Abstract: A method of making an electromagnetic coil for use in a high-temperature electromagnetic machine includes pre-coating magnet wire with a high-temperature insulation precursor to produce pre-coated magnet wire, winding, while applying in-situ a glass-ceramic slurry, the pre-coated magnet wire into a predetermined coil shape to produce a wet-wound green coil, and thermally processing the wet-wound green coil to produce a processed coil. In some instances, a second layer of a high-temperature insulation may be applied to the processed coil to produce a further insulated processed coil, and then thermally processing the further insulated processed coil to produce a further processed electromagnetic coil.

Abstract: A high-temperature heterostructure conductor includes an electrically conductive heterostructure core, a second electrically conductive material, a ceramic layer and a dielectric layer. The electrically conductive heterostructure core includes a first electrically conductive material and an intermetallic layer that is formed on and surrounds the first electrically conductive material. The second electrically conductive material surrounds the intermetallic layer. The ceramic layer is formed or disposed on and surrounds the second electrically conductive material. The dielectric layer is disposed on and surrounding the ceramic layer.

Abstract: Methods for fabricating protective coating systems for gas turbine engine applications are provided. An exemplary method of applying a protective coating to a substrate includes the steps of providing a substrate formed of a ceramic matrix composite material, forming a first coating layer directly on to the substrate and comprising an oxygen barrier material, a compliance material, or a bonding material and forming a second coating layer directly on to the first coating layer and comprising a thermal barrier material. The method optionally includes forming a third coating layer partially directly on to the second coating layer and partially within at least some of the plurality of pores of the second coating layer.

Abstract: A method for manufacturing an electromagnetic coil with an intentionally engineered heat flow path is provided. The method includes defining at least one preferential heat flow path for heat to flow for the electromagnetic coil. A coil cartridge in which to encase the electromagnetic coil is designed by selecting dimensions of different portions of the insulating coil cartridge that will result in the at least one preferential heat flow path. The electromagnetic coil is then encased in coil cartridge material to produce an encased electromagnetic coil.

Abstract: A method for manufacturing an electromagnetic coil with an intentionally engineered heat flow path is provided. The method includes defining at least one preferential heat flow path for heat to flow from the electromagnetic coil. A plurality of different materials are selected, each having different heat flow properties. A determination is made as to which portions of the electromagnetic coil should be coated with each of the different materials that will result in the at least one preferential heat flow path. The determined portions of the electromagnetic coil are then coated with each of the different materials to make a coated electromagnetic coil, and the coated electromagnetic coil is encased in a coil cartridge.

Abstract: A protective coating system includes a substrate that has an exterior surface exhibiting a degree of valley/hill surface irregularity including a plurality of hills and a plurality of valleys and a first coating layer formed directly on to the exterior surface of the substrate and that conforms to the exterior surface of the substrate such that the first coating layer has a non-uniform coating thickness over the substrate. The protective coating system further includes a second coating layer formed directly on to the exterior surface of the first coating layer. The second coating layer includes a plurality of pores within the second coating layer. Still further, the protective coating system includes a third coating layer formed within at least some of the plurality of pores within the second coating layer.

Abstract: A protective coating system includes a substrate that has an exterior surface exhibiting a degree of valley/hill surface irregularity including a plurality of hills and a plurality of valleys and a first coating layer formed directly on to the exterior surface of the substrate and that conforms to the exterior surface of the substrate such that the first coating layer has a non-uniform coating thickness over the substrate. The protective coating system further includes a second coating layer formed directly on to the exterior surface of the first coating layer. The second coating layer includes a plurality of pores within the second coating layer. Still further, the protective coating system includes a third coating layer formed within at least some of the plurality of pores within the second coating layer.

Abstract: Protective coating systems for gas turbine engine applications and methods for fabricating such protective coating systems are provided. An exemplary protective coating system includes a substrate formed of a ceramic matrix composite material, a first coating layer formed directly on to the substrate and comprising an oxygen barrier material, a compliance material, or a bonding material and a second coating layer formed directly on to the first coating layer and comprising a thermal barrier material. The exemplary protective coating optionally includes a third coating layer partially formed directly on to the second coating layer and partially formed within at least some of the plurality of pores of the second coating layer.

Abstract: Methods for fabricating protective coating systems for gas turbine engine applications are provided. An exemplary method of applying a protective coating to a substrate includes the steps of providing a substrate formed of a ceramic matrix composite material, forming a first coating layer directly on to the substrate and comprising an oxygen barrier material, a compliance material, or a bonding material and forming a second coating layer directly on to the first coating layer and comprising a thermal barrier material. The method optionally includes forming a third coating layer partially directly on to the second coating layer and partially within at least some of the plurality of pores of the second coating layer.

Abstract: Disclosed is a ceramic matrix composite (CMC) material including rare earth phosphate ceramic fibers embedded in a ceramic matrix, wherein the ceramic matrix also optionally includes a rare earth phosphate material. Methods for manufacturing the CMC material and gas turbine engine components formed of the CMC material are also disclosed.

Abstract: Embodiments of a gas turbine engine actuation system are provided, as are embodiments of a high temperature actuator and methods for the manufacture thereof. In one embodiment, the gas turbine engine actuation system includes an actuated gas turbine engine component and a high temperature actuator, which has a rotor mechanically linked to the actuated gas turbine engine component and a stator surrounding at least a portion of the rotor. The stator includes, in turn, a coil support structure having a plurality of spokes extending radially therefrom. A plurality of pre-formed electromagnetic coils is circumferentially distributed about the coil support structure. Each of the plurality of pre-formed electromagnetic coils is inserted over at least one of the plurality of spokes in a radial direction. The stator further includes an inorganic dielectric material in which each of the plurality of pre-formed electromagnetic coils is at least partially embedded.

Abstract: Embodiments of an electromagnetic coil assembly are provided, as are methods for the manufacture of an electromagnetic coil assembly. In one embodiment, the method includes joining a first end portion of a braided lead wire to a coiled magnet wire. A dielectric-containing material is applied in a wet-state over the coiled magnet wire and over the first end portion of the braided lead wire. The dielectric-containing material is cured to produce an electrically-insulative body in which the coiled magnet wire and the first end portion of the braided lead wire are at least partially embedded. Prior to application of the dielectric-containing material, the braided lead wire is at least partially impregnated with a masking material deterring wicking of the dielectric-containing material into an intermediate portion of the braided lead wire.

Abstract: Disclosed is a ceramic matrix composite (CMC) material including rare earth phosphate ceramic fibers embedded in a ceramic matrix, wherein the ceramic matrix also optionally includes a rare earth phosphate material. Methods for manufacturing the CMC material and gas turbine engine components formed of the CMC material are also disclosed.

Abstract: Embodiments of an electromagnetic coil assembly are provided, as are methods for the manufacture of an electromagnetic coil assembly. In one embodiment, the method for manufacturing an electromagnetic coil assembly includes the steps of providing a braided aluminum lead wire having a first end portion and a second end portion, brazing the first end portion of the braided aluminum lead wire to a first electrically-conductive interconnect member, and winding a magnet wire into an electromagnetic coil. The second end portion of the braided aluminum lead wire is joined to the magnet wire after the step of brazing.

Abstract: Embodiments of a high temperature electromagnetic coil assembly are provided, as are embodiments of a method for fabricating such a high temperature electromagnetic coil assembly. In one embodiment, the high temperature electromagnetic coil assembly includes a coiled anodized aluminum wire and an electrically-insulative, high thermal expansion ceramic body in which the coiled anodized aluminum wire is embedded. The electrically-insulative, high thermal expansion ceramic body has a coefficient of thermal expansion greater than 10 parts per million per degree Celsius and less than the coefficient of thermal expansion of the coiled anodized aluminum wire.

Abstract: Embodiments of an electromagnetic coil assembly are provided, as are methods for the manufacture of an electromagnetic coil assembly. In one embodiment, the method for manufacturing an electromagnetic coil assembly includes the steps of providing a braided aluminum lead wire having a first end portion and a second end portion, brazing the first end portion of the braided aluminum lead wire to a first electrically-conductive interconnect member, and winding a magnet wire into an electromagnetic coil. The second end portion of the braided aluminum lead wire is joined to the magnet wire after the step of brazing.

Abstract: Embodiments of a high temperature electromagnetic coil assembly are provided, as are embodiments of a method for fabricating such a high temperature electromagnetic coil assembly. In one embodiment, the high temperature electromagnetic coil assembly includes a coiled anodized aluminum wire and an electrically-insulative, high thermal expansion ceramic body in which the coiled anodized aluminum wire is embedded. The electrically-insulative, high thermal expansion ceramic body has a coefficient of thermal expansion greater than 10 parts per million per degree Celsius and less than the coefficient of thermal expansion of the coiled anodized aluminum wire.

Abstract: Embodiments of an electromagnetic coil assembly are provided, as are methods for the manufacture of an electromagnetic coil assembly. In one embodiment, the method includes joining a first end portion of a braided lead wire to a coiled magnet wire. A dielectric-containing material is applied in a wet-state over the coiled magnet wire and over the first end portion of the braided lead wire. The dielectric-containing material is cured to produce an electrically-insulative body in which the coiled magnet wire and the first end portion of the braided lead wire are at least partially embedded. Prior to application of the dielectric-containing material, the braided lead wire is at least partially impregnated with a masking material deterring wicking of the dielectric-containing material into an intermediate portion of the braided lead wire.

Abstract: Protective coating systems for gas turbine engine applications and methods for fabricating such protective coating systems are provided. An exemplary protective coating system includes a substrate formed of a ceramic matrix composite material, a first coating layer formed directly on to the substrate and comprising an oxygen barrier material, a compliance material, or a bonding material and a second coating layer formed directly on to the first coating layer and comprising a thermal barrier material. The exemplary protective coating optionally includes a third coating layer partially formed directly on to the second coating layer and partially formed within at least some of the plurality of pores of the second coating layer.

Abstract: By way of example, a method for manufacturing an electromagnetic coil assembly includes the steps of providing a braided aluminum lead wire having a first end portion and a second end portion, brazing the first end portion of the braided aluminum lead wire to a first electrically-conductive interconnect member, and winding a magnet wire into an electromagnetic coil. The second end portion of the braided aluminum lead wire is joined to the magnet wire after the step of brazing.