Abstract: A method of assembling a part is provided and includes forming a first section of the part, defining, in the first section, passages with dimensions as small as 0.005 inches (0.127 mm), forming a second section of the part, metallurgically bonding the first and second sections whereby the passages are delimited by the first and second sections and executing the metallurgically bonding without modifying a condition of the passages.

Abstract: A method of repair of a part is provided and includes removing a section that is damaged from the part, casting a replacement section for the part, the replacement section having a geometry similar to that of the section in an undamaged condition and bonding the replacement section to the part using field assisted sintering technology (FAST).

Abstract: An alloy comprising by weight percent: 16.0-26.0 Cr; 23.0-34.0 Mo; 21.0-31.0 Ta; 0.50-3.5 Ti; and 17.0-27.0 V.

Abstract: A method of assembling a part is provided and includes forming a first section of the part, defining, in the first section, passages with dimensions as small as 0.005 inches (0.127 mm), forming a second section of the part, metallurgically bonding the first and second sections whereby the passages are delimited by the first and second sections and executing the metallurgically bonding without modifying a condition of the passages.

Abstract: A coating system for a turbine engine component is disclosed. The coating system includes a substrate, an optional bond coat, a synthetic oxide layer and a top coat. The synthetic oxide layer is formed by atomic layer deposition and includes two or more oxides.

Abstract: A method of repair of a part is provided and includes removing a section that is damaged from the part, casting a replacement section for the part, the replacement section having a geometry similar to that of the section in an undamaged condition and bonding the replacement section to the part using field assisted sintering technology (FAST).

Abstract: An inspection method is provided during which an inspection device is inserted into an interior of a powerplant using a tool. The inspection device includes an actuator. The powerplant includes a component disposed within the interior of the powerplant. The inspection device is adhered to the component within the interior of the powerplant. Vibrations are induced in the component using the actuator. A vibratory response is measured in the component excited by the vibrations using a sensor to provide sensor data. A characteristic of the component is determined based on the sensor data.

Abstract: A method of forming a fuel cell layer includes forming a separator plate including a plurality of corrugations defining a plurality of anode flow channels at a first side of the separator plate and a plurality of cathode flow channels at a second side of the separator plate opposite the first side. A support layer is formed, including a porous portion and a solid portion at least partially surrounding the porous portion. The support layer and the separator plate are stacked, and the support layer is secured to the separator plate via a field-assisted sintering or spark plasma sintering (FAST) process.

Abstract: A method of inspecting an indirectly accessible cavity of a gas turbine engine is provided. The method includes memorizing a guide tube formed of smart metal alloy (SMA) into a bent shape and straightening the guide tube. The method also includes installing a scope, which includes a connecting line to which an inspection element is attached, into the guide tube. The method then includes inserting the guide tube into the gas turbine engine toward a location of the indirectly accessible cavity, heating the guide tube to cause the guide tube to return to the bent shape in order to bring the inspection element into the indirectly accessible cavity and using the inspection element to perform an inspection of the indirectly accessible cavity.

Abstract: A method of assembling a part is provided and includes forming a first section of the part, defining, in the first section, passages with dimensions as small as 0.005 inches (0.127 mm), forming a second section of the part, metallurgically bonding the first and second sections whereby the passages are delimited by the first and second sections and executing the metallurgically bonding without modifying a condition of the passages.

Abstract: In a method for manufacturing a turbine engine element such as a blade or vane, the element has an airfoil. The method includes: applying a load across an assembly of a first cast portion of the airfoil and a second cast portion of the airfoil; and applying current across a junction of the first cast portion and the second cast portion to fuse the second cast portion to the first cast portion.

Abstract: A gas turbine engine component having a substrate; a thermal barrier coating on the substrate having a porous microstructure; and a reflective layer conforming to the porous microstructure of the thermal barrier coating, wherein the reflective layer comprises a conforming nanolaminate defined by alternating layers of platinum group metal materials selected from the group consisting of platinum group metal-based alloys, platinum group metal intermetallic compounds, mixtures of platinum group metal with metal oxides and combinations thereof. A capping layer can be added over the reflective layer. A supporting layer can be added between the reflective layer and the thermal barrier coating. A process is also disclosed.

Abstract: A gas turbine engine component having a substrate; a thermal barrier coating on the substrate having a porous microstructure; and a reflective layer conforming to the porous microstructure of the thermal barrier coating, wherein the reflective layer comprises a conforming nanolaminate defined by alternating layers of platinum group metal materials selected from the group consisting of platinum group metal-based alloys, platinum group metal intermetallic compounds, mixtures of platinum group metal with metal oxides and combinations thereof. A capping layer can be added over the reflective layer. A supporting layer can be added between the reflective layer and the thermal barrier coating. A process is also disclosed.

Abstract: In a method for manufacturing a turbine engine element such as a blade or vane, the element has an airfoil. The method includes: applying a load across an assembly of a first cast portion of the airfoil and a second cast portion of the airfoil; and applying current across a junction of the first cast portion and the second cast portion to fuse the second cast portion to the first cast portion.

Abstract: A component of an aero-propulsion apparatus, wherein the component includes a material and has a surface, and a thin film on the surface, wherein the thin film is configured to undergo a detectible change in properties when exposed to a temperature exceeding a threshold temperature. Methods are also disclosed.

Abstract: A fabrication apparatus for fabricating ceramic structures of controlled size and composition is provided. The fabrication apparatus includes an additive manufacturing machine configured to dispense preceramic materials in a printed pattern, the printed pattern corresponding to the ceramic structures of the controlled size and composition, a radiation emitter configured to emit curing radiation toward the printed pattern to cure the preceramic materials and a lamp element configured to shine light on the preceramic materials to convert the preceramic materials to ceramics.

Abstract: A solid oxide fuel cell or solid oxide electrolyzer includes a plurality of fuel cell layers stacked along a stacking axis. Each fuel cell layer including a stacked arrangement of elements including a cathode, an anode, an electrolyte located between the anode and the cathode, a support layer positioned at the anode opposite the electrolyte, and a separator plate located at the support layer opposite the anode. The separator plate is configured to contact the cathode of an adjacent fuel cell layer of the plurality of fuel cell layers. The separator plate defines a plurality of anode flow channels configured to deliver a fuel therethrough and a plurality of cathode flow channels configured to deliver an air flow therethrough. The separator plate is formed from a bulk metallic glass material.

Abstract: An article comprises a first portion comprising a first alloy and a second portion comprising a second alloy that is metallurgically bonded to the first portion to form a monolithic article. The metallurgical bonding involves the application of an electrical current across the bond line and results in a retention of a metallurgical structure of the first portion and of a metallurgical structure of the second portion immediately adjacent to a bond line. The first portion has a first dominant property and the second portion has a second dominant property. The first dominant property is different from the second dominant property. The first dominant property is selected to handle operating conditions at a first position of the article where the first portion is located and the second dominant property is selected to handle operating conditions at a second position of the article where the second portion is located.

Abstract: A brake component is disclosed. In various embodiments, the brake component includes a ceramic matrix composite (CMC) structure including a plurality of nominally dense plies, interleaved with a plurality of interlayers, wherein the plurality of nominally dense plies and the plurality of interlayers are bonded by at least one of a Field Assisted Sintering Technique (FAST), a Spark Plasma Sintering (SPS) process, or a localized heating process. In various embodiments, the brake component is a rotor disk or a stator disk.

Abstract: An advanced passive clearance control (APCC) control ring is provided. The APCC control ring includes first and second cover sections, first and second wall sections and a control ring. At least one of the first and second cover sections is bonded to corresponding edges of the first and second wall sections by field assisted sintering technology (FAST) processing along a bond surface to form an enclosure for the control ring.