Abstract: An electroformed sheath for protecting an airfoil includes a sheath body and a mandrel insert is provided. The sheath body includes a leading edge. The sheath body includes a pressure side wall and an opposed suction side wall, which side walls meet at the leading edge and extend away from the leading edge to define a cavity between the side walls. The sheath body includes a head section between the leading edge and the cavity. The mandrel insert is positioned between the pressure side and suction side walls, and includes a generally wedge-shaped geometry. A method for protecting an airfoil includes: 1) securing a mandrel insert to a mandrel; 2) electroplating a sheath body onto the mandrel and the mandrel insert; 3) removing the mandrel from the sheath body so that a sheath cavity is defined within the sheath body; and 4) securing the airfoil within the sheath cavity.

Abstract: A composite component and a plated polymer component are disclosed. The composite component may comprise a body portion formed from an organic matrix composite, a first metal coating applied to a surface of the body portion, and an outer metal layer on the first metal coating that is erosion-resistant. The plated polymer component may comprise a polymer substrate, a metal plating layer applied to a surface of the polymer substrate, and at least one selectively thickened region in the metal plating layer. The at least one selectively thickened region may assist in protecting the plated polymer component against wear and/or erosion.

Abstract: A method for balancing a rotatable component is disclosed This method comprises and then plating the component to deposit a metal layer onto the component until the component is balanced. In addition, and alternative method for balancing a rotatable component is disclosed. This method comprises attaching a balancing weight to the rotatable component and rotating the component. This is followed by plating the component and the balancing weight to deposit a metal layer onto the balancing weight and the component until the component is balanced.

Abstract: A rotary blade is provided that includes a root, an airfoil, and a tip insert. The airfoil is attached to the root, and has a suction side surface, a pressure side surface, a leading edge, a trailing edge, a tip, and a slot disposed within the tip. The slot extends in a chordwise direction between the leading edge and trailing edge. The tip insert has a base end and a rub end. The base end of the tip insert is disposed within the slot. The rub end of the tip insert extends radially outward from the airfoil tip.

Abstract: A protective coating for a surface exposed to hot gas flow comprises a thermal layer, a conducting layer and an abrasive layer. The thermal layer comprises alumina having a sufficient amount of impurities to lower the thermal layer thermal conductivity. The layer is formed from a powder having a thermal conductivity no more than 10 BTU in/hr ft2° F., and overlies the surface. The conducting layer overlies the thermal layer. The abrasive layer comprises abrasive particles bonded in a metal matrix that is electroplated onto the conducting layer.

Abstract: A composite component and a plated polymer component are disclosed. The composite component may comprise a body portion formed from an organic matrix composite, a first metal coating applied to a surface of the body portion, and an outer metal layer on the first metal coating that is erosion-resistant. The plated polymer component may comprise a polymer substrate, a metal plating layer applied to a surface of the polymer substrate, and at least one selectively thickened region in the metal plating layer. The at least one selectively thickened region may assist in protecting the plated polymer component against wear and/or erosion.

Abstract: The present disclosure relates generally to a fan blade assembly. In an embodiment, the fan blade assembly includes an airfoil having a forward edge covered by a sheath. The airfoil and the sheath are made from dissimilar conductive materials. A nonconductive coating is applied to at least one of the sheath receiving surface of the airfoil and/or the airfoil contact surface of the sheath before the sheath is bonded to the airfoil.

Abstract: A vented plated polymer component is disclosed. The vented plated polymer component may comprise a polymer substrate, a metal plating deposited on a surface of the polymer substrate, and at least one vent formed through the metal plating. The at least one vent may extend from an outer surface of the metal plating to the surface of the polymer substrate, and it may be sized to allow an escape of a gas from the polymer substrate to an external environment surrounding the plated polymer component.

Abstract: An airfoil includes an aluminum airfoil body with a pressure side, suction side, leading edge and trailing edge; and a titanium foil layer covering at least part of one of the pressure side and the suction side.

Abstract: Aviation components comprising a polymeric substrate having an outer surface wherein a metal is plated onto the outer surface to form a plated layer are disclosed. A method to make aviation components comprising a polymeric substrate having an outer surface and where a metal is plated onto the outer surface is disclosed. An over-plated heating element for shedding ice from an aircraft component having a polymeric substrate with a pocket to receive a heating element, a metal deposited onto the substrate, a heating element positioned within the pocket and a covering layer deposited onto the heating element and the plated layer is disclosed.

Abstract: Plated polymeric gas turbine engine parts and methods for fabricating lightweight plated polymeric gas turbine engine parts are disclosed. The parts include a polymeric substrate plated with one or more metal layers. The polymeric material of the polymeric substrate may be structurally reinforced with materials that may include carbon, metal, or glass. The polymeric substrate may also include a plurality of layers to form a composite layup structure.

Abstract: A plated polymer component is disclosed. The plated polymer component may comprise a polymer substrate having an outer surface, a metal plating attached to the outer surface of the polymer substrate, and at least one interlocking feature connecting the polymer substrate and the metal plating. The interlocking feature may improve the interfacial bond strength between the polymer substrate and the metal plating.

Abstract: A method for fabricating a ceramic component is disclosed. The method may comprise: 1) forming a polymer template having a shape that is an inverse of a shape of the ceramic component, 2) placing the polymer template in a mold; 3) injecting the polymer template with a ceramic slurry, 4) firing the ceramic slurry at a temperature to produce a green body, and 5) sintering the green body at an elevated temperature to provide the ceramic component.

Abstract: A method for balancing a rotatable component is disclosed This method comprises and then plating the component to deposit a metal layer onto the component until the component is balanced. In addition, and alternative method for balancing a rotatable component is disclosed. This method comprises attaching a balancing weight to the rotatable component and rotating the component. This is followed by plating the component and the balancing weight to deposit a metal layer onto the balancing weight and the component until the component is balanced.

Abstract: A tip region of an airfoil has a wear coating that is deposited using physical vapor deposition in conjunction with a mechanical mask. The mask is positioned with respect to the region portion of the tip to expose only a portion of the tip region to be coated. A physical vapor deposition coating source such as cathode arc (CAT ARC) is used to coat the exposed portion of the tip region with the wear coating.

Abstract: A method of stripping gamma/gamma prime polycrystalline alloy bond coats from single crystal gamma/gamma prime nickel based superalloys, including the steps of grit blasting followed by the use of hydrochloric acid solutions, followed by rinsing. The cycle may be repeated several times, with visual inspection between cycles.

Abstract: An electroformed sheath for protecting an airfoil includes a sheath body and a mandrel insert is provided. The sheath body includes a leading edge. The sheath body includes a pressure side wall and an opposed suction side wall, which side walls meet at the leading edge and extend away from the leading edge to define a cavity between the side walls. The sheath body includes a head section between the leading edge and the cavity. The mandrel insert is positioned between the pressure side and suction side walls, and includes a generally wedge-shaped geometry. A method for protecting an airfoil includes: 1) securing a mandrel insert to a mandrel; 2) electroplating a sheath body onto the mandrel and the mandrel insert; 3) removing the mandrel from the sheath body so that a sheath cavity is defined within the sheath body; and 4) securing the airfoil within the sheath cavity.

Abstract: A process for improving the adherence of a thermal barrier coating to a substrate includes the steps of providing a substrate, depositing a masking layer of aluminum, an aluminum alloy, or titanium alloy, or titanium on a surface of the substrate, depositing a non-thermally grown oxide layer of alumina or titania on the masking layer, and depositing a thermal barrier coating on the oxide layer.

Abstract: A method for protecting a fan blade with an airfoil, a tip, a root and a sheath, the root to be inserted into a hub includes peening the airfoil of the blade; inserting a scrim cloth between the fan blade and the sheath to galvanically isolate the fan blade from the sheath; bonding the sheath to the blade with an epoxy adhesive; peening the blade root; bonding wear pads to the root with epoxy adhesive to galvanically isolate the root from the hub; applying a protective cover to the tip of the blade; and applying a coating to all exposed areas of the blade to inhibit corrosion.

Abstract: A disk made of a first material has a groove in which a blade made of a second material is retained. A strip is placed between the blade and the disk to minimize rubbing damage to the blade and the disk and an insulating material is place between the rub strip and the blade for minimizing damaging responses of the blade to galvanic forces created by rubbing of the first material and the second material.