Abstract: A method of manufacturing a turbine engine component comprises the steps of fabricating an inner hub, casting a plurality of blades, forming a blade ring, and bonding the blade ring to the inner hub. Each blade comprises a blade root and an airfoil body extending from the blade root. The blade ring comprises, at least in part, the plurality of blades coupled by a first bonding technique. The blade ring is bonded to the inner hub using a second bonding technique.

Abstract: Compressor impellers, compressor sections, and methods of manufacturing compressor impellers and cooling the compressor impellers are provided. In an embodiment, and by way of example only, a compressor impeller includes a bore section and a rim section. The bore section comprises a first nickel-based alloy and includes an inner disk portion and a first plurality of blade portions extending therefrom. The rim section comprises a second nickel-based alloy and includes an outer disk portion and a second plurality of blade portions. The outer disk portion is bonded to the inner disk portion of the bore section, and the second plurality of blade portions is bonded to the first plurality of blade portions of the bore section.

Abstract: A radial diffuser comprises a housing, a plurality of diffuser vanes, and a plurality of integral service vanes. The housing includes an air inlet and an air outlet, and defines a radial section extending radially outward from the air inlet, an axial section extending axially to the air outlet, and a transition including a bend and extending between the radial and axial sections. The diffuser vanes are coupled to the housing, and are disposed in, and define diffusion flow passages. The integral service vanes are coupled to the housing, extend around the bend, and define transition flow passages, each in fluid communication with at least one diffusion flow passage. At least some of the integral service vanes include a service passage extending therethrough and configured to allow a service conduit to extend therethrough without crossing either a diffusion flow passage or a transition flow passage.

Abstract: Methods of forming flowbodies and flowbodies are provided. In an embodiment, by way of example only, a method includes providing a first sheet of a first material comprising a metal, providing a second sheet of a second material comprising a composite, attaching a portion of the first sheet to a first position on a preform, securing a portion of the second sheet to a second position on the preform, and winding the first sheet and the second sheet around the preform to form the first flowbody, the first flowbody including a laminate comprising alternating layers of the first sheet and the second sheet.

Abstract: A diffuser particle separator may be integrated into a gas turbine engine to remove corrosive dust and salt particles from the engine's core air flow. The air flow may pass over a series of particle accumulator entrance orifices, trapping particles in a particle accumulator while allowing the air flow to continue unimpeded. Since dust deposits may become molten at high temperatures, removal of dust from the core and secondary airflow may be critical for long-life superalloy and ceramic components, particularly those with small diameter air-cooling holes and thermal barrier coatings.

Abstract: A method of manufacturing a turbine engine component comprises the steps of fabricating an inner hub, casting a plurality of blades, forming a blade ring, and bonding the blade ring to the inner hub. Each blade comprises a blade root and an airfoil body extending from the blade root. The blade ring comprises, at least in part, the plurality of blades coupled by a first bonding technique. The blade ring is bonded to the inner hub using a second bonding technique.

Abstract: Compressor impellers, compressor sections, and methods of manufacturing compressor impellers and cooling the compressor impellers are provided. In an embodiment, and by way of example only, a compressor impeller includes a bore section and a rim section. The bore section comprises a first nickel-based alloy and includes an inner disk portion and a first plurality of blade portions extending therefrom. The rim section comprises a second nickel-based alloy and includes an outer disk portion and a second plurality of blade portions.

Abstract: A radial diffuser comprises a housing, a plurality of diffuser vanes, and a plurality of integral service vanes. The housing includes an air inlet and an air outlet, and defines a radial section extending radially outward from the air inlet, an axial section extending axially to the air outlet, and a transition including a bend and extending between the radial and axial sections. The diffuser vanes are coupled to the housing, and are disposed in, and define diffusion flow passages. The integral service vanes are coupled to the housing, extend around the bend, and define transition flow passages, each in fluid communication with at least one diffusion flow passage. At least some of the integral service vanes include a service passage extending therethrough and configured to allow a service conduit to extend therethrough without crossing either a diffusion flow passage or a transition flow passage.

Abstract: A gas turbine engine having a compressor rotor and turbine rotor in back-to-back relation and annular groove therebetween. A nonrotating seal is disposed in the groove. A dual pilot ring is disposed at the radial inner end of the groove. The dual pilot ring includes an inner annular ring and an outer annular ring radially spaced apart to define a clearance gap. The inner ring is mounted to radially facing piloting surfaces on both the compressor and turbine rotors and maintains concentricity between the two rotors as they grow at different thermal rates. The outer annular ring transfers axial loads between the rotors.

Abstract: A transition assembly for directing the gas flow from a combustor to an axial turbine includes a transition liner having a shroud disposed about its outer surface and abutting thereto at a plurality of points to defining a plurality of cooling air passages therebetween. The downstream end of the assembly is circumscribed by the first stage stator and extends axially to just upstream of the first stage turbine rotor. At this end a plurality of circumferentially spaced struts are mounted between the liner and the shroud to define a plurality of axially facing nozzles which are angled to impart a pre-swirl to the cooling air exiting therefrom.

Abstract: A turbine rotor is formed from a turbine disk having a rim with a circumferential direction, and a plurality of turbine blade segments each fixed to the turbine disk around a circumference of the rim of the turbine disk. The turbine blade segments are oriented such that the elastic modulus of the turbine blade segments parallel to the circumferential direction is less than that of the rim of the turbine disk parallel to the circumferential direction. This arrangement is preferably achieved using single crystal turbine blade segments made of an an alloy having a cubic crystal structure, such as a nickel-based superalloy, with a <010> direction oriented radially and a <001> direction oriented circumferentially.

Abstract: A bicast vane and shroud rings is provided in which thermal stresses are minimized. The vane has a flange portion along its inner and outer edge. These flange portions extend from the mid-chord of the vane part way towards the leading and trailing edges and follow the camber of the vane. Each of the flange portions has a width greater than that of the vane so has to form an overhang or lip about which conventional shroud rings are cast. As the flange portions approach the leading and trailing edges their width decreases and the overhang blends into the inner and outer edge to form rounded tops and bottoms at the leading and trailing edge. These rounded tops and bottoms reduce stress concentrations in the shroud rings and increase shroud material near these edges. Additionally, a stress relieving member is provided that embraces the top and bottom edges of the thin trailing edge, and inhibits the melting of the trailing edge during bicasting.

Abstract: A composite seal rotor is provided for sealing between the rotating components of a gas turbine engine held together by the compressive force of a lockup assembly and a housing circumscribing the rotating components and having carbon face seals mounted thereto. The seal rotor is comprised of a metal base portion disposed between two of said rotating components for transmitting said compressive force therethrough, and a ceramic surface for sealingly engaging said carbon face seal.

Abstract: A radial inflow rotor for a gas turbine engine has a dual structure for improving the low cycle fatigue life of the saddle region. The interior core or hub of the rotor is a high strength polycrystalline alloy while a series of outer blade segments is individually cast as single crystals and bonded so that their low modulus (100) crystallographic axis is aligned substantially tangential to the rotor's circumference at the saddle.