Abstract: A method (56) for fabricating an integral assembly (24) is disclosed. The method comprises providing (56) a first workpiece (26) having a first surface (46) and a second workpiece (28) having a second surface (50), performing a first bonding process between the first surface (46) of the first workpiece (26) and the second surface (50) of the second workpiece (28) to form a sub-assembly workpiece (48), and performing a second bonding process between a third surface (52) of the sub-assembly workpiece (48) and a fourth surface (54) of a third workpiece (30) to form the integral assembly (24). The material properties of the first workpiece (26) are different from material properties of the third workpiece (30).

Abstract: A method of diffusion bonding two components together comprises providing a first component having a first bonding surface, and a second component having a second bonding surface. Each of the first bonding surface and the second bonding surface is etched. A cold working process is applied to each of the first bonding surface and the second bonding surface. Each of the first bonding surface and the second bonding surface is then etched. The first component is positioned adjacent to the second component with the first bonding surface abutting against the second bonding surface, to define a joint surface between the first component and the second component. A peripheral edge of the joint surface is sealed. The first bonding surface is diffusion bonded to the second bonding surface.

Abstract: A method of attaching a projection to a thin walled component, the thin walled component having a first surface and an opposite second surface, the method comprises the steps of: (i) providing a thin walled component; (ii) identifying a first position on the first surface of the thin walled component; (iii) building a hollow thin walled lattice structure on the second surface at a second position using a liquid metal deposition process, the second position corresponding to the first position; and (iv) building a projection on the first surface at the first position using a liquid metal deposition process.

Abstract: A powder deposition apparatus for producing a component comprises a base plate, an annular stack of heating elements, accommodating the base plate, one or more insulating elements, being interleaved between adjoining heating elements, a mechanism operable to deposit a plurality of layers of a powder material onto the base plate, and a laser energy source operable to selectively fuse a portion of the deposited layer. The annular stack of heating elements is sized such that a predetermined clearance is defined between the component and the annular stack of heating elements. As successive layers of the powder material are deposited onto the base plate, the base plate is lowered into the stack of heating elements, the heating elements being actuated sequentially to maintain a pre-determined temperature profile in the deposited layers.

Abstract: A method of manufacturing a component from a nickel-based superalloy comprises the steps of: providing a vacuum induction casting furnace; positioning a component mould onto a chill plate within the furnace; casting a component blank; peening the surface of the component blank; applying a surface modification technique to the surface of the component blank; solution heat treating the component blank at or above the ??-solvus temperature for the superalloy; and precipitation heat treating the component blank.

Abstract: A method (56) for fabricating an integral assembly (24) is disclosed. The method comprises providing (56) a first workpiece (26) having a first surface (46) and a second workpiece (28) having a second surface (50), performing a first bonding process between the first surface (46) of the first workpiece (26) and the second surface (50) of the second workpiece (28) to form a sub-assembly workpiece (48), and performing a second bonding process between a third surface (52) of the sub-assembly workpiece (48) and a fourth surface (54) of a third workpiece (30) to form the integral assembly (24). The material properties of the first workpiece (26) are different from material properties of the third workpiece (30).

Abstract: The present invention relates to a method of forming a three-dimensional component by additive layer manufacturing. The method comprises scanning a fusing energy beam having a fusing beam focus spot across a layer of powered material in a series of fusing scan lines to fuse the powder material to form a layer of fused material whilst scanning a heating energy beam having a heating beam focus spot in a series of heating scan lines across the material fused by the fusing energy beam. The centre of the fusing beam focus spot and the centre of the heating beam focus spot are off-set from one another and spaced by up to an amount equal to the sum of the radius (y) of the heating beam focus spot and two times the radius (x) of the fusing beam focus spot.

Abstract: A method of manufacturing an article, the method comprising: controlling an additive manufacturing printer to build an article in a cavity of a build chamber from a powdered material, the build chamber being removable from the additive manufacturing printer and including one or more heaters configured to provide thermal energy to the cavity of the building chamber; and controlling the one or more heaters of the build chamber to heat the article to a predetermined temperature while building the article to prevent the article from cracking while the build chamber and the article are transferred from the additive manufacturing printer to a heater, the predetermined temperature being between the upper temperature of the ductility drop temperature range of the powdered material and the sintering temperature of the powdered material.

Abstract: A method of manufacturing a component from a nickel-based superalloy comprises the steps of: providing a vacuum induction casting furnace; positioning a component mould onto a chill plate within the furnace; casting a component blank; peening the surface of the component blank; applying a surface modification technique to the surface of the component blank; solution heat treating the component blank at or above the ??-solvus temperature for the superalloy; and precipitation heat treating the component blank.

Abstract: A method of attaching a projection to a thin walled component, the thin walled component having a first surface and an opposite second surface, the method comprises the steps of: (i) providing a thin walled component; (ii) identifying a first position on the first surface of the thin walled component; (iii) building a hollow thin walled lattice structure on the second surface at a second position using a liquid metal deposition process, the second position corresponding to the first position; and (iv) building a projection on the first surface at the first position using a liquid metal deposition process.

Abstract: A powder deposition apparatus for producing a component comprises a base plate, an annular stack of heating elements, accommodating the base plate, one or more insulating elements, being interleaved between adjoining heating elements, a mechanism operable to deposit a plurality of layers of a powder material onto the base plate, and a laser energy source operable to selectively fuse a portion of the deposited layer. The annular stack of heating elements is sized such that a predetermined clearance is defined between the component and the annular stack of heating elements. As successive layers of the powder material are deposited onto the base plate, the base plate is lowered into the stack of heating elements, the heating elements being actuated sequentially to maintain a pre-determined temperature profile in the deposited layers.

Abstract: An arrangement for heating and cooling a turbine casing of a gas turbine engine, the arrangement comprising an inboard duct, adjacent to an inboard surface of the turbine casing, an outboard facing wall of the inboard duct having a plurality of impingement holes opening towards the inboard surface of the casing, through which temperature control fluid can pass from within the inboard duct to impinge upon the inboard surface of the turbine casing.

Abstract: An arrangement for heating and cooling a turbine casing of a gas turbine engine, the arrangement comprising an inboard duct, adjacent to an inboard surface of the turbine casing, an outboard facing wall of the inboard duct having a plurality of impingement holes opening towards the inboard surface of the casing, through which temperature control fluid can pass from within the inboard duct to impinge upon the inboard surface of the turbine casing.

Abstract: A method is disclosed for measuring the crystallographic orientation of a component cast by a directional solidification process. The method comprises the steps of: illuminating at least a region of the component surface with substantially coherent light, measuring the mean angle and intensity of the light reflected from the component surface, and correlating said mean angle and intensity to the crystallographic orientation of the component. The method has been found to lend itself particularly well to automation.

Abstract: A mould for use in directionally solidifying a component has a casting cavity including a single crystal selector spiral which is a helical passage having not less than 1¼ and not more than 1½ turns.

Abstract: A method is disclosed for measuring the crystallographic orientation of a component cast by a directional solidification process. The method comprises the steps of: illuminating at least a region of the component surface with substantially coherent light, measuring the mean angle and intensity of the light reflected from the component surface, and correlating said mean angle and intensity to the crystallographic orientation of the component. The method has been found to lend itself particularly well to automation.

Abstract: A deflector element is provided, in order to improve temperature interface control with respect to directional solidification of a component casting. This deflector element is formed during the mould making process and is arranged to be positioned with respect to a part of a principal mould formation within which the final cast component is produced. The deflector element ensures a uniform temperature throughout the component cross-section relative to other parts of the component as it is solidified.

Abstract: A deflector element 3,13 is provided, in order to improve temperature interface control with respect to directional solidification of a component casting. This deflector element 3,13 is formed during the mould making process and is arranged to be positioned with respect to a part 6 of a principal mould formation 2,12 within which the final cast component is produced. The deflector element 3,13 ensures a uniform temperature throughout the component cross-section relative to other parts of the component as it is solidified.