Abstract: A fuel injector provided for gas turbine engine has a nozzle including pilot fuel and mains fuel discharge orifice's for respectively spraying pilot and mains fuel flows into a combustor of the engine. The injector further has a feed arm extending to the nozzle for feeding fuel to the pilot and mains discharge orifices from pilot and mains supplies respectively. The nozzle and the feed arm contain one or more pilot passages for flow of the pilot fuel flow from the pilot supply to the pilot discharge orifice and one or more mains passages for flow of the mains fuel flow from the mains supply to the mains discharge orifice. The nozzle and the feed arm contain a plurality of the pilot passages and/or a plurality of the mains passages. The pilot and the mains passages intertwine repeatedly, and are both smoothly curved as they intertwine around each other.

Abstract: The manufacture of a casing which has a boss includes providing two canister portions a first defining an outer wall geometry of a casing including a boss and a second defining an inner wall geometry of the casing. The casing is made using known PHIP methods. The second canister portion includes an array of holes or recesses which, when the canister portions are aligned, face a recess on the first canister portion which defines the boss such that in the nett shape COS an array of pedestals is provided aligned with the boss. The dimension from an exposed end of a pedestal to an exposed surface of the boss is sufficient to receive a bolt thread of the minimum length required to secure a component to the boss.

Abstract: A method for the manufacture of a component of defined geometry from two or more materials using a powder bed ALM process includes providing a bed of a first powdered material, selectively fusing portions of the first powdered material to build up a first three dimensional portion of the component geometry and fusing a powder containment bund from the first material to contain unfused first powdered material. A bed of a second powdered material is deposited onto the powder containment bund and selectively fused to build up a second three dimensional portion of the component geometry. Unfused first powdered material can subsequently be removed from a first side of the bund and unfused second powder from a second side of the bund. Remaining parts of the bund which do not form part of the defined geometry of the component can be removed to provide the net shape component.

Abstract: A method of forming a plurality of components by additive layer manufacturing includes forming at least one annular support structure joining the plurality of components with the plurality of components being spaced around the circumference of at least one annular support structure. Concentric inner and outer annular supports may be provided.

Abstract: An energy source for an additive manufacturing arrangement comprises a workpiece and a powder delivery device. The energy source is characterised in that it comprises a plurality of discrete energy sources. The plurality of discrete energy sources may be coordinated in use to deliver energy simultaneously to a plurality of regions of the workpiece in a matrix form.

Abstract: A fuel injector provided for gas turbine engine has a nozzle including pilot fuel and mains fuel discharge orifice's for respectively spraying pilot and mains fuel flows into a combustor of the engine. The injector further has a feed arm extending to the nozzle for feeding fuel to the pilot and mains discharge orifices from pilot and mains supplies respectively. The nozzle and the feed arm contain one or more pilot passages for flow of the pilot fuel flow from the pilot supply to the pilot discharge orifice and one or more mains passages for flow of the mains fuel flow from the mains supply to the mains discharge orifice. The nozzle and the feed arm contain a plurality of the pilot passages and/or a plurality of the mains passages. The pilot and the mains passages intertwine repeatedly, and are both smoothly curved as they intertwine around each other.

Abstract: A powder bed additive layer manufacturing apparatus for manufacturing a component, the apparatus including a base plate including a set of axes X, Y, Z and a first re-coater blade. The base plate includes a build surface for receiving powder, and the build surface includes a non-planar surface profile for complementing the shape of a component non-planar surface. The first re-coater blade has a blade profile that corresponds with a non-planar surface profile of the build surface. The first re-coater blade is configurable such that it can traverse across the build surface, for providing a layer of powder having a consistent depth across the non-planar build surface during the manufacturing process.

Abstract: A method for the manufacture of a component having a defined geometry and dimensions is described. In sequence, the steps of the method involve; a) using an additive layer manufacturing process, budding a three-dimensional net shape of the component; b) applying a subtractive surface finishing operation to the product of step a); c) applying a heat treatment to the product of step b) whereby to provide a component to the defined geometry and dimensions.

Abstract: A method for the manufacture of a component of defined geometry from two or more materials using a powder bed ALM process includes providing a bed of a first powdered material, selectively fusing portions of the first powdered material to build up a first three dimensional portion of the component geometry and fusing a powder containment bund from the first material to contain unfused first powdered material. A bed of a second powdered material is deposited onto the powder containment bund and selectively fused to build up a second three dimensional portion of the component geometry. Unfused first powdered material can subsequently be removed from a first side of the bund and unfused second powder from a second side of the bund. Remaining parts of the bund which do not form part of the defined geometry of the component can be removed to provide the net shape component.

Abstract: An apparatus and method for performing an ALM process is described. A first energy beam source (1) provides an energy beam (1b) which selectively melts a substrate powder (3) into a melt pool. A second energy beam source (2) provides an energy beam (2b) to heat condition substrate powder proximate to the melt pool. The path of the second energy beam (2b) is controlled by a controller (6) to oscillate independently of the path followed by the first energy beam (1b). The method may be applied to control and optimise heating and cooling rates of the sintered substrate during the ALM process enabling its microstructure to be controlled to suit the end use of the product and reduce the occurrence of residual stresses and consequent crack propagation.

Abstract: The manufacture of a casing which has a boss includes providing two canister portions a first defining an outer wall geometry of a casing including a boss and a second defining an inner wall geometry of the casing. The casing is made using known PHIP methods. The second canister portion includes an array of holes or recesses which, when the canister portions are aligned, face a recess on the first canister portion which defines the boss such that in the nett shape COS an array of pedestals is provided aligned with the boss. The dimension from an exposed end of a pedestal to an exposed surface of the boss is sufficient to receive a bolt thread of the minimum length required to secure a component to the boss.

Abstract: A combustion chamber includes at least one annular wall. The annular wall includes a plurality of segments and each segment has a first portion, a second portion and a third portion. The first portion of each segment extends circumferentially, the third portion of each segment extends circumferentially and the second portion of each segment extends radially to connect the first portion and third portion of the segment. The segments are arranged such that the first portion of each segment overlaps the third portion of an adjacent segment and the first portion of each segment is bolted to the third portion of the adjacent segment. The segments are cast and define a double wall combustion chamber and enable easier construction of the combustion chamber and replacement of damaged segments.

Abstract: A head part of an annular gas turbine combustion chamber including: an end wall with a passage opening for accommodating a burner, the end wall including a set back portion adjacent the passage opening; a heat shield covering a back side of the end wall which faces towards the combustion chamber, the heat shield including a protruding portion shaped to cooperate with the set back portion of the end wall; and a burner collar adapted to fit within the passage opening and receive a burner, the burner collar including a protruding portion radially protruding from an outer surface of the burner collar; wherein the head part of the annular gas turbine combustion chamber is configured such that in an installed configuration the protruding portion of the burner collar is held between the protruding portion of the heat shield and the set back portion of the end wall.

Abstract: A coated turbine engine article having a first wall and a second wall, wherein the first wall has a shielding feature integral with the article and which inhibits entry of a coating material into an open passage extending between the first wall and the second wall when the coating material is directed towards the article using a line of sight process.

Abstract: A method of forming an aperture in an article includes directing a laser at the article and traversing the high energy beam to form a cut extending along the periphery of the aperture in a first direction to a second point on the periphery and then reversing the direction of cutting along the periphery till the aperture is formed.

Abstract: A combustion chamber includes at least one annular wall. The annular wall includes a plurality of segments and each segment has a first portion, a second portion and a third portion. The first portion of each segment extends circumferentially, the third portion of each segment extends circumferentially and the second portion of each segment extends radially to connect the first portion and third portion of the segment. The segments are arranged such that the first portion of each segment overlaps the third portion of an adjacent segment and the first portion of each segment is bolted to the third portion of the adjacent segment. The segments are cast and define a double wall combustion chamber and enable easier construction of the combustion chamber and replacement of damaged segments.

Abstract: A head part of an annular gas turbine combustion chamber including: an end wall with a passage opening for accommodating a burner, the end wall including a set back portion adjacent the passage opening; a heat shield covering a back side of the end wall which faces towards the combustion chamber, the heat shield including a protruding portion shaped to cooperate with the set back portion of the end wall; and a burner collar adapted to fit within the passage opening and receive a burner, the burner collar including a protruding portion radially protruding from an outer surface of the burner collar; wherein the head part of the annular gas turbine combustion chamber is configured such that in an installed configuration the protruding portion of the burner collar is held between the protruding portion of the heat shield and the set back portion of the end wall.

Abstract: A securing system is provided for securing a component to a gas turbine engine casing. The system has a core engine casing formed from a front casing portion and a rear casing portion. The casing portions have respective casing flanges at which the casing portions are detachably joined together. The system further has a component flange extending from a component. The component flange is configured so that, when the casing portions are joined together, the component flange is trapped between the casing flanges. One of the casing flanges projects inwards from the casing to form an airtight seal with the component flange on the inside of the casing. The other of the casing flanges projects outwards from the casing to form an airtight seal with the component flange on the outside of the casing.

Abstract: A method of removing a deposit from a passage extending through a component includes immersing the passage within a liquid, and directing a liquid jet at the passage from a source within the liquid bath and with a sufficient velocity so as to remove at least a portion of the deposit.

Abstract: A method of joining a first article to a second article using adjustment features located in an assigned scrap portion of the first article. The first article can be a casing for a turbine engine the first article being the casing skin and the second article a flange. The adjustment features are springs that can be stretched to increase the circumference of the skin. Following the correct sizing of the skin and joining to the flange the attachment features are removed along with the assigned scrap portion of the skin.