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 sensor supply tube assembly is provided for disposition within a compressor outlet through which a main flowpath is defined and a sensor port transversely coupled to the compressor outlet. The sensor supply tube assembly includes first and second tubes. The first tube is formed to direct main flowpath fluid from the compressor outlet and through a portion of the sensor port and includes first and second ends disposed within the sensor port and the compressor outlet, respectively, and a curved section interposed between the first and second ends. The second tube includes a sleeve tightly fittable between the first end and the sensor port and a base. The base has an exterior surface from which the sleeve extends and which is disposed and configured to non-rotatably abut with an interior surface of the compressor outlet.

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 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 heat sink that can be positioned around a rotating shaft includes a cylindrical body with a first end and a second end, a bore running through the body with a first opening at the first end of the body and a second opening at the second end of the body, fins extending radially outward from the body and running from the first end to the second end of the body, and channels defined between the fins and running from the first end to the second end of the body.

Abstract: A rotary machine includes a shaft extending through the rotary machine; a bearing positioned around the shaft; and an air deflector mounted on the shaft between the bearing and the shaft, wherein the air deflector has a first cylindrical body portion that is connected to a second cylindrical body portion with a ramp portion. A method for cooling a bearing positioned around a rotating shaft includes providing air to a cavity that surrounds a rotating shaft; deflecting the air towards an inner surface of a bearing that is positioned radially outward of the rotating shaft, wherein the air is deflected with an air deflector that is mounted on the rotating shaft; and flowing the air between an outer surface of the air deflector and the inner surface of the bearing.

Abstract: A first stage turbine nozzle includes a first stage hub portion extending axially along a central axis, a first stage disk portion attached to the first stage hub portion and centered on the central axis, and a plurality of first stage vanes positioned radially around and attached to the first stage disk portion. Each vane extends a vane height H away from the first stage disk portion and each vane has a first end positioned at a diameter D away from the central axis. The first stage turbine nozzle also includes a plurality of first stage throats defined between radially adjacent first stage vanes. Each first stage throat has a throat width W between radially adjacent first stage vanes. The first stage turbine nozzle also includes a coating on a sidewall of each first stage vane.

Abstract: A second stage turbine nozzle includes a second stage disk portion having a central axis, and a plurality of second stage vanes positioned radially around and attached to the second stage disk portion. Each second stage vane extends a vane height H away from the second stage disk portion and each second stage vane has a first end positioned at a diameter D away from the central axis. The second stage turbine nozzle also includes a plurality of second stage throats defined between radially adjacent second stage vanes. Each second stage throat has a throat width W between radially adjacent second stage vanes. The second stage turbine nozzle also includes a coating on a sidewall of each second stage vane, wherein a surface roughness of the sidewall is between 125 microinches Ra and 200 microinches Ra.

Abstract: A heat sink that can be positioned around a rotating shaft includes a cylindrical body with a first end and a second end, a bore running through the body with a first opening at the first end of the body and a second opening at the second end of the body, fins extending radially outward from the body and running from the first end to the second end of the body, and channels defined between the fins and running from the first end to the second end of the body.

Abstract: An air cycle machine comprises rotating components that include a fan, a compressor, and a first turbine. The air cycle machine also includes a cooling airflow path that receives cooling air from a cooling air source, directs the cooling air to an air-cooled bearing for at least one of the rotating components, and discharges the cooling air. The airflow path is isolated from an inlet of the compressor by a seal member, and the airflow path is configured to maintain pressure at the seal member above a pressure at the compressor inlet.

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 rotary machine includes a shaft extending through the rotary machine; a bearing positioned around the shaft; and an air deflector mounted on the shaft between the bearing and the shaft, wherein the air deflector has a first cylindrical body portion that is connected to a second cylindrical body portion with a ramp portion. A method for cooling a bearing positioned around a rotating shaft includes providing air to a cavity that surrounds a rotating shaft; deflecting the air towards an inner surface of a bearing that is positioned radially outward of the rotating shaft, wherein the air is deflected with an air deflector that is mounted on the rotating shaft; and flowing the air between an outer surface of the air deflector and the inner surface of the bearing.

Abstract: A nozzle and shroud for use in an air cycle machine has a plate and a shroud curving in a first axial direction about a center axis of the shroud relative to the plate. A plurality of vanes extends in a second axial direction away from the plate. The plurality of vanes extends for a height away from the plate and a width defined as the closest distance between two adjacent vanes, with a ratio of the height to the width being between 0.1091 and 0.1401. An air cycle machine and a method of repair are also disclosed.

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 ram air fan has a fan impeller and a motor. The impeller and motor are mounted within a housing. An inlet header delivers air to an inlet for the fan. An air supply system delivers air from an internal cavity of the inlet header to the motor and air bearings. The air supply system includes a conduit extending through the housing. A connection from the conduit extends from a J-shaped tube mounted within the inlet header. The J-shaped tube extends to a remote end, with a perforated member positioned on the remote end.

Abstract: A nozzle for use in an air cycle machine has a plate. A plurality of vanes extends in a second axial direction away from the plate. The plurality of vanes extends for a height away from the plate and a width defined as the closest distance between two adjacent vanes, with a ratio of the nozzle height to the nozzle width being between 0.3563 and 0.4051. An air cycle machine and a method are also disclosed.

Abstract: A nozzle and shroud for use in an air cycle machine has a plate and a shroud curving in a first axial direction about a center axis of the shroud relative to the plate. A plurality of vanes extends in a second axial direction away from the plate. The plurality of vanes extends for a height away from the plate and a width defined as the closest distance between two adjacent vanes, with a ratio of the height to the width being between 1.3653 and 1.7992. An air cycle machine and a method of repair are also disclosed.

Abstract: A nozzle and shroud for use in an air cycle machine has a plate and a shroud curving in a first axial direction about a center axis of the shroud relative to the plate. A plurality of vanes extends in a second axial direction away from the plate. The plurality of vanes extends for a height away from the plate and a width defined as the closest distance between two adjacent vanes, with a ratio of the height to the width being between 1.7377 and 2.1612. An air cycle machine and a method of repair are also disclosed.

Abstract: A thrust plate includes an annular-shaped body having a scalloped outer edge that forms a first circumference defined by a first diameter. The thrust plate further includes a plurality of cooling slots formed in a first surface of the body. The cooling slots are formed between each pair of adjacent scallops. A center of each cooling slot extends towards the center of the thrust plate at a common predetermined angle with respect to one another.