Abstract: One embodiment includes a fuel injector. The fuel injector assembly comprises a conduit for conveying fuel from a fuel inlet to a nozzle. The conduit is located in a support, with the conduit, the nozzle, and the support being a single unitary piece. A thermally compliant feature is located at the nozzle which allows the fuel injector to adjust for differential thermal expansion.

Abstract: An embodiment of an apparatus includes a centrifugal drive unit, an arm assembly, an optional dynamic balancing ring, and a workpiece fixture. The arm assembly is operatively connected to the centrifugal drive unit and configured to revolve about a primary axis perpendicular to the arm. The workpiece fixture is mounted to the arm assembly, and is configured to rotate at least one workpiece about at least one secondary axis outboard of the primary axis.

Abstract: A septum-tied tube pack is provided that includes a first outer wall formed by a multiple of first connected radiuses. A second outer wall is formed by a multiple of second connected radiuses. A first end radius connects the first outer wall and the second outer wall. A second end radius connects the first outer wall and the second outer wall. A multiple of septum elements extend between the first outer wall and the second outer wall. A gas turbine engine is also provided that includes an engine case structure and a fluid conduit mounted to the engine case structure. The fluid conduit includes a septum-tied tube pack section.

Abstract: A method is provided for additive manufacturing. This method includes monitoring a current to a recoater blade. The monitored current is compared to a predetermined current. An operation is initiated in response to the monitored current exceeding the predetermined current. Another method for additive manufacturing includes comparing a movement of a recoater blade to an expected movement. A single exposure sequence is initiated in response to movement of the recoater blade being different than an expected movement. An additive manufacturing system is also provided which includes a recoated blade and a control. The control is operable to identify resistance to movement of the recoater blade.

Abstract: A method of forming a metal component with two and three dimensional internal functionally graded alloy composition gradients includes forming the component by a powder based layer-by-layer additive manufacturing process. The areal composition distribution of each powder layer is determined by simultaneously depositing different powders and powder mixtures through a mixing valve attached to a single nozzle during powder deposition. The layers are then sintered with a directed energy source to form a forging preform. The preform is then forged to form a component.

Abstract: A method of forming a reinforced polymeric component includes securing a plurality of pins within a mold and wrap ping reinforcing fibers around the pins to form a web of reinforcing fibers. The web of reinforcing fibers has a plurality of layers. The method of forming a reinforced polymeric component further includes adding a polymer to the mold and processing the polymer to form a molded polymeric component that contains the pins and the web of reinforcing fibers. A reinforced polymeric component includes a web of reinforcing fibers wrapped around a plurality of pins. The web of reinforcing fibers includes a plurality of layers. The reinforced polymeric component further includes a molded and processed polymer containing the web of reinforcing fibers and pins.

Abstract: In various embodiments, a fuel injector may comprise a fuel nozzle and a pilot stage. The fuel nozzle may define a main fuel channel, a secondary fuel channel, a simplex fuel channel and a heat shield area. The main fuel channel may be disposed about at least a portion of the simplex fuel channel. The secondary fuel channel may be disposed about at least a portion of the simplex fuel channel. The heat shield area may be configured to separate and protect the fuel channels from a heat load to prevent fuel coking. The pilot stage may be operatively coupled to the fuel nozzle and may be configured to receive fuel from the secondary fuel channel or the simplex fuel channel. The main stage may be operatively coupled to the fuel nozzle. The main stage may be configured to receive fuel from the main fuel channel.

Abstract: A method includes designing a part. The part includes at least one internal structure. The internal structure is designed to provide strain mitigation, energy dissipation, or impact resistance for the part during an emergency condition. The part is built by a layer-by-layer additive manufacturing process. While building the part, the internal structure is connected to the part.

Abstract: A system for dispersing a catalyst in a fuel includes a first reservoir containing the fuel, and a second reservoir including an agitator and containing a quantity of the catalyst suspended in the fuel. The system also includes a first conduit extending from the first reservoir, a second conduit extending from the second reservoir, and a mixing nozzle connected to the first conduit and the second conduit. The mixing nozzle includes a first meter positioned within the first conduit, a second meter positioned within the second conduit, a valve positioned upstream from the second meter within the second conduit, a junction in flow communication with the first conduit and the second conduit, a mixer downstream from the junction, a sensor positioned between the mixer and an outlet; and a controller connected to the valve and the first and second meters, the controller receiving feedback from the sensor.

Abstract: A method includes building a tubular object by a layer-by-layer additive manufacturing process. A structure integrally connected to the tubular object for supporting a portion of the tubular object is formed during building of the tubular object. The structure provides vibration dampening, heat shielding, heat transfer, stiffening, energy absorption, or mounting after the tubular object is built.

Abstract: A heat exchanger article includes a hollow tube that has a tube wall with an interior surface and an exterior surface. The interior surface defines a flow passage through the hollow tube. The hollow tube also includes a vane cluster in the flow passage. The vane cluster includes a plurality of vanes and each of the vanes extends inwardly from the tube wall.

Abstract: A heat exchanger system for a gas turbine engine includes a plurality of fins; and an additively manufactured heat transfer tube that extends through the plurality of fins, the additively manufactured heat transfer tube follows a non-linear path though said plurality of fins.

Abstract: A damper-seal assembly for a gas turbine engine includes an additively manufactured seal and an additively manufactured damper inseparably assembled with the additively manufactured seal.

Abstract: A multi-component fastener is provided having a body and a sleeve. The body has a shank that extends lengthwise between a head and a distal end. The shank includes a first outer surface. The body includes a first material. The sleeve has a wall defined by an outer surface and an inner surface. The inner surface defines an interior cavity. The wall extends lengthwise between a first end and a second end. At least a portion of the sleeve outer surface contiguous with the first end is threaded. The sleeve includes a second material that is dissimilar to the first material. A portion of the shank including the distal end is disposed within the interior cavity of the sleeve. The sleeve and the shank are fixed to one another.

Abstract: An assembly is provided for a turbine engine. The assembly includes a fuel injector and a fuel vaporizer. A nozzle of the fuel injector is adapted to direct fuel to impinge against the fuel vaporizer. The fuel vaporizer is adapted to substantially vaporize the impinging fuel.

Abstract: A method of forming an object includes installing multiple foil drums within a processing chamber of an ultrasonic consolidation system. The multiple foil drums each include different materials than the other foil drums. The multiple foil drums are positioned so that one of the foils is selected to be placed on top of the build platform. The selected foil is welded onto the build platform or onto a previously processed layer. A portion of the welded foil is then cut. The multiple foil drums are retracted away from the build platform. The portion of the welded foil that was just cut is then consolidated to the object. The build platform is incrementally lowered before the process is repeated to form the next layer of the object.

Abstract: A heat exchanger assembly for a gas turbine engine including a frame, including a non-planar outer wall, a non-planar inner wall spaced radially inward from the non-planar outer wall to form a frame cavity therebetween, an inlet side extending between the non-planar outer wall and the non-planar inner wall, an inlet passage extending through the inlet side, an outlet side extending between the non-planar outer wall and the non-planar inner wall opposite the inlet side; an outlet passage extending through the outlet side, and a continuous non-planar core disposed within the frame cavity and in flow communication with the inlet passage and the outlet passage.

Abstract: A shrouded conduit is provided for arranging, for example, in a gas path of a turbine engine. The shrouded conduit includes a tubular shroud extending longitudinally along a centerline. The shrouded conduit also includes a fluid conduit extending longitudinally in the shroud. A first portion of the fluid conduit is connected laterally to and may be formed integral with a first portion of the shroud.

Abstract: A method is provided involving an additive manufacturing system. This method includes a step of forming a first fluid conduit using the additive manufacturing system. The method also includes a step of providing a fluid coupling. The fluid coupling includes the first fluid conduit and a second fluid conduit. The first fluid conduit is connected to and fluidly coupled with the second fluid conduit. The first fluid conduit has a first configuration. The second fluid conduit has a second configuration that is different than the first configuration.