Abstract: An exhaust duct for an engine includes an outer exhaust duct and a nested exhaust duct capable of having at least two configurations. The nested exhaust duct is circumferentially surrounded by the outer exhaust duct for a first length of the nested exhaust duct in a first configuration. The nested exhaust duct is circumferentially surrounded by the outer exhaust duct for a second length of the nested exhaust duct in a second configuration, which is less than the first length.

Abstract: An abrasive flow machining (AFM) system includes a first abrasive media reservoir, means for connecting the first abrasive media reservoir to an additive manufacturing (AM) system build plate, and means for directing abrasive media from the first abrasive media reservoir through the plurality of abrasive media flow channels in the AM system build plate into a plurality of flow channels in the structure. The AM system build plate includes a unitized additive structure built on the AM system build plate during an AM system build campaign and a plurality of abrasive media flow channels extending entirely through a thickness of the AM system build plate to facilitate an in-process surface finishing operation.

Abstract: A stator vane for a gas turbine engine combustor has a vane segment that includes a vane having a leading edge, a trailing edge, a suction side, a pressure side, a vane inner base, and a vane outer base, an inner shroud segment attached to the vane at the vane inner base, and an outer shroud segment attached to the vane at the vane outer base. The stator vane further includes a support structure attached to the vane at a vane trailing edge, and a first weld shield attached to the support structure by a first connector. The first weld shield is positioned over and spaced away from the suction side. The vane, inner shroud segment, outer shroud segment, support structure, and first weld shield are integrally formed during a single, continuous additive manufacturing process.

Abstract: A powder bed fusion (PBF) additive manufacturing (AM) machine includes a build plate configured to function as a platform to support one or more parts built using the PBF AM machine. The build plate further includes a thermal history indicator positioned on the build plate, attached to the build plate, or physically integrated with the build plate such that the thermal history indicator experiences the same temperature as the build plate. The thermal history indicator is configured to display a durable visual indication of achievement of a temperature associated with a post-processing step performed after the one or more parts are built on the build platform.

Abstract: A stator vane for a gas turbine engine combustor has a vane segment that includes a vane having a leading edge, a trailing edge, a suction side, a pressure side, a vane inner base, and a vane outer base, an inner shroud segment attached to the vane at the vane inner base, and an outer shroud segment attached to the vane at the vane outer base. The stator vane further includes a support structure attached to the vane at a vane trailing edge, and a first weld shield attached to the support structure by a first connector. The first weld shield is positioned over and spaced away from the suction side. The vane, inner shroud segment, outer shroud segment, support structure, and first weld shield are integrally formed during a single, continuous additive manufacturing process.

Abstract: A build powder characterization system for an additive manufacturing (AM) machine includes a build powder collection system, a build powder analyzer, and a controller. The build powder collection system configured to collect build powder during an AM machine build campaign. The build powder analyzer configured to receive from the build powder collection system the collected build powder, to analyze selected build powder properties, and to communicate to a controller data reflecting properties of the collected build powder. The controller is configured to process data, received from the build powder analyzer, reflecting properties of the collected build powder.

Abstract: A method of manufacturing a nested combustor liner includes manufacturing a nested combustor liner into a green state including a plurality of annular interior walls radially adjacent to one another and circumferentially surrounding an exhaust duct aperture and a plurality of annular exterior walls radially adjacent to one another and radially spaced apart from and circumferentially surrounding the plurality of annular interior walls and an ignitor wall attached to a first annular interior wall at a first interior end, extending radially toward and attached to a first annular exterior wall at a first exterior end. The method includes assembling the plurality of annular interior walls and the plurality of annular exterior walls, forming an assembled combustor liner. The method includes densifying the assembled combustor liner.

Abstract: A method of repairing a stator stage is disclosed herein. The method includes receiving a stator stage including a plurality of stator vanes disposed between an outer diameter and an inner diameter, analyzing the stator stage for defects, determining based on the analysis that there is a first defect on an edge of a first stator vane of the plurality of stator vanes, removing a portion of the first stator vane including the first defect to form a first scallop on the edge of the first stator vane, repairing the first stator vane including filling the first scallop to fill the first stator vane to its original size and shape creating a repaired portion, and performing a blending process to the stator stage including the first stator vane and the repaired portion to smooth the plurality of stator vanes.

Abstract: A method for repairing a stator stage is disclosed herein. The method includes receiving a stator stage including a plurality of stator vanes disposed between an outer diameter and an inner diameter, analyzing the stator stage for defects, determining there is a first defect in a first segment of a the stator stage, the first segment including at least one of a first portion of the outer diameter, a first portion of the inner diameter, or a first stator vane, removing the first segment from the stator stage forming a void in the stator stage, manufacturing a second segment that is the same size as the first segment, attaching the second segment to the stator stage to fill the void, performing a blending process on the stator stage including the second segment to smooth the plurality of stator vanes including the second stator vane.

Abstract: A build plate for a powder bed fusion-laser (PBF-L) additive manufacturing system has a support region and a top region. The top region is formed on the support region by a cold spray process, such that the top region is under a compressive stress. The build plate can be prepared by preparing the build plate support region to receive the top region and depositing, using a cold spray process, a layer of metal on the support region. The layer of metal is formed with a compressive stress to form the top region. The top region is then machined to provide a desired surface roughness.

Abstract: An assembly is provided for a turbine engine. This engine assembly includes a combustor, an engine case, a support structure and a monolithic body. The combustor includes a combustor wall and a combustion chamber within the combustor. The combustor wall forms a peripheral boundary of the combustion chamber. The engine case forms a peripheral boundary of a plenum along the combustor. The support structure extends radially from the combustor wall to the engine case. The monolithic body includes the combustor wall, the engine case, the support structure and a plurality of ports arranged circumferentially about an axis. Each of the ports is fluidly coupled with the plenum and projects axially through the support structure. The ports include a first port. The first port includes a cross-sectional geometry that laterally tapers as the first port extends radially outward within the monolithic body.

Abstract: A method for determining whether build powder is fit for reuse in a laser powder bed fusion additive manufacturing (LPBF) process includes constructing a model for determining a Powder Reuse Index indicative of whether build powder is fit for reuse in the LPBF process based upon LPBF process operating parameters. A build design is selected to be built using the LPBF process to collect data for constructing the model for determining the Powder Reuse Index. A plurality of test pieces the selected build design are built using a LPBF system with different layouts or set ups. Quality characteristics are determined for each of the plurality of test pieces and, using the quality characteristics for each of the plurality of test pieces, a relative importance of each LPBF process build parameter as to whether a batch of build powder is fit for reuse is determined.

Abstract: A method of fabricating a tooling fixture suitable for use in infiltrating a fibrous preform includes generating a model of the tooling fixture, the model being conformal and complementary to a geometry of the fibrous preform, additively manufacturing the tooling fixture by extruding a carbon-containing ink in a layer-by-layer manner, and consolidating the extruded carbon-containing ink to form a consolidated tooling fixture.

Abstract: A unitized build assembly for a gas turbine engine includes an exhaust duct, a hot section with a locking structure and including a combustor and turbine section. The hot section at least partially circumferentially surrounds the exhaust duct. The build assembly includes a compressor section with an interface structure and is proximal to the hot section. The hot section at least partially circumferentially surrounds at least part of the compressor section and the locking structure is configured to engage the interface structure to limit movement of the hot section relative to the compressor section.

Abstract: An exhaust duct for an engine includes an outer exhaust duct and a nested exhaust duct capable of having at least two configurations. The nested exhaust duct is circumferentially surrounded by the outer exhaust duct for a first length of the nested exhaust duct in a first configuration. The nested exhaust duct is circumferentially surrounded by the outer exhaust duct for a second length of the nested exhaust duct in a second configuration, which is less than the first length.

Abstract: A core engine article includes a combustor liner defining a combustion chamber therein and a turbine nozzle. The combustor liner includes a plurality of injector ports, and the plurality of injector ports have a shape that tapers to a corner on a forward side of the injector ports. The turbine nozzle includes a plurality of airfoils. The combustor liner and turbine nozzle are integral with one another. A method of making a core engine article is also disclosed.

Abstract: An additively manufactured attritable engine includes an engine case, a fuel ring integral and conformal with the engine case, and a fuel manifold attached to the fuel ring and configured to deliver fuel to the fuel ring. The engine also includes a fuel injector attached to the fuel ring and configured to receive fuel from the fuel ring.

Abstract: An assembly is provided for a turbine engine. This engine assembly includes a combustor, an engine case, a support structure and a monolithic body. The combustor includes a combustor wall and a combustion chamber within the combustor. The combustor wall forms a peripheral boundary of the combustion chamber. The engine case forms a peripheral boundary of a plenum along the combustor. The support structure extends radially from the combustor wall to the engine case. The monolithic body includes the combustor wall, the engine case, the support structure and a plurality of ports arranged circumferentially about an axis. Each of the ports is fluidly coupled with the plenum and projects axially through the support structure. The ports include a first port. The first port includes a cross-sectional geometry that laterally tapers as the first port extends radially outward within the monolithic body.

Abstract: An exhaust duct for an engine includes an outer exhaust duct and a nested exhaust duct capable of having at least two configurations. The nested exhaust duct is circumferentially surrounded by the outer exhaust duct for a first length of the nested exhaust duct in a first configuration. The nested exhaust duct is circumferentially surrounded by the outer exhaust duct for a second length of the nested exhaust duct in a second configuration, which is less than the first length.

Abstract: An attritable engine includes an engine case, which includes an outer wall and a fuel rail integral with the outer wall. The fuel rail includes a fuel line integral with the outer wall, a fuel ring configured to receive fuel from the fuel line, and an injector throat configured to receive aerated fuel from the fuel ring. The engine case includes counter distortion webbing defining the injector throat and is integral with the fuel rail and the outer wall. The engine case includes a combustion chamber configured to receive fuel from the injector throat.