Abstract: An airfoil for a gas turbine engine according to an example of the present disclosure includes, among other things, an airfoil body extending between leading and trailing edges and extending from a root section, and the airfoil body defining pressure and suction sides. The airfoil body defines a recessed region extending inwardly from at least one of the pressure and suction sides, and the airfoil body includes one or more ribs that define a plurality of pockets within a perimeter of the recessed region. A plurality of cover skins is welded to the airfoil body along the one or more ribs to enclose respective ones of the plurality of pockets. The plurality of cover skins are formed from a common cover having a perimeter that is dimensioned to mate with the perimeter of the recess.

Abstract: An airfoil for a gas turbine engine includes a first portion joined to a second portion along an interface such that at least the first portion establishes an airfoil section and the second portion establishes a root section. The airfoil section includes an airfoil body that extends between leading and trailing edges in a chordwise direction, between pressure and suction sides separated in a thickness direction, and from the root section to a tip portion in a spanwise direction. A recessed region extends inwardly from at least one of the pressure and suction sides. The airfoil body includes at least one rib that bounds a respective pocket within a perimeter of the recessed region. The recessed region and the at least one rib are dimensioned to extend across the interface. A cover skin is coupled to the airfoil body along the at least one rib to enclose the recessed region.

Abstract: A furnace for removing a molybdenum-alloy refractory metal core through sublimation comprising a retort furnace having an interior; a sublimation fixture insertable within the interior of the retort furnace, the sublimation fixture configured to receive at least one turbine blade having the molybdenum-alloy refractory metal core; a flow passage thermally coupled to the retort furnace configured to heat a fluid flowing through the flow passage and deliver the fluid to the molybdenum-alloy refractory metal core causing sublimation of the molybdenum-alloy refractory metal core.

Abstract: During a bonding process, a tip cap and an airfoil base are provided. The tip cap is arranged on the airfoil base. The tip cap is diffusion bonded to the airfoil base.

Abstract: A fixture assembly includes a first fixture portion, a second fixture portion that interfaces with the first fixture portion, and a sub-fixture movably mounted to the first fixture portion. A multiple of actuators selectively move the sub-fixture toward the second fixture portion. A method of manufacturing a fan blade includes deploying the sub-fixture from the first fixture portion to effectuate a peripheral diffusion bond to join the blade body and the cover of the fan blade.

Abstract: A clamp for securing a component to an isogrid case of a gas turbine engine includes a top having an attachment feature for coupling the clamp to the component. The clamp further includes a bottom. The clamp further includes two sides extending from the top towards the bottom, each of the two sides being thicker at the bottom than at the top, and the two sides defining a shaped slot closer to the bottom than the top for receiving a rib of the isogrid case.

Abstract: A tool for simultaneous local stress relief of each of a multiple of linear friction welds includes a columnar track defined along an axis, the columnar track having a helical slot; and a support structure engaged with the helical slot to translate and rotate a heat treat fixture portion along the axis.

Abstract: A mounting plate for forming a gas turbine engine component according to an example of the present disclosure includes, among other things, a plate body defining an abutment dimensioned to mate with a forming die. The plate body defines at least one internal cooling circuit. The at least one internal cooling circuit includes a passageway having an intermediate portion interconnecting inlet and outlet portions. The intermediate portion is dimensioned to follow a perimeter of the abutment. The intermediate portion includes a plurality of fins extending partially from a first sidewall towards a second sidewall opposed to the first sidewall. A method of forming a gas turbine engine component is also disclosed.

Abstract: A furnace for removing a molybdenum-alloy refractory metal core through sublimation comprising a retort furnace having an interior; a sublimation fixture insertable within the interior of the retort furnace, the sublimation fixture configured to receive at least one turbine blade having the molybdenum-alloy refractory metal core; a flow passage thermally coupled to the retort furnace configured to heat a fluid flowing through the flow passage and deliver the fluid to the molybdenum-alloy refractory metal core causing sublimation of the molybdenum-alloy refractory metal core.

Abstract: A fixture assembly including a first fixture portion; a second fixture portion that interfaces with the first fixture portion; and a bladder assembly mounted to the second fixture portion to face the first fixture portion. A method of manufacturing a fan blade includes inserting a blade body and a cover into a fixture; and deploying a bladder assembly within the fixture to press the cover into the blade body.

Abstract: An airfoil for a gas turbine engine according to an example of the present disclosure includes, among other things, an airfoil body extending between leading and trailing edges in a chordwise direction and extending from a root section in a spanwise direction, and the airfoil body defining pressure and suction sides separated in a thickness direction. The airfoil body defines a recessed region extending inwardly from at least one of the pressure and suction sides, and the airfoil body includes one or more ribs that define a plurality of pockets within a perimeter of the recessed region. A plurality of cover skins is welded to the airfoil body along the one or more ribs to enclose respective ones of the plurality of pockets. The plurality of cover skins formed from a common cover having a perimeter that is dimensioned to mate with the perimeter of the recess. A method of forming a gas turbine engine component is also disclosed.

Abstract: A furnace for removing a molybdenum-alloy refractory metal core through sublimation comprising a retort furnace having an interior; a sublimation fixture insertable within the interior of the retort furnace, the sublimation fixture configured to receive at least one turbine blade having the molybdenum-alloy refractory metal core; a flow passage thermally coupled to the retort furnace configured to heat a fluid flowing through the flow passage and deliver the fluid to the molybdenum-alloy refractory metal core causing sublimation of the molybdenum-alloy refractory metal core.

Abstract: An airfoil for a gas turbine engine includes a first portion joined to a second portion along an interface such that at least the first portion establishes an airfoil section and the second portion establishes a root section. The airfoil section includes an airfoil body that extends between leading and trailing edges in a chordwise direction, between pressure and suction sides separated in a thickness direction, and from the root section to a tip portion in a spanwise direction. A recessed region extends inwardly from at least one of the pressure and suction sides. The airfoil body includes at least one rib that bounds a respective pocket within a perimeter of the recessed region. The recessed region and the at least one rib are dimensioned to extend across the interface. A cover skin is coupled to the airfoil body along the at least one rib to enclose the recessed region.

Abstract: A laser welding by-product removal device comprises a housing that includes distal and proximate ends separated along a central axis by a peripheral sidewall. A first plenum circumscribes the peripheral sidewall at the proximate housing end and includes a gas inlet and a first plenum base surface that includes a plurality of gas outlet holes. A second plenum circumscribes the peripheral sidewall between the first plenum and the distal housing end, where the second plenum includes a second plenum base surface, radially inner and outer sidewalls that extend axially distal from the second plenum base surface. The second plenum includes a top surface extending between the radially inner and outer sidewalls, and a by-product outlet in the top surface, where at least one of the second plenum base surface and the radially outer sidewall includes a plurality of by-product inlet holes.

Abstract: An airfoil for a gas turbine engine according to an example of the present disclosure includes, among other things, a first portion welded to a second portion along an interface such that at least the first portion establishes an airfoil section and the second portion establishes a root section mountable to a rotatable hub. The airfoil section includes an airfoil body extending between leading and trailing edges in a chordwise direction, extending between pressure and suction sides separated in a thickness direction, and extending from the root section in a spanwise direction to a tip portion. A recessed region extends inwardly from at least one of the pressure and suction sides. The airfoil body includes at least one rib bounding a respective pocket within a perimeter of the recessed region. A cover skin is welded to the airfoil body along the at least one rib to enclose the recessed region. A method of forming a gas turbine engine component is also disclosed.

Abstract: An airfoil for a gas turbine engine according to an example of the present disclosure includes, among other things, an airfoil body extending between leading and trailing edges in a chordwise direction and extending from a root section in a spanwise direction, and the airfoil body defining pressure and suction sides separated in a thickness direction. The airfoil body defines a recessed region extending inwardly from at least one of the pressure and suction sides, and the airfoil body includes one or more ribs that define a plurality of pockets within a perimeter of the recessed region. A plurality of cover skins is welded to the airfoil body along the one or more ribs to enclose respective ones of the plurality of pockets. The plurality of cover skins formed from a common cover having a perimeter that is dimensioned to mate with the perimeter of the recess. A method of forming a gas turbine engine component is also disclosed.

Abstract: An airfoil includes a first airfoil piece and a second airfoil piece that is bonded to the first airfoil piece at a joint. The first airfoil piece and the second airfoil piece are formed of aluminum alloys. At least one of the aluminum alloys is an aluminum alloy composition that has greater than 0.8% by weight of zinc. The joint includes a braze element of magnesium, zinc, or combinations thereof in a higher concentration than in other portions of the first airfoil piece and the second airfoil piece.

Abstract: A self-leveling container that contains argon gas for laser welding of a work piece includes a base surface, a plurality of pleated sidewalls, each comprising an associated distal sidewall end and an associated proximate sidewall end, where the proximate sidewall end is sealed to the base surface. A frame includes a plurality of frame segments, each secured to an associated one of the distal sidewall ends. A plurality of actuators, each located with one intersection of the plurality of frame segments, linearly move its associated one intersection of the plurality frame segments so a plane formed by the frame segments remains parallel to a planar surface.

Abstract: An airfoil for a gas turbine engine according to an example of the present disclosure includes, among other things, an airfoil body defining a recessed region and including at least one rib dimensioned to loop about a respective pocket within a perimeter of the recessed region. At least one cover skin is welded to the airfoil body along the at least one rib to enclose the recessed region. The at least one cover skin is welded to the at least one rib along a respective weld path. The weld path defines a weld width, the at least one rib defines a rib width, and a ratio of the weld width to the rib width is equal to or greater than 3:1 for each position along the weld path. A method of forming a gas turbine engine component is also disclosed.

Abstract: During a bonding process, a tip cap and an airfoil base are provided. The tip cap is arranged on the airfoil base. The tip cap is diffusion bonded to the airfoil base.