Abstract: A process for producing an internal cavity in a CMC article and mandrels used therewith. The process entails incorporating a mandrel made of a fusible material that is melted and drained during a thermal treatment of a CMC preform to form the CMC article. The mandrel material is preferably non-wetting and non-reactive with any constituents of the CMC preform during the thermal treatment. The mandrel is preferably tin or an alloy of tin.

Abstract: A turbomachine system includes a rotor that defines a longitudinal axis of the turbomachine system. A first blade is coupled to the rotor, and the first blade has first and second laminated plies. A first band is coupled to the first blade and is configured to resist separation of the first and second laminated plies.

Abstract: An injection system includes a plurality of actuators. Each of the actuators is configured to move one or more portions of a center body of the fuel injector. The system also includes a controller configured to control each of the plurality of actuators individually to change a flow rate or a direction of output of a mixture of fuel and air from an output of the center body of the fuel injector.

Abstract: A method of applying a barrier coating to a component is provided. The method includes providing the component and preparing a slurry comprising a mixture. The mixture includes about 50-90 percent by volume fraction of a barrier coating composition, the barrier coating composition and 10-50 percent by volume fraction of a plurality of short fibers. The method includes applying at least one layer of the slurry to at least a portion of the component and curing the slurry on the portion of the component to obtain a fiber-reinforced barrier coating.

Abstract: A fiber composite assembly and a process of fabricating a fiber composite assembly are disclosed. The fiber composite assembly includes a first composite layer having a first fiber and a second composite layer having a second layer. The first fiber includes a helical portion and the second fiber extends to within the helical portion of the first fiber. A process of fabricating a fiber composite assembly includes elongating a wound fiber preform to form a helical fiber or positioning the first fiber in the first composite layer and positioning the second fiber in the second composite layer.

Abstract: A gas turbine blade may have a bond coat applied to its surface. A porous substrate may be applied to the bond layer and one or more protective layers may be applied to the bond layer such that the fiber mesh is embedded between the bond layer and the protective layer to prevent creep.

Abstract: A turbine blade assembly is disclosed. In one embodiment, the turbine blade assembly may generally include a turbine blade having a root portion and an airfoil. The airfoil may extend radially from the root portion to an airfoil tip. Additionally, the turbine blade assembly may include a composite rod extending within the turbine blade. The composite rod may include a first end coupled to the airfoil at the airfoil tip and a second end coupled to the root portion. Moreover, the coefficient of thermal expansion of the composite rod may be designed to be less than or equal to the coefficient of thermal expansion of the airfoil.

Abstract: A laser machining system useful for machining internal cavities where visual monitoring is difficult or impossible may include a laser generator, a rod configured to extend from and retract towards the laser generator, an articulated mirror mounted on the rod and configured to reflect a laser beam generated by the laser generator, one or more sensors, and a controller that may receive data from the sensor and determine how and whether to manipulate, based on the data, the rod and the articulated mirror to direct the laser beam generated by the laser generator.

Abstract: A method for adhering a coating to a substrate structure comprises selecting a substrate structure having an outer surface oriented substantially parallel to a direction of radial stress, modifying the outer surface to provide a textured region having steps to adhere a coating thereto, and applying a coating to extend over at least a portion of the textured region, wherein the steps are oriented substantially perpendicular to the direction of radial stress to resist deformation of the coating relative to the substrate structure. A rotating component comprises a substrate structure having an outer surface oriented substantially parallel to a direction of radial stress. The outer surface defines a textured region having steps to adhere a coating thereto, and a coating extends over at least a portion of the textured region. The steps are oriented substantially perpendicular to the direction of radial stress to resist creep.

Abstract: A turbine bucket that includes a platform and an airfoil extending radially outward from the platform. The airfoil includes a root segment and a tip segment. The root segment includes a first end and a second end. The root first end extends from a radially outer surface of the platform. The root segment extends from the root first end to the root second end. The tip segment includes a tip first end and a tip second end. The tip first end is removably coupled to the root second end. The tip segment extends outward from the root second end to the tip second end.

Abstract: In certain embodiments of the present disclosure a method for modifying a composite article is described. The method includes positioning a plug made from composite material at a site on the composite article. The method further includes rotating at least one of the plug and the article at a rate of speed sufficient to form an inertia bond between the plug and the site of the composite article. The plug and the site are engaged to effect an inertia bond therebetween.

Abstract: A nozzle for a turbine includes a duct member having a substantially uniform wall thickness. Nozzles made of different materials can be used.

Abstract: Methods for repairing a turbine airfoil constructed from a CMC material are provided via filling a cavity located in the turbine airfoil with a ceramic paste (e.g., including a ceramic powder and a binder), heating the ceramic paste in the cavity to remove the binder, thereby forming a porous ceramic material, and adding a molten ceramic material to the porous ceramic material. The cavity can be defined in an airfoil of the turbine airfoil (e.g., on a tip or cap of the airfoil). Intermediates formed during the repair of a turbine airfoil are also provided. The intermediate can generally include an airfoil comprising a CMC material, a cavity defined in the airfoil, and a porous ceramic material filling the cavity.

Abstract: A method for manufacturing a composite includes perforating an outer ply to create perforations through the outer ply and inserting a filler material into the perforations. The method further includes laminating the outer ply to an inner ply.

Abstract: A system for reinforcing a substrate includes a rotary device, a first guide connected to the rotary device, and a form positioned against the first guide. A reinforcement is supplied to wind around the form and against the first guide. A method for reinforcing a substrate includes connecting a first guide to a rotary device and positioning a form on a first side of the first guide. The method further includes winding a reinforcement around the form and against the first side of the first guide.

Abstract: A turbine shroud assembly is disclosed, the shroud assembly including an outer shroud, at least one inner shroud attached to the outer shroud, and at least one discourager enclosed within the inner shroud. The discourager prevents the hot gas or steam in the turbine from having a direct line of access to the outer shroud. In one embodiment, one inner shroud is provided for the shroud assembly, with one discourager enclosed within the inner shroud, the discourager positioned offset from the inner shroud so as to extend past the inner shroud and into an inner shroud of a neighboring shroud assembly. In another embodiment, a plurality of inner shrouds are provided, each inner shroud enclosing a discourager, the discouragers being adjacent to each other within the inner shrouds and positioned offset from the inner shrouds so as to cover a gap between the inner shrouds.

Abstract: A turbine blade assembly is disclosed. In one embodiment, the turbine blade assembly may generally include a turbine blade having a root portion and an airfoil. The airfoil may extend radially from the root portion to an airfoil tip. Additionally, the turbine blade assembly may include a composite rod extending within the turbine blade. The composite rod may include a first end coupled to the airfoil at the airfoil tip and a second end coupled to the root portion. Moreover, the coefficient of thermal expansion of the composite rod may be designed to be less than or equal to the coefficient of thermal expansion of the airfoil.

Abstract: A system for reinforcing a substrate includes a rotary device, a first guide connected to the rotary device, and a form positioned against the first guide. A reinforcement is supplied to wind around the form and against the first guide. A method for reinforcing a substrate includes connecting a first guide to a rotary device and positioning a form on a first side of the first guide. The method further includes winding a reinforcement around the form and against the first side of the first guide.

Abstract: A process of forming a material having nano-particles and a material having nano-particles are disclosed. The process includes arranging nano-particles in a predetermined pattern within a matrix material. The material includes arranged nano-particles forming a predetermined pattern in the matrix material.

Abstract: Aspects of the invention provide for an aperture reinforcement structure. In one embodiment, a composite laminate is disclosed, including: a first sheet of material having a first aperture therein; a second sheet of material having a second aperture therein corresponding to the first aperture; and a reinforcement structure having: a continuous fiber including a plurality of convolutions affixed to at least one of the first sheet of material or the second sheet of material, the plurality of convolutions surrounding at least one of the first aperture or the second aperture; and a resin binding the plurality of convolutions to one another.