Abstract: A liner support system for an exhaust liner in an aircraft engine. The liner support system includes a plurality of posts that space the exhaust liner from the exhaust duct, the plurality of posts spacing the exhaust liner from the exhaust duct further supporting the exhaust liner. Each post includes an interface region adjacent to the back side of the exhaust liner sealed to the back side of the exhaust liner, a shank extending to a low pressure region, and a hollow passageway internal to the shank, providing fluid communication between the interface region and the low pressure region. The low pressure region results in pressure against the liner, pulling the liner adjacent the post interface region against the post while preventing fluid leakage between the exhaust liner and the interface region. The posts create a pattern of alternating pressures in the liner allowing for elimination of hangers.

Abstract: Combustor assemblies are provided. For example, a combustor assembly includes a combustor liner defining a combustion chamber and an annular combustor dome positioned at a forward end of the combustor liner that defines a plurality of dome apertures. The combustor assembly further includes an annular heat shield positioned between the combustor dome and the combustion chamber, a plurality of adapters positioned forward of the heat shield, and a plurality of collars. The heat shield defines a plurality of heat shield apertures that are aligned with the dome apertures. One adapter is attached to the combustor dome at each dome aperture, and the adapters are. One collar extends through each heat shield aperture to couple the heat shield to the combustor dome. Further, ceramic matrix composite (CMC) heat shields are provided that may include an annular body defining a plurality of heat shield apertures, as well as inner and outer wings.

Abstract: An apparatus for continuous powder-based additive manufacturing of a large annular object or multiple smaller objects simultaneously is described. The build unit(s) of the apparatus includes a powder delivery mechanism, a powder recoating mechanism and an irradiation beam directing mechanism. The build unit(s) is attached to a rotating mechanism such that the build unit(s) rotates around and above the annular powder bed during production. The rotating mechanism is supported onto a central tower, and both the rotating mechanism and the tower are concentric with the non-rotating annular powder bed. An additive manufacturing method using the apparatus involves repetitive and continuous cycles of at least simultaneously rotating the build unit(s) to deposit powder onto the powder bed and irradiating the powder to form a fused additive layer. The continuous additive manufacturing process may be further aided with a helical configuration of the powder bed build surface.

Abstract: Combustor assemblies for gas turbine engines are provided. For example, a combustor assembly comprises a combustor dome, a first heat shield having an edge, a second heat shield having an edge, and a seal extending from the edge of the first heat shield to the edge of the second heat shield such that the seal spans a gap between the first heat shield and the second heat shield. In another embodiment, the seal has a first contact portion contacting the edge of the first heat shield, a second contact portion contacting the edge of the second heat shield edge, and a connecting portion connecting the first portion and the second portion. The first contact portion and the second contact portion project away from the connecting portion. Methods for sealing between adjacent heat shields of a combustor assembly also are provided.

Abstract: A liner support system for an exhaust liner in an aircraft engine. The liner support system includes a plurality of posts that space the exhaust liner from the exhaust duct, the plurality of posts spacing the exhaust liner from the exhaust duct further supporting the exhaust liner. Each post includes an interface region adjacent to the back side of the exhaust liner sealed to the back side of the exhaust liner, a shank extending to a low pressure region, and a hollow passageway internal to the shank, providing fluid communication between the interface region and the low pressure region. The low pressure region results in pressure against the liner, pulling the liner adjacent the post interface region against the post while preventing fluid leakage between the exhaust liner and the interface region. The posts create a pattern of alternating pressures in the liner allowing for elimination of hangers.

Abstract: An additive manufacturing apparatus for building an object is provided. The apparatus includes a build chamber having at least one chamber wall, a powder delivery mechanism, and a build platform. The build chamber and build platform defines while in operation a powder bed. At least one surface of the build chamber or build platform is moveable in a manner that is capable of adjusting forces on the object in the powder bed.

Abstract: The present disclosure generally relates to methods and apparatuses for additive manufacturing (AM) that utilize compression chambers to reduce pressure on grown objects. In one aspect, the disclosure provides a method for fabricating an object. The method includes (a) irradiating a layer of powder in a build area above a build platform to form a fused region; (b) providing a subsequent layer of powder over the build area; and (c) repeating steps (a) and (b) until at least a portion of the object, at least one chamber, and a tube are formed in the build area. The chamber encloses a region of unfused powder and the tube extends from a passage within the build platform to the chamber. The method also includes (d) removing unfused powder from within the chamber via the tube and the passage. The disclosure also provides an apparatus for forming compression chambers within an object.

Abstract: An apparatus for continuous powder-based additive manufacturing of a large annular object or multiple smaller objects simultaneously is described. The build unit(s) of the apparatus includes a powder delivery mechanism, a powder recoating mechanism and an irradiation beam directing mechanism. The build unit(s) is attached to a rotating mechanism such that the build unit(s) rotates around and above the annular powder bed during production. The rotating mechanism is supported onto a central tower, and both the rotating mechanism and the tower are concentric with the non-rotating annular powder bed. An additive manufacturing method using the apparatus involves repetitive and continuous cycles of at least simultaneously rotating the build unit(s) to deposit powder onto the powder bed and irradiating the powder to form a fused additive layer. The continuous additive manufacturing process may be further aided with a helical configuration of the powder bed build surface.

Abstract: An apparatus for continuous powder-based additive manufacturing of a large annular object or multiple smaller objects simultaneously is described. The build unit(s) of the apparatus includes a powder delivery mechanism, a powder recoating mechanism and an irradiation beam directing mechanism. The build unit(s) is attached to a rotating mechanism such that the build unit(s) rotates around and above the annular powder bed during production. The rotating mechanism is supported onto a central tower, and both the rotating mechanism and the tower are concentric with the non-rotating annular powder bed. An additive manufacturing method using the apparatus involves repetitive and continuous cycles of at least simultaneously rotating the build unit(s) to deposit powder onto the powder bed and irradiating the powder to form a fused additive layer. The continuous additive manufacturing process may be further aided with a helical configuration of the powder bed build surface.

Abstract: Combustor assemblies and combustor heat shields are provided. As one example, a combustor assembly comprises a flow path assembly including an outer wall, an inner wall, and a combustor dome that define a combustion chamber and are formed from a ceramic matrix composite (CMC) material. The combustor dome defines a plurality of dome openings, and a heat shield is positioned between the combustor dome and the combustion chamber that comprises a plurality of heat shield segments. Each heat shield segment defines a heat shield aperture that is aligned with a dome opening, and an aft surface of each segment is concave and a forward surface of each segment is convex. One of a plurality of fuel-air mixers is positioned through each heat shield aperture and dome opening, and one collar of a plurality of collars extends through each heat shield aperture to couple the heat shield to the fuel-air mixer.

Abstract: Various methods and assemblies are provided for producing composite components having formed in features. For example, a method may comprise depositing a composite material on a base tool; aligning an aperture forming tool with a tooling aperture in the base tool; inserting the aperture forming tool through the composite material to form an aperture in the composite material; deploying a feature forming tool to press the composite material into one or more recesses; and processing the composite material with the feature forming tool in contact with the composite material. In some embodiments, the feature forming tool includes a stem extending through the composite material and into the base tool, as well as a feature forming head that is brought into contact with and processed with the composite material. In other embodiments, a tooling assembly holds a pin in place during processing to fix the pin in the composite component.

Abstract: An apparatus for powder-based additive manufacturing of an object is provided. The apparatus includes a powder delivery mechanism, a powder recoating mechanism, an irradiation beam directing mechanism and a temperature control mechanism that at least measures a real-time temperature of at least one growing part of a built object. The apparatus includes a build unit, a positioning mechanism, and a rotating mechanism. The build unit attaches to the positioning mechanism providing the build unit with independent movements in at least two dimensions. The build unit also attaches to the rotating mechanism and rotates around and above a build platform during production. A method of manufacturing the object using the apparatus includes repetitive cycles of depositing powder onto a build platform, irradiating at least one selected portion of the powder to form at least one fused layer, and measuring a real-time temperature of at least one selected portion of the at least one fused layer.

Abstract: A slip joint assembly for joining multiple pipes is provided. The slip joint assembly includes a flow expander that is connected to a downstream pipe and is tapered toward a forward end. An inlet bellmouth is coupled to the forward end of the flow expander and defines a flared inlet positioned within an upstream pipe. An annular seal assembly is coupled to the upstream pipe and includes a ball seal positioned around and forming a seal with the flow expander to operably couple the upstream pipe and the downstream pipe. An internal diameter of the annular seal assembly is smaller than a diameter of the flared inlet.

Abstract: A heat exchanger includes a heat exchanger core, a header defining a header manifold, and a transition portion that provides fluid communication between the heat exchanger core and the header manifold. The transition portion includes a transition tube extending between the header and the heat exchanger core, a header junction where the transition tube joins the header, and a splitting junction that splits the transition tube into the plurality of heat exchange tubes. The header junction may define elliptical inlet apertures, a large filleted joint, and a junction thickness that is greater than a header wall thickness.

Abstract: An additive manufacturing apparatus includes: a build drum, the build drum having a peripheral wall defining a worksurface, the build drum being mounted for rotation about a central axis; a drive mechanism operable to rotate the build drum about the central axis, to hold a solidifiable material on the worksurface by centrifugal force; and a material deposition and solidification apparatus, including: a material depositor operable to deposit the solidifiable material on the worksurface; and an apparatus operable to selectively solidify the solidifiable material.

Abstract: Various methods and assemblies are provided for producing composite components having formed in features. For example, a method may comprise depositing a composite material on a base tool; bringing a feature forming tool into contact with the composite material; and processing the composite material with the feature forming tool in contact with the composite material. The processed composite material forms a green state composite component. The feature forming tool comprises a sheet having one or more elements for interacting with one or more elements of the base tool to form one or more features of the composite component. In some embodiments, the method also may comprise sealing a bag around the feature forming tool and the composite material after bringing the tool into contact with the composite material and removing the bag and the feature forming tool from the green state composite component after processing.

Abstract: Combustor assemblies are provided. For example, a combustor assembly includes a combustor liner defining a combustion chamber and an annular combustor dome positioned at a forward end of the combustor liner that defines a plurality of dome apertures. The combustor assembly further includes an annular heat shield positioned between the combustor dome and the combustion chamber, a plurality of adapters positioned forward of the heat shield, and a plurality of collars. The heat shield defines a plurality of heat shield apertures that are aligned with the dome apertures. One adapter is attached to the combustor dome at each dome aperture, and the adapters are. One collar extends through each heat shield aperture to couple the heat shield to the combustor dome. Further, ceramic matrix composite (CMC) heat shields are provided that may include an annular body defining a plurality of heat shield apertures, as well as inner and outer wings.

Abstract: An additively manufactured fastener and a method of manufacturing the same are provided. The fastener includes a shank defining an internal passageway and a head defining a distribution plenum in fluid communication with the internal passageway. The head further defines a cooling face defining a plurality of cooling holes for receiving a flow of cooling air from the internal passageway and the distribution plenum. In addition, an impingement baffle is positioned in the distribution plenum and defines impingement holes for directing the flow of cooling air onto the cooling face.

Abstract: Combustor assemblies for gas turbine engines are provided. For example, a combustor assembly comprises a combustor dome, a first heat shield having an edge, a second heat shield having an edge, and a seal extending from the edge of the first heat shield to the edge of the second heat shield such that the seal spans a gap between the first heat shield and the second heat shield. In another embodiment, the seal has a first contact portion contacting the edge of the first heat shield, a second contact portion contacting the edge of the second heat shield edge, and a connecting portion connecting the first portion and the second portion. The first contact portion and the second contact portion project away from the connecting portion. Methods for sealing between adjacent heat shields of a combustor assembly also are provided.

Abstract: The present disclosure is directed to a sealing system for a turbine engine including an engine component, the engine component defining an oblique sealing surface defining an annular shape. The oblique sealing surface defines an oblique angle with a centerline of the engine component. The sealing system includes a seal housing and a seal ring. The seal housing is annular and includes a groove that is defined by a first sidewall, a second sidewall, and an end wall connecting the first sidewall and the second sidewall. The seal ring is positioned at least partially within the groove in the seal housing. The seal ring defines a seal contact surface for forming a seal with the oblique sealing surface of the engine component.