Abstract: A turbopump such as a liquid oxygen (LOX) turbopump for a liquid rocket engine is formed using a metal additive manufacturing process in which a single-piece impeller is formed within a single piece housing, the impeller being trapped within the single piece housing. The impeller is formed with an axial bore in which a shaft is inserted after the impeller and housing have been formed. The turbopump includes a protective coating that forms a reaction resistant surface on the base metal in areas of the base metal that are exposed to an oxidizer during pumping. The protective coating may be an enamel glass, a superalloy layer beneath an enamel glass layer, a composite layer of a mixture of enamel glass and superalloy, a composite mixture of oxide and superalloy, or a composite layer of a mixture of enamel glass, superalloy, and oxide.

Abstract: A turbopump for a liquid rocket engine in which an oxidizer is pumped, where the turbopump is formed with a single piece rotor within a single piece housing by a metal additive manufacturing process, and where surfaces exposed to the oxidizer is coated with enamel glass to provide a smooth surface over the rough printed surface and to provide burn resistance to the base metal from exposure to the oxidizer such as oxygen. A Mondaloy coating can be used below the enamel glass coating to add additional burn resistance to the base metal.

Abstract: A gas turbine engine with a closed-loop liquid metal cooling fluid system for cooling stator vanes within the turbine, in which the stator vanes are made of a metallic material that will not react with the liquid metal cooling fluid. The stator vane may be made from a typical metal material such as ferrous metal alloys, nickel alloys or cobalt (Co) alloys, and an insert or liner made of molybdenum or tantalum may be placed inside to protect the outer vane material from reacting with a liquid metal such as bismuth, lead (Pb), indium, or alloy mixtures of thereof. In the case where the liquid coolant is bismuth, the liquid bismuth must be purged from the cooling system before the fluid cools and solidifies so the solidified bismuth does not expand and break the vanes.

Abstract: A gas turbine engine with a closed loop liquid metal cooling fluid system for cooling stator vanes within the turbine, in which the stator vanes include a liquid metal cooling passage lined with Tantalum or Molybdenum and a liquid metal cooling fluid of Bismuth or Lead or Zinc or Tin or alloy mixtures of these metals.

Abstract: The present invention relates to a method for forming an article having a protective ceramic coating which reduces radiation heat transport through the ceramic coating. The protective ceramic coating includes one or more embedded reflective metallic layers for reducing the radiation heat transport. The method for forming the protective coating broadly comprises the steps of forming a ceramic coating on a substrate and embedding at least one reflective metallic layer within the ceramic coating.

Abstract: The present invention relates to a method for forming an article having a protective ceramic coating which reduces radiation heat transport through the ceramic coating. The protective ceramic coating includes one or more embedded reflective metallic layers for reducing the radiation heat transport. The method for forming the protective coating broadly comprises the steps of forming a ceramic coating on a substrate and embedding at least one reflective metallic layer within the ceramic coating.

Abstract: The present invention relates to a method for forming an article having a protective ceramic coating which reduces radiation heat transport through the ceramic coating. The protective ceramic coating includes one or more embedded reflective metallic layers for reducing the radiation heat transport. The method for forming the protective coating broadly comprises the steps of forming a ceramic coating on a substrate and embedding at least one reflective metallic layer within the ceramic coating.

Abstract: The present invention relates to a method for forming an article having a protective ceramic coating which reduces radiation heat transport through the ceramic coating. The protective ceramic coating includes one or more embedded reflective metallic layers for reducing the radiation heat transport. The method for forming the protective coating broadly comprises the steps of forming a ceramic coating on a substrate and embedding at least one reflective metallic layer within the ceramic coating.

Abstract: A gas turbine abradable seal is prepared by plasma spraying an oxidation resistant metallic material and boron nitride. The resultant structure comprises a metallic matrix encompassing a lubricating amount of boron nitride, with porosity of less than about 15 percent and a fabricated surface roughness of less than about 600 microinches. The reduced surface roughness and substantially reduced permeability of this seal provide substantially enhanced engine efficiency, and improved durability.

Abstract: A thermal barrier coating for high temperature applications has improved resistance to heat flow. The coating comprises a large number of these (nanometer scale) layers separated by interfaces which are effective in retarding heat flow. The coating material will typically be oxide based ceramics and the coating has particular applications in gas turbine engines.

Abstract: A gas turbine abradable seal is prepared by plasma spraying an oxidation resistant metallic material and boron nitride. The resultant structure comprises a metallic matrix encompassing a lubricating amount of boron nitride, with porosity of less than about 15 percent and a fabricated surface roughness of less than about 600 microinches. The reduced surface roughness and substantially reduced permeability of this seal provide substantially enhanced engine efficiency, and improved durability.

Abstract: Gas turbine engine coatings must often be removed during engine maintenance and repair. The techniques utilized to accomplish this task, machining, chemical stripping, machining followed by chemical stripping, or grit blasting, frequently result in component damage or destruction. Liquid jet erosion can be utilized to remove seals, coatings, or portions thereof without damaging the engine hardware.

Abstract: Gas turbine engine coatings must often be removed during engine maintenance and repair. The techniques utilized to accomplish this task, machining, chemical stripping, machining followed by chemical stripping, or grit blasting, frequently result in component damage or destruction. Liquid jet erosion can be utilized to remove seals, coatings, or portions thereof without damaging the engine hardware.