Abstract: A turbine engine component for a gas turbine engine includes an inner disk, an outer shroud, and a plurality of blades. Each blade comprises a blade root and an airfoil body. The blade root is plated at least in part with a noble metal, and is coupled to the inner disk. The airfoil body extends at least partially between the blade root and the outer shroud.

Abstract: A rotor component assembly including at least one void space formed therein that provides for reduction in weight of the component and/or cooling of the component during operation. The rotor component is formed by positioning a coated mild steel insert within a mold having an internal cross-section substantially the same in dimensions as the final rotor component. The mold is filled with a superalloy metal powder and undergoes hot-isostatic pressing to consolidate the powder about the coated core insert and form a superalloy structure. The mold is removed from about the superalloy structure and the core insert is removed from within the superalloy structure, thereby defining the at least one internal void within the rotor component.

Abstract: A dual alloy turbine rotor is provided and includes an integrally formed blade ring and a disk. The blade ring is made of a first alloy and includes a ring portion and a plurality of airfoils extending therefrom, where the ring portion includes an inner surface, and each airfoil includes an internal cavity formed therein. The disk is made of a second alloy and may have a beveled outer peripheral surface. The disk is disposed within the ring portion such that the disk outer peripheral surface contacts at least a portion of the ring portion inner surface. Methods of manufacturing the turbine rotor are also provided.

Abstract: A coating system is used on an engine component having an outer surface configured to be exposed to a first plurality of particles impinging against the outer surface at an angle within a first angle range and a second plurality of particles impinging at an angle in a second angle range. The system includes a bond layer overlying the engine component outer surface, a first erosion-resistant layer comprising a first material that is more resistant to erosion by particles impinging the component outer surface at an angle within the first angle range than by particles impinging within the second angle range, an interlayer overlying the first erosion-resistant layer, and a second erosion-resistant layer comprising a second material that is more resistant to erosion by particles impinging the component outer surface at an angle within the second angle range than by particles impinging within the first angle range.

Abstract: A spun metal form used to manufacture a dual alloy turbine wheel. The spun metal form prevents braze alloy contamination of the hub/casting interface by relocating the braze joint away from the interface. The spun metal form allows for the re-working of components after failed vacuum brazing and increases the time to failure of dual alloy turbine wheels.

Abstract: A coating system is used on an engine component having an outer surface configured to be exposed to a first plurality of particles impinging against the outer surface at an angle within a first angle range and a second plurality of particles impinging at an angle in a second angle range. The system includes a bond layer overlying the engine component outer surface, a first erosion-resistant layer comprising a first material that is more resistant to erosion by particles impinging the component outer surface at an angle within the first angle range than by particles impinging within the second angle range, an interlayer overlying the first erosion-resistant layer, and a second erosion-resistant layer comprising a second material that is more resistant to erosion by particles impinging the component outer surface at an angle within the second angle range than by particles impinging within the first angle range.

Abstract: A turbine engine component for a gas turbine engine includes an inner disk, an outer shroud, and a plurality of blades. Each blade comprises a blade root and an airfoil body. The blade root is plated at least in part with a noble metal, and is coupled to the inner disk. The airfoil body extends at least partially between the blade root and the outer shroud.

Abstract: A dual alloy turbine rotor is provided and includes an integrally formed blade ring and a disk. The blade ring is made of a first alloy and includes a ring portion and a plurality of airfoils extending therefrom, where the ring portion includes an inner surface, and each airfoil includes an internal cavity formed therein. The disk is made of a second alloy and may have a beveled outer peripheral surface. The disk is disposed within the ring portion such that the disk outer peripheral surface contacts at least a portion of the ring portion inner surface. Methods of manufacturing the turbine rotor are also provided.

Abstract: A coating system is used on an engine component having an outer surface configured to be exposed to a first plurality of particles impinging against the outer surface at an angle within a first angle range and a second plurality of particles impinging at an angle in a second angle range. The system includes a bond layer overlying the engine component outer surface, a first erosion-resistant layer comprising a first material that is more resistant to erosion by particles impinging the component outer surface at an angle within the first angle range than by particles impinging within the second angle range, an interlayer overlying the first erosion-resistant layer, and a second erosion-resistant layer comprising a second material that is more resistant to erosion by particles impinging the component outer surface at an angle within the second angle range than by particles impinging within the first angle range.

Abstract: A rotor component assembly including at least one void space formed therein that provides for reduction in weight of the component and/or cooling of the component during operation. The rotor component is formed by positioning a coated mild steel insert within a mold having an internal cross-section substantially the same in dimensions as the final rotor component. The mold is filled with a superalloy metal powder and undergoes hot-isostatic pressing to consolidate the powder about the coated core insert and form a superalloy structure. The mold is removed from about the superalloy structure and the core insert is removed from within the superalloy structure, thereby defining the at least one internal void within the rotor component.

Abstract: A hoop stress relief mechanism is disclosed for use on a rotary body to relieve stress caused by both thermal and centrifugal forces. The mechanism may consist of a J-shaped slot cut from the outer rim of the rotary body a distance inwardly toward the axis of rotation, the slot having a curve in its inward end that curves back towards the outer rim. The J-shaped slot may extend through the rotary body to join its two faces. The J-shaped slot may be fabricated by an electric discharge wire machine. The electric discharge wire machine may make multiple passes in order to smooth the bottom surface of the curved slot portion.

Abstract: A spun metal form used to manufacture a dual alloy turbine wheel. The spun metal form prevents braze alloy contamination of the hub/casting interface by relocating the braze joint away from the interface. The spun metal form allows for the re-working of components after failed vacuum brazing and increases the time to failure of dual alloy turbine wheels.

Abstract: A spun metal form used to manufacture a dual alloy turbine wheel. The spun metal form prevents braze alloy contamination of the hub/casting interface by relocating the braze joint away from the interface. The spun metal form allows for the re-working of components after failed vacuum brazing and increases the time to failure of dual alloy turbine wheels.

Abstract: A spun metal form used to manufacture a dual alloy turbine wheel. The spun metal form prevents braze alloy contamination of the hub/casting interface by relocating the braze joint away from the interface. The spun metal form allows for the re-working of components after failed vacuum brazing and increases the time to failure of dual alloy turbine wheels.