and the fan rotor are formed of non-metallic materials.

Abstract: A variable diffuser includes a backing plate, a shroud, a first divider between the backing plate and the shroud, a first diffuser channel between the backing plate and the first divider, a second diffuser channel between the first divider and the shroud, the second diffuser channel, and a valve controlling flow through the second diffuser channel. The valve moves between a first position and a second position. The first diffuser channel includes a first channel inlet and a first outlet. The second diffuser channel includes a second channel inlet adjacent to the first channel inlet and a second outlet adjacent to the first outlet.

Abstract: An impeller for use in a fan system includes a hub extending along an axis of rotation and having a hub outer surface. There also are a plurality of blades extending radially outwardly of the hub outer surface. The blades have a unique cross-section at several different locations that result in relatively thin blades. A fan system and method are also disclosed.

Abstract: An air cycle machine includes an air inlet connected to an air cycle compressor. Air downstream of the air cycle compressor is connected to be delivered across a first turbine. The air cycle compressor is driven by the first turbine through a shaft. Air downstream of the first turbine is connected to a second turbine. The second turbine is connected to deliver air downstream. The second turbine is connected with a second shaft to drive a fan rotor. The fan rotor delivers a source of air across a primary heat exchanger positioned between the inlet and the air cycle compressor. The air cycle compressor and the first turbine are formed of a metal. The second turbine and the fan rotor are formed of non-metallic materials.

Abstract: An impeller for use in a fan system includes a hub extending along an axis of rotation and having a hub outer surface. There also are a plurality of blades extending radially outwardly of the hub outer surface. The blades have a unique cross-section at several different locations that result in relatively thin blades. A fan system and method are also disclosed.

Abstract: A compressor includes a rotor configured to compress air and driven by a shaft. A motor is drives the shaft. The first and second journal bearings facilitate rotation of the shaft. The first journal bearing is upstream from the motor and the second journal bearing is downstream from the motor. The transfer tube is configured to provide cooling air from a bearing cooling air inlet to the first journal bearing. A method for cooling a compressor is also disclosed.

Abstract: A seal plate for a rotary machine includes a hub centered on a central axis of the rotary machine, a disk portion extending radially outwards from the hub, and a variable lattice structure in an interior of the seal plate. The variable lattice structure includes a first region of the seal plate having a first lattice structure, and a second region of the seal plate having a second lattice structure. The second lattice structure bf the second region is denser than the first lattice structure of the first region. The second region is a deflection region, a stress region, or an energy containment region of the seal plate.

Abstract: Aircraft and aircraft blower systems are described. The blower systems include a shaft, a motor having a stator and a rotor, the rotor being operably coupled to the shaft, a fan operably coupled to the shaft and configured to be driven by rotation of the shaft, one or more bearings arranged along the shaft, and a high pressure cooling source configured to supply high pressure air to the one or more bearings.

Abstract: A replacement compressor outlet housing includes a compressor outlet housing, having a volute and a radially inwardly extending finger extending from a radially inner end of the volute. The radially inwardly extending finger is welded to an insert. The insert has a bearing support defining a bore. The insert has a web connecting a ledge to the bearing support. The radially inwardly extending finger welded to the ledge.

Abstract: A method of repairing a compressor outlet housing includes the steps of obtaining a damaged compressor outlet housing having a radially outer volute, a radially inwardly extending finger extending to an axially extending ledge, a radially inwardly extending web extending radially inwardly from the ledge, and a radially inner bearing support defining a bore. The method identifies a damaged section within at least one of the bearing support, the web, and the ledge, and removes at least the bearing support and the web to leave a remaining part. The method then inserts an insert having at least a replacement bearing support and a replacement web into the remaining part after the removal step. The method then welds the insert to the remaining part to provide a repaired compressor housing. A method of replacing a compressor outlet housing and a replacement compressor outlet housing are also disclosed.

Abstract: A compressor includes a rotor driven by a shaft and configured to compress air and a motor for driving the shaft. At least one bearing facilitates rotation of the shaft. A motor cooling loop is configured to provide motor cooling air to the motor. A bearing cooling loop is configured to provide bearing cooling air to the at least one bearing. A bearing support is configured to support the least one bearing, the bearing support includes an opening. A duct is configured to communicate air from the opening to an inlet of the compressor. A method for cooling a compressor is also disclosed.

Abstract: Aircraft and aircraft blower systems are described. The blower systems include a shaft, a motor having a stator and a rotor, the rotor being operably coupled to the shaft, a fan operably coupled to the shaft and configured to be driven by rotation of the shaft, one or more bearings arranged along the shaft, and a high pressure cooling source configured to supply high pressure air to the one or more bearings.

Abstract: An air cycle machine is provided including a plurality of components operably coupled via a shaft, the shaft being rotatable about an axis. A cooling airflow path receives cooling air from a cooling air source, directs the cooling air to at least one air-cooled bearing associated with one of the plurality of components, and discharges the cooling air. A cooling conduit is arranged in fluid communication with the cooling airflow path, wherein cooling air provided to the cooling conduit from the cooling airflow path has a first temperature and cooling air returned to the cooling airflow path has a second temperature, the second temperature being less than the first temperature.