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.

Abstract: A nozzle for use in an air cycle machine has a plate. A plurality of vanes extend away from the plate. The plurality of vanes extend for a height away from the plate. A width is defined as the closest distance between two adjacent vanes. A ratio of the height to the width is between 3.253 and 3.800. An air cycle machine and a method of repair are also disclosed.

Abstract: According to one aspect, an air cycle machine includes a fan rotor, a diffuser cone axially aligned with the fan rotor, and a strut plate assembly. The strut plate assembly includes a first strut plate and a second strut plate with an ejector formed between the first strut plate and the second strut plate. The first strut plate is axially positioned between the fan rotor and the ejector, and the second strut plate is axially positioned between the fan rotor and the diffuser cone. The first strut plate includes a plurality of outer struts and is absent inner struts between the fan rotor and the ejector. The second strut plate includes a plurality of inner struts and outer struts, where the inner struts are axially positioned between the ejector and the diffuser cone.

Abstract: A ram air fan housing includes an outer cylindrical housing portion centered on a central axis, with a first end and a second end positioned axially away from the first end. The ram air fan housing also includes an inner cylindrical housing portion centered on a central axis, with a first end and a second end positioned axially away from the first end. The first end of the outer cylindrical housing portion is connected to the first end of the inner cylindrical housing portion with a disk portion. The ram air fan housing also includes a first drain hole in the outer cylindrical housing portion adjacent to the second end of the outer cylindrical housing portion.

Abstract: A bearing assembly includes a shaft and a thrust runner attached to the shaft. The shaft runner protrudes radially outward from the shaft. A thrust bearing is positioned axially adjacent to the thrust runner. A first flow passage is between the thrust runner and a first face of the thrust bearing. A second flow passage is between a second face of the thrust bearing and a housing. A restriction feature restricts a flow of fluid through the second flow passage.

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: An air supply controller is configured to supply cooling air to an air cycle machine. The controller includes a chamber having a first inlet configured to receive air from a first source, a second inlet configured to receive air from a second source, and an outlet configured to pass air from first inlet and/or the second inlet to an air cycle machine. A control member is disposed within the chamber and configured to move from a first position to a second position. When the control member is in the first position it obstructs an airflow from the second inlet to the outlet and permits an airflow from the first inlet to the outlet. When the control member is in the second position it obstructs the airflow from the first inlet to the outlet and permits the airflow from the second inlet to the outlet.

Abstract: A turbine nozzle for an air cycle machine includes a disk having a central axis and a plurality of airfoils extending from a surface of the disk. The plurality of airfoils is arranged radially about the disk section to direct a flow of a fluid passing thereby. A relief cut adjacent the airfoils, wherein the relief cut provides a channel in a least a portion of the surface of the disk.

Abstract: A turbine thrust shaft providing a thrust disk having a surface P and a surface Q, and a shaft body formed through the thrust disk, the shaft body including a first plurality of holes, wherein the first plurality of holes are spaced apart and each hole of the first plurality of holes has a first diameter between 0.0600 inches to 0.0680 inches and has a first center disposed a first distance between 0.1400 inches to 0.1600 inches from surface P, and a second plurality of holes wherein the second plurality of holes are spaced apart and each hole of the second plurality of holes has a second diameter between 0.0960 inches to 0.1040 inches and has a second center disposed a second distance between 2.1350 inches to 2.1550 inches from surface Q.

Abstract: An annular backing plate for a diffuser in a centrifugal compressor comprises an inner diameter and an outer diameter disposed radially opposite the inner diameter. The backing plate also includes a first surface extending between the inner diameter and the outer diameter of the backing plate. A step is formed on the first surface proximate the inner diameter, wherein the step shifts a portion of the first surface encompassed by the step axially aft relative a portion of the first surface not encompassed by the step.

Abstract: A cabin air compressor assembly that include a cabin air compressor disposed at a compressor inlet and a cabin air compressor motor operably connected to the cabin air compressor. At least one cooling flow inlet is configured to direct a cooling flow through various pathways in the cabin air compressor assembly, including across the cabin air compressor motor. A blower is configured to boost the cooling flow across the cabin air compressor motor, thereby increasing cooling flow provided to the air compressor motor. A static seal plate is downstream of the blower and guides the boosted cooling flow toward a cooling flow exit. In addition, the static seal plate isolates boosted cooling flow from a moving rotor of the cabin air compressor, and also forms part of a containment structure that contains fragments and breakage that may come from the cabin air compressor rotor.

Abstract: An air cycle machine (ACM) compressor housing includes a body including an exterior surface and an interior portion. An inlet is integrally formed with the body. The inlet includes an inlet passage fluidically connected with the interior portion. An outlet is integrally formed with the body. The outlet includes an outlet passage fluidically connected with the interior portion. A bypass is integrally formed with the body. The bypass includes a bypass passage fluidically connected with the interior portion. The bypass passage includes a first end portion extending outwardly from the body, a second end portion and an intermediate portion extending therebetween. The first end portion includes a wall thickness of between about 0.330-inch (8.382-mm) and 0.390-inch (9.906-mm).

Abstract: A turbine bypass housing is provided. The housing includes a body having an inlet end and an outlet end and defining an interior, an outlet flange is configured at the outlet end and has a rim diameter, and an inlet flange is configured at the inlet end and has a flange thickness. An interior wall of the body has a first fillet radius proximal to the inlet flange and at least one boss is configured on an exterior of the body, wherein the boss defines a boss aperture therein, the boss aperture extending from an exterior of the body to the interior of the body. The flange thickness is 0.200±0.005 inches (0.508±0.013 cm).

Abstract: An example terminal stud of a ram air fan connection assembly has a threaded portion extending from a head that is held within a slot of a base. The head has a sidewall that interfaces directly with the base. The sidewall has a length and a height. A ratio of the length to the height is from 2.18 to 2.35.

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: An aspect includes a compressor diffuser and shroud for a motor driven compressor assembly. The motor driven compressor assembly includes a first stage compressor and a second stage compressor. The compressor diffuser and shroud of the first stage compressor includes a diffuser portion, a compressor inlet portion, and a shroud portion. The diffuser portion includes a diffuser portion outer lip having a first sealing lip outer diameter to provide a first sealing interface to a first stage compressor housing. The compressor inlet portion includes an inlet portion outer lip having a second sealing lip outer diameter to provide a second sealing interface. The shroud portion includes a curvature between the diffuser portion outer lip and the inlet portion outer lip to align with a first stage compressor rotor, where a ratio of the first sealing lip outer diameter to the second sealing lip outer diameter is between 1.622 and 1.628.

Abstract: An aspect includes a compressor diffuser and shroud for a motor driven compressor assembly. The motor driven compressor assembly includes a first stage compressor and a second stage compressor. The compressor diffuser and shroud of the second stage compressor includes a diffuser portion and a shroud portion. The diffuser portion includes a diffuser portion outer lip having a first sealing lip outer diameter to provide a first sealing interface to a second stage compressor housing. The shroud portion includes a curvature between the diffuser portion outer lip and a compressor inlet to align with a second stage compressor rotor, where a ratio of the first sealing lip outer diameter to an innermost diameter of the compressor diffuser and shroud is between 2.698 and 2.711.

Abstract: A turbine seal plate includes an inner rim with a labyrinth seal land that defines a central bore having a labyrinth seal diameter. The turbine seal plate also includes a housing coupling ring arranged radially outward of the inner rim. A housing pilot extends axially from the housing coupling ring and substantially parallel to the labyrinth seal land with respect to a radially inner portion of the housing pilot. The housing pilot has a housing pilot thickness, and a ratio of the housing pilot thickness to the labyrinth seal diameter is between 0.08 and 0.14. A frusto-conical body extends between the radially inner portion of the housing pilot and the inner rim of the turbine seal plate.

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.