Abstract: In accordance with an exemplary embodiment, a method of forming a dispersion-strengthened aluminum alloy metal includes the steps of providing a dispersion-strengthened aluminum alloy composition in a powdered form, directing a low energy density laser beam at a portion of the powdered alloy composition, and withdrawing the laser beam from the portion of the powdered alloy composition. Subsequent to withdrawal of the laser beam, the portion of the powdered alloy composition cools at a rate greater than or equal to about 106° C. per second, thereby forming the dispersion-strengthened aluminum alloy metal.

Abstract: An impeller or axial stage compressor disk backface shroud for use with a gas turbine engine is disclosed. The backface shroud includes, but is not limited to, a substantially funnel shaped body having a surface. The substantially funnel shaped body is configured to be statically mounted to the gas turbine engine substantially coaxially with the impeller or axial stage compressor disk. The surface and a backface of the impeller or axial stage compressor disk form a cavity that guides an airflow portion to a turbine when the substantially funnel shaped body is mounted coaxially with the impeller or axial stage compressor disk and axially spaced apart therefrom. The airflow portion has a tangential velocity and a recessed groove in the surface of the backface shroud is oriented generally transversely to the tangential velocity to at least partially interfere with the airflow portion, thus affecting static pressure in the cavity.

Abstract: In accordance with an exemplary embodiment, a method for manufacturing a component using additive manufacturing techniques includes providing a 3D design model for the component, adding one or more crack resistant features to the 3D design model of the component to produce an enhanced design model, and manufacturing the component using an additive manufacturing technique in accordance with the enhanced design model. The one or more crack resistant features are provided to reduce or eliminate the incidence of cracking in the manufactured component.

Abstract: A method is provided that includes depositing metal powder over a seed crystal having a predetermined primary orientation, scanning an initial pattern into the metal powder to melt or sinter the deposited metal powder, and re-scanning the initial pattern to re-melt the scanned metal powder and form an initial layer having the predetermined primary orientation. The method further includes depositing additional metal powder over the initial layer, scanning an additional pattern into the additional metal powder to melt or sinter at least a portion of the additional metal powder, re-scanning the additional pattern to re-melt a portion of the initial layer and the scanned deposited additional metal powder to form a successive layer having the predetermined primary orientation, and repeating the steps of depositing additional metal powder, scanning the additional pattern, and re-scanning the additional pattern, until a final shape of the component is achieved.

Abstract: A method is provided for manufacturing an engine component. The method includes providing a structural bridge device on a base block; forming a component portion on the structural bridge device with an additive manufacturing technique; removing the component portion from the base block and the structural bridge device; and finishing the component portion to form the engine component.

Abstract: A turbine rotor blade for a turbine section of an engine is provided. The rotor blade includes a platform and an airfoil extending from the platform into a mainstream gas path of the turbine section. The airfoil includes a pressure side wall, a suction side wall joined to the pressure side wall at a leading edge and a trailing edge, and a tip cap extending between the suction side wall and the pressure side wall. The rotor blade further includes an internal cooling circuit having a tip cap passage configured to deliver cooling air to the tip cap and a flow accelerator positioned within the tip cap passage of the internal cooling circuit.

Abstract: In accordance with an exemplary embodiment, a method of manufacturing a stator airfoil assembly includes forming an interior wall of a stator airfoil using an additive manufacturing technique, forming an exterior wall of the stator airfoil using the additive manufacturing technique, and forming a plurality of internal ribs between the interior wall and the exterior wall using the additive manufacturing technique. A cooling air circuit is formed in a space between the interior wall and the exterior wall. Further, the interior wall, the exterior wall, and the internal ribs are formed simultaneously as an integral structure by using the additive manufacturing technique.

Abstract: A turbine nozzle is provided and includes a first ring having a first microstructure, a vane extending from the first ring, a first porous zone between the first ring and the vane that is more porous than the first microstructure to attenuate thermo-mechanical fatigue cracking between the vane and the first ring. Methods of manufacturing the turbine nozzle are also provided.

Abstract: The disclosed embodiments generally relate to non-destructive evaluation methods. In an embodiment, a method for non-destructive evaluation of a aerospace component includes positioning a first plurality of sensors in the region of interest, positioning a second plurality of sensors in the region of interest, inducing a vibration in the region of interest using the first plurality of sensors and receiving a resonance frequency spectra using the second plurality of sensors, and comparing the received resonance frequency spectra against a reference spectra to determine the presence of an anomaly in the region of interest.

Abstract: Apparatus and methods are provided for converting methane in a feed stream to acetylene. A hydrocarbon stream is introduced into a supersonic reactor and pyrolyzed to convert at least a portion of the methane to acetylene. The reactor effluent stream may be treated to convert acetylene to another hydrocarbon process.

Abstract: Apparatus and methods are provided for converting methane in a feed stream to acetylene. A hydrocarbon stream is introduced into a supersonic reactor and pyrolyzed to convert at least a portion of the methane to acetylene. The reactor effluent stream may be treated to convert acetylene to another hydrocarbon process.

Abstract: Apparatus and methods are provided for converting methane in a feed stream to acetylene. A hydrocarbon stream is introduced into a supersonic reactor and pyrolyzed to convert at least a portion of the methane to acetylene. The reactor effluent stream may be treated to convert acetylene to another hydrocarbon process.

Abstract: Substantially defect-free titanium aluminide components and methods are provided for manufacturing the same from articles formed by consolidation processes. The method includes providing an intermediate article comprised of a titanium aluminide alloy and formed by a consolidation process. The intermediate article is encapsulated with an aluminum-containing encapsulation layer. The intermediate article is compacted after the encapsulation step. A substantially defect-free titanium aluminide component comprises a compacted three-dimensional article comprised of titanium aluminide and formed by a consolidation process and an aluminum-containing encapsulation layer on at least one surface of the compacted three-dimensional article. The aluminum-containing encapsulation layer comprises an aluminide material, MCrAlY wherein M is cobalt, nickel, or a combination of cobalt and nickel, or TiAlCr.

Abstract: A turbine blade includes an airfoil defined by a convex suction side wall, a concave pressure side wall, a leading edge, a trailing edge, a root, and a tip, the walls and the tip each including an interior surface that defines an interior with the root, the interior including an airfoil cooling circuit for directing airflow through the blade, and a platform supporting the airfoil and having a leading side edge, a trailing side edge, suction side edge, a pressure side edge, an airfoil-facing wall, and a root-facing wall, the platform including a platform cooling circuit having an inlet on the leading side edge and an outlet. The turbine blade may be included in a turbine rotor assembly.

Abstract: A method is provided for manufacturing a component. The method includes forming a diffusion coating on a first intermediate article formed by an additive manufacturing process. The diffusion coating is removed from the first intermediate article forming a second intermediate article. The diffusion coating is formed by applying a layer of coating material on at least one surface of the first intermediate article and diffusion heat treating the first intermediate article and the layer. The diffusion coating comprises a surface additive layer and a diffusion layer below the surface additive layer. The formation of the diffusion coating and removal thereof may be repeated at least once.

Abstract: A turbine blade includes a blade portion, the blade portion comprising a tip outer wall and a trailing edge, an internal cooling circuit, the internal cooling circuit being configured for directing cooling air within the blade portion, and a tip trailing edge slot positioned adjacent to the tip outer wall and the trailing edge, the tip trailing edge slot being fluidly connected to the internal cooling circuit. The tip outer wall is recessed at the tip trailing edge slot such that the tip outer wall is not provided over the trailing edge slot, thereby allowing cooling air to flow from the cooling circuit, into the trailing edge slot, and radially over the tip outer wall.

Abstract: A heat exchange system includes a first flow passage and a second flow passage. The heat exchange system is configured to transfer heat between a first fluid flowing through the first flow passage and a second fluid flowing through the second flow passage. The first flow passage includes an inlet header, a plurality of tubes, and an outlet header. The inlet header includes a plurality of header-tube transition portions configured to allow the first fluid to flow from the inlet header and into the tubes, the plurality of header-tube transition portions each including a smoothly curved inlet portion and a tapered tube connection portion.

Abstract: A method is provided for manufacturing a component. The method includes forming a diffusion coating on a first intermediate article formed by an additive manufacturing process. The diffusion coating is removed from the first intermediate article forming a second intermediate article having at least one enhanced surface. The diffusion coating is formed by applying a layer of coating material on at least one surface of the first intermediate article and diffusion heat treating the first intermediate article and the layer. The diffusion coating comprises a surface additive layer and a diffusion layer below the surface additive layer. The formation of the diffusion coating and removal thereof may be repeated at least once.

Abstract: A turbine component for a turbine of an engine is provided. The turbine component includes a blade portion of a first material; and an attachment portion coupled to the blade portion, the attachment portion being a second material.

Abstract: A seal plate for directing an airflow includes a hub, main pumping vanes, and splitter vanes. The hub has a tubular section and an annular flange section flared outwardly relative to the tubular section to define a flow surface. The main pumping vanes are disposed circumferentially on the flow surface around the annular flange section and each has a canted section located radially inward relative to a straight section and aligned with a flow direction of the airflow. The straight section extends along a first plane including a centerline of the seal plate. The splitter vanes are disposed circumferentially on the flow surface around the annular flange section such that at least one splitter vane is disposed between the straight sections of two adjacent main pumping vanes. Each splitter vane has a length that is less than a length of each of the two adjacent main pumping vanes.