Abstract: A method for manufacturing a workpiece 1, 2 uses a forming tool 4, 5 having a cavity 3. An embossing element 6 profiled on at least one surface is arranged on at least one surface of the forming tool 4, 5 for producing a surface structure, and with the profile of the embossing tool 6 is imparted to the surface of the workpiece 1, 2 during a forming process.

Abstract: A compressor blade 1 of a gas-turbine engine has a flow-exposed leading edge 2. A component 3, made of wear-resistant material and featuring a higher erosive wear resistance than the base material, is attached to at least part of a length of the leading edge 2 The component 3 forming the flow-exposed leading edge 2 is strip-shaped, has an essentially rectangular cross-section and, with reference to a sectional plane perpendicular to the radial direction, is arranged only on an inflow side of the compressor blade profile in a partial area of a sectional surface of the inflow area.

Abstract: A gas-turbine engine fan blade made of a textile composite material includes short carbon fiber intermediate layers (8) for forming the blade root arranged between splayed carbon fiber layers (7) in the blade root (2). In a compressive stress-affected zone (11) of the blade root, the fiber layers extend parallel to the flanks (12) of the blade root. The diversion of the carbon fiber layers (7) up to the splayed area is effected in a transition area (13). A glass fiber outer layer (10) arranged on the flanks (12) of the blade root gradually runs out at a transition zone (15) of the transition area (13), this zone being diverted at a certain radius. Between the glass fiber outer layer and the outer carbon fiber layer there is a carbon fiber layer (9) oriented at +/?45°.

Abstract: An axial-flow compressor for a gas turbine engine has a rotor drum (2) in thermally lower loaded first compressor stages (3 to 6) which includes a one-piece ring, or rotor rings (7 to 10) attached to one another. Fiber belts (18, 21) are wound onto these rings close to the rotor blades and include carbon fibers embedded in a high-temperature resistant polymer matrix. As the rotor disks can be dispensed with, since their function will be assumed by the fiber belts, the compressor features low weight, requires limited space only, and, in addition, can be produced cost-effectively.

Abstract: On an engine shaft of hybrid design with an externally toothed power transmission element (3) connected at the ends of a fiber-composite plastic tube (2), the power transmission element is of a two-part design and includes a toothed part (5) made of steel of a specific hardness and, frontally weldedly connected thereto, a tapering adapter part (7) enclosed by a fiber-composite material to form a scarf-type joint and having a thermal expansion approximately equal to the expansion behavior of the fiber-composite material. This ensures, also at elevated temperatures, safe connection between the fiber-composite material and the power transmission element, as well as transmission of high forces.

Abstract: A titanium sheet to be formed is heated in a sealingly closed tool by the radiation heat from the heating elements integrated into the tool to a forming temperature not exceeding 600° C., and is deformed towards a cold tool contour by the action of a non-oxidizing gaseous pressure medium introduced into the tool and heated to the hot-forming temperature, as well as by underpressure generated on the side of the workpiece facing away from the pressure medium.

Abstract: The intake cone for a gas-turbine engine is wound in one piece from fiber compound material with fiber layers crossing one another. It is provided with a fiber compound belt, wound in the circumferential direction of the intake cone, in the connecting area with a mounting flange, which is of segmented design and thus features reduced circumferential stiffness, of a metallic retaining ring attached to a fan rotor disk. The intake cone is easily manufacturable with almost constant wall thickness and in high quality, can reliably be subjected to non-destructive testing and, in combination with the mounting flange, which is flexible in the radial direction, ensures safe connection of the two components despite the different thermal and elastic behavior of the respective materials.

Abstract: An abradable labyrinth seal for a fluid-flow machine seals a sealing gap between a stationary carrier (9) provided with an abradable lining (10) of porous material formed by hollow bodies (11) and a rotary component (4) provided with sealing fins (8) oriented towards the abradable lining. In a preferred embodiment, elongated hollow bodies (11) conforming in shape and size are linearly arranged as an ordered cellular structure side by side and one above the other in x, y and z directions and are interfacially or fully interfacially connected to each other with or without open pores (12). The hollow bodies (11) are arranged such that the tips of the sealing fins (8) are approximately centrally oriented to the hollow bodies (11).

Abstract: A method for joining components in TiAl with a braze includes heating the braze with a laser.

Abstract: In a supersonic area, on a leading edge (2) of a compressor blade (1) for a gas turbine engine, a replaceable, longitudinally elastically deformable leading edge rail (7) with slender tip (11) and limited weight is positively held in a locating groove (3) and at a stop (6) and elastically locked by the curved blade form. While the maintenance effort is reduced, safe operation and long service life of the compressor (fan) are ensured.

Abstract: With a method for manufacturing welded rotors for a turbine, especially a gas-turbine engine, in which two or more rotor disks are joined to each other by conventional welding processes using welds extending radially to the rotor axis and the weld zone is subsequently thermally treated at a certain temperature to relieve residual tensile stresses by relaxation, the weld is set to a significantly lower non-relaxatory temperature level than the heat-affected zone adjoining the weld so that, as a result of the high temperature gradient, a residual compressive stress or at least a substantially reduced residual tensile stress is impressed on the weld. Compared to conventionally heat treated and welded rotors, improved strength properties in the weld zone and an increased service life are obtained as a result of the reduced tensile stresses.

Abstract: A hybrid component for a gas-turbine engine includes a supporting structure (2) in fiber-composite material and a metallic structure (3) intimately connected to the latter via a thin highly elastic intermediate layer (7) made of thermoplastic polyurethane. The highly elastic material not only provides for a firm connection between the metallic structure and the supporting structure, but also for an absorption of the in-service vibrations and a compensation of the different expansion behavior of the fiber-composite material and the metal. Furthermore, a concentrated load applied to the component by an impinging foreign body is converted by the highly elastic intermediate layer into an area load, thereby substantially reducing the hazard of damaging the supporting structure due to crack formation.

Abstract: When manufacturing hybrid components, especially the fan blades or stator vanes of an aircraft gas turbine including a metallic enveloping structure and a supporting structure in fiber-composite material, the mating faces of the metallic structure are cleaned and roughened with plasma prior to fitting the fiber-composite material and the metallic molecules activated so that high attractive forces take effect and an intimate, extremely strong adhesive connection is produced between the metal and the fiber-composite material. Fan blades or stator vanes of the fan structure of a gas-turbine engine which are manufactured according to this method are capable of transmitting high loads and feature a long service life.

Abstract: A low-pressure turbine shaft (11) for a gas-turbine engine includes a fiber-composite plastic tube (13) with fiber layers provided in an inner wall area for taking up and transmitting torsional forces, and, in an outer wall area, with fiber layers suitably oriented for influencing stiffness and damping characteristics. The fiber layers are embedded in a high temperature resistant plastic matrix. A load input element (14) is an attachment flange (24) made of fiber-composite plastic material integrally formed on a fiber-composite plastic tube (13). A load output element (15) is a metallic driven protrusion inseparably connected to the fiber layers transmitting the torsional forces. Alternatively, the load input element may be provided as a metallic driving protrusion, which is firmly connected to the fiber layers taking up the torsional forces.

Abstract: On a low-pressure turbine shaft made of fiber-composite material, the connection to the metallic driven protrusion or the driving protrusion (1), respectively, is made via an adapter (3) formed onto the latter, with pylons (6) extending beyond the circumferential area of the latter and on which the fibers (4) are deflected and guided in accordance with the fiber orientation in the fiber-composite material, enabling high torsional forces to be transmitted via the small connecting zone.

Abstract: For the manufacture of a tubular low-pressure turbine shaft made of a fiber-composite material with metallic driven/driving protrusions (2) attached to its ends, the fiber material is wound onto a winding core (4) provided in the form of a closed tube and made of high-strength material and onto a conically tapered adapter (3) formed on the driven/driving protrusion. By expanding the winding core with a pressurized liquid medium, the fiber material embedded in a synthetic resin is compacted as a function of the design of the winding body and the liquid pressure. Upon curing of the synthetic resin at elevated temperature the winding core is pressure-relieved and removed with reduced diameter.

Abstract: A method for manufacturing a stator vane 7 of a stator vane cascade 6 of a fan structure of an aircraft gas turbine, includes circumferentially welding two essentially flat metallic sheets 10, 11. A space between the sheets 10, 11 is formed in an injection mold by a filling pressure during a plastics injection process.

Abstract: A method for manufacturing integrally bladed rotors by laser brazing a rotor disk (1) made of a nickel or titanium-base material to blades (3) made of titanium aluminide. A brazing metal similar to the blade material is used, which is introduced into the laser beam (4) as brazing power jet (5) and whose heat capacity, which is controlled by the melting temperature and the volume of the molten metal bath This provides for melting of the disk material and alloying with this material, but not for melting of the blade material, to which it is connected by adhesion. Such blisk features a low blade weight, reduced centrifugal effects and enhanced service life.

Abstract: With the manufacture of turbine engine rotor drums, the opposite joining surfaces of rotor disks are brought into contact and at least one of the two rotor disks clamped into a fixture is set in a circular movement until the joining areas reach a pasty state due to the frictional heat. The circular movement of the rotor disks, in which the axis of the rotor disk moves along a circular path, is optically recorded and deviations due to imbalance are corrected by weight compensation at the fixture. Upon reaching the pasty material state the joining areas weld together, with the rotor disks being at rest and in axial alignment. Manufacture is cost-effective and guarantees precise axial alignment of the rotor disks and a long service life of the engine rotor drums.

Abstract: The manufacture or repair of blisks, in particular high-pressure turbine blisks for gas-turbine engines is accomplished by producing a joint between the rotor disk and the pre-manufactured blades by circular friction welding. Due to the small forces and the low acceleration required for heat generation by friction and the balanced circular movement during frictional welding at a constant setting angle between disk and rotor, exact and uniform arrangement and alignment of the blades on the periphery of the rotor disk are possible even with small and complex joining surfaces of the turbine blades and with dissimilar materials.