Abstract: A method of making a rotor assembly of a turbojet includes building the rotor assembly via layer-by-layer additive manufacturing. A turbine portion is formed and a compressor portion is integrally formed with the turbine portion. A shaft portion is integrally formed with the compressor portion. A material of the rotor assembly includes a nickel based alloy.

Abstract: A lubrication system for an attritable engine includes a bearing chamber, a fluid filtering inlet configured to receive a fluid, and a fluid filtering outlet located downstream of the fluid filtering inlet and configured to deliver the fluid to the bearing chamber. The lubrication system also includes a lattice, integral and conformal with the attritable engine, configured to filter the fluid, and located between the fluid filtering inlet and the fluid filtering outlet. The lubrication system also includes a metering port, configured to meter the fluid and located downstream of the lattice and upstream of the fluid filtering outlet.

Abstract: A combustor may comprise an outer wall defining, at least, a portion of a combustion chamber. A dilution chute may extend from an interior surface of the outer wall. A support structure may extend between the dilution chute and the interior surface of the outer wall. A spall plate may extend from the interior surface of the outer wall. The spall plate may be located between the support structure and an outlet of the combustion chamber.

Abstract: A method for forming a combustor of a gas turbine engine includes additively manufacturing a combustor wall of the combustor. The combustor wall includes a component, projecting from a surface of the combustor wall, and a support structure in communication with the component and the surface of the combustor wall. The support structure is a lattice structure.

Abstract: A unitary rub strip comprises a casing having an inner surface and an outer surface opposite the inner surface; a unitary rub strip is formed integral with the casing proximate the inner surface, wherein the unitary rub strip comprises a modified structure within the casing configured to abrade responsive to an interaction with a rotating element.

Abstract: An additively manufactured combustor shell may comprise a radially outward surface, a radially inward surface opposite the radially outward surface, and an injector port defining a fuel injection channel. The injector port may comprise an inlet structure extending from the radially outward surface, and an outlet structure may extending from the radially inward surface. A support structure may extend between the outlet structure and the radially inward surface. The support structure may be configured to vaporize upon ignition of a fuel within the combustion chamber.

Abstract: An adapter for connecting a cold-spray nozzle to a cold-spray machine includes a receiver having a first end and a second end and defining an internal space for receiving the cold-spray nozzle; an end cap engageable with the first end of the receiver for securing the cold-spray nozzle in the receiver and having an opening aligned with an outlet of the cold-spray nozzle; and a threaded connection at the second end of the receiver, the threaded connection being configured for connection to the cold-spray machine.

Abstract: A method for inspecting a component made using an additive manufacturing process, the component having an internal conduit, is disclosed. In various embodiments, the method includes the steps of: attaching a fluid-blocking header to the component, the fluid-blocking header having an internal conformal surface configured to mate with an external conformal surface of the component; introducing a plugging media into the internal conduit; activating the fluid-blocking header to freeze the plugging media in a vicinity of the fluid-blocking header; pressurizing the internal conduit of the component; and analyzing a fluid flow characteristic at an outlet of the component to assess an occurrence of a blockage within the internal conduit.

Abstract: An additively manufactured attritable engine includes a compressor section, a combustion section, a turbine section, and an engine case wall, which surrounds the compressor section, the combustion section, and the turbine section. The engine case wall includes a first cavity embedded in the engine case wall that defines an injector that is in fluid communication with the combustion section. The engine case wall includes at least one second cavity embedded within the engine case wall and defines at least one cooling channel that is in thermal communication through the engine case wall with the injector.

Abstract: An additively manufactured attritable engine includes a compressor section, a combustion section, a turbine section, and an engine case wall, which surrounds the compressor section, the combustion section, and the turbine section. The engine case wall includes a first cavity embedded in the engine case wall that defines an injector that is in fluid communication with the combustion section. The engine case wall includes a second cavity embedded within the engine case wall and defines a fuel feed passage that is in thermal communication through the exterior surface of the engine case wall.

Abstract: A turbine engine has: a compressor; a combustor; a turbine, a gas flowpath passing consecutively through the compressor, combustor, and turbine; and inlet member along the gas flowpath upstream of the compressor. The inlet member includes the unitarily-formed single piece combination of: a three dimensional (3D) lattice portion; and a nose cap body surrounding the lattice portion.

Abstract: A powder recoater for an additive manufacturing machine can include a body, a recoater blade extending downwardly from the body, and at least two distance probes attached to the body and configured to determine a distance to a build plate to determine if a recoater blade is parallel to the build plate and/or if a build plate is level. The at least two distance probes can be touch probes configured to determine if a build plate is contacting one or more of the probes. Any other suitable probe type is contemplated herein.

Abstract: An exhaust manifold for an additive manufacturing system can include a manifold housing, at least one baffle movable relative to the manifold housing configured to modify an exhaust flow area defined in part by the at least one baffle, and an actuator operatively connected to the at least one baffle configured to move the at least one baffle. The manifold housing can define a housing channel. The at least one baffle can be one or more moveable baffles at least partially disposed within the housing channel and configured to move relative to the housing to modify a respective exhaust flow area of a respective baffle of the one or more moveable baffles. The actuator can be operatively connected to each of the one or more movable baffles and configured to move the one or more movable baffles relative to the housing.

Abstract: A monolithic combustor apparatus comprises an outer casing comprising a forward flange, a fuel manifold disposed on the outer casing and defining an annular chamber extending perimetrically around the outer casing, a combustor liner disposed within the outer casing, the combustor liner defining an annular combustion chamber, a first annular plenum disposed between the outer casing and the combustor liner, an inner liner disposed radially from the combustor liner, a first inner flange extending forward from the combustor liner, and a second inner flange extending radially inward from the first inner flange.

Abstract: A method of manufacturing an additively manufactured component may comprise operating an additive manufacturing machine to form a first structure including an elongate portion having a blind design surface, operating the additive manufacturing machine to form a removal tool proximate the blind design surface, wherein the blind design surface and the removal tool are at least partially enclosed by and in contact with a support material, and translating the removal tool along the blind design surface to separate a portion of the support material from the blind design surface.

Abstract: A component is provided for a gas turbine engine. This component includes a monolithic body configured with an internal passage. The internal passage extends along a centerline within the monolithic body. The internal passage has a cross-sectional geometry perpendicular to the centerline. The cross-sectional geometry of at least a first portion of the internal passage has a teardrop shape.

Abstract: An attritable engine includes an engine case, which includes an outer wall and a fuel rail integral with the outer wall. The fuel rail includes a fuel line integral with the outer wall, a fuel ring configured to receive fuel from the fuel line, and an injector throat configured to receive aerated fuel from the fuel ring. The engine case includes counter distortion webbing defining the injector throat and is integral with the fuel rail and the outer wall. The engine case includes a combustion chamber configured to receive fuel from the injector throat.

Abstract: A health monitoring system for monitoring a lifecycle of an additively manufactured component having a microcrystalline structure that can be subjected to a cyclic operational stress is disclosed. The health monitoring system includes a plurality of additively manufactured health monitoring coupons disposed on the component in a representative position that is subjected to the cyclic operational stress, with the health monitoring coupons configured to be individually removable from the health monitoring system by precision machining.

Abstract: A gas shield for an additive manufacturing system includes a bracket and a flexible curtain mounted to the bracket. A method of additively manufacturing includes removably mounting a gas shield to at least partially segregate a powder dispenser and a chamber.

Abstract: An additive manufacturing method for an aircraft part having a polymer body and a metallic structural feature includes generating data defining the aircraft part with the metallic structural feature. A build process is determined for the polymer body of the aircraft part. The polymer body of the aircraft part is manufactured. A build path for a near net shape metallic structure is determined. The near net shape metallic structure is manufactured using an additive manufacturing process to direct metallic powder from a cold-spray nozzle on at least a section of the polymer body. The near net shape metallic structure is machined to provide the aircraft part having the polymer body and the metallic structural feature.