Abstract: A method of generating a smooth optimized part design for a workpiece is presented. Topology optimization is performed based on design objectives, to generate surface data describing an optimized but unfinished surface of the workpiece. The surface data is used to generate volumetric data describing the workpiece structure. A three dimensional smoothing filter is applied to the volumetric data. A manufacturing design is generated from the resulting smoothed volumetric data.

Abstract: An illustrative example container includes a plurality of internal support members having a surface contour that at least approximates a minimum surface. The plurality of internal support members collectively provide structural support for carrying loads on the container. The plurality of internal support members collectively establish a plurality of cavities for at least temporarily containing fluid. An outer shell is connected with at least some of the internal support members. The outer shell includes a plurality of curved surfaces. The outer shell encloses the cavities.

Abstract: An electrochemical machining system comprises a component having a passage, the passage has an opening and an internal surface formed along the passage, a conductive wire has insulation covering portions of the conductive wire forming gaps having exposed wire; the conductive wire is inserted in the passage; a power source is coupled to the component and the conductive wire forms an electrical circuit, wherein the component comprises an anode and the conductive wire comprises a cathode; and an electrolyte within the passage contacting the internal surface and the exposed wire, wherein the electrolyte comprises a charge-carrying liquid configured to complete the electrical circuit between the cathode and anode.

Abstract: A pressure vessel configured to store a pressurized fluid is provided including a plurality of lobes. Each lobe includes at least one vertically arranged interior wall. The plurality of lobes are positioned in a side by side configuration such that a first interior wall of a first lobe is positioned adjacent a second interior wall of a second adjacent lobe. The first interior wall and the second interior wall are configured to contact one another at a first point of tangency. A first tangent intersects the first lobe at the first point of tangency and a second tangent intersects the second lobe at the first point of tangency. The first tangent and the second tangent are separated by about 120 degrees.

Abstract: An embodiment of a fan blade includes an interior region between a metallic pressure sidewall and a metallic suction sidewall. Each sidewall extends in span from a base to a tip, and extends in chord from a leading edge to a trailing edge. The interior region of the fan blade includes a first fully dense metallic portion and a first porous metallic portion. The first fully dense metallic portion has a volume occupying at least 10% of a total volume of the interior region, and substantially no porosity. The first porous metallic portion is integrally joined to the fully dense metallic portion, and is selected from a structured lattice, an unstructured foam, and combinations thereof.

Abstract: A heat transfer system is disclosed that includes a plurality of electrocaloric elements (12) including an electrocaloric film (14), a first electrode (16) on a first side of the electrocaloric film, and a second electrode (18) on a second side of the electrocaloric film. A fluid flow path (20) is disposed along the plurality of electrocaloric elements, formed by corrugated fluid flow guide elements (19).

Abstract: A multi-layer structure includes a substrate with a surface and with particles partially covering and partially embedded in the surface. The particles have high thermal conductivity and low electrical conductivity. A dielectric layer on the surface partially covers the partially embedded particles. A metal layer on the dielectric layer covering the partially covered particles forms a thermal interface material (TIM) for electronic packaging applications.

Abstract: A method of generating a smooth optimized part design for a workpiece is presented. Topology optimization is performed based on design objectives, to generate surface data describing an optimized but unfinished surface of the workpiece. The surface data is used to generate volumetric data describing the workpiece structure. A three dimensional smoothing filter is applied to the volumetric data. A manufacturing design is generated from the resulting smoothed volumetric data.

Abstract: A ceramic component retention system includes a metallic component, a ceramic component, and at least one spring element arranged between the metallic component and the ceramic component. The metallic component has a first coefficient of thermal expansion, and the ceramic component has a second coefficient of thermal expansion. The at least one spring element is configured to mechanically couple the ceramic component to the metallic component.

Abstract: A ceramic component retention system includes a metallic component, a ceramic component, and at least one spring element arranged between the metallic component and the ceramic component. The metallic component has a first coefficient of thermal expansion, and the ceramic component has a second coefficient of thermal expansion. The at least one spring element is configured to mechanically couple the ceramic component to the metallic component.

Abstract: An impingement manifold includes a fluid inlet passage and a pressurized chamber. The pressurized chamber includes at least one lobe. The at least one lobe includes a flow improving feature configured to minimize vorticity of a flow field within the pressurized chamber, and at least one flow outlet.

Abstract: A multi-layer structure includes a substrate with a surface and with particles partially covering and partially embedded in the surface. The particles have high thermal conductivity and low electrical conductivity. A dielectric layer on the surface partially covers the partially embedded particles. A metal layer on the dielectric layer covering the partially covered particles forms a thermal interface material (TIM) for electronic packaging applications.

Abstract: A cast component includes a cast structure having a primary geometry formed by a mold. Also included is a structural deposit formed by cold spraying one or more layers of powdered material on an outer surface of the cast structure, the structural deposit defining at least one feature of the overall outer geometry of the cast component in addition to the primary geometry. Also provided are methods of manufacturing the cast component.

Abstract: An illustrative example container includes a plurality of internal support members having a surface contour that at least approximates a minimum surface. The plurality of internal support members collectively provide structural support for carrying loads on the container. The plurality of internal support members collectively establish a plurality of cavities for at least temporarily containing fluid. An outer shell is connected with at least some of the internal support members. The outer shell includes a plurality of curved surfaces. The outer shell encloses the cavities.

Abstract: A pressure vessel configured to store a pressurized fluid is provided including a plurality of lobes. Each lobe includes at least one vertically arranged interior wall. The plurality of lobes are positioned in a side by side configuration such that a first interior wall of a first lobe is positioned adjacent a second interior wall of a second adjacent lobe. The first interior wall and the second interior wall are configured to contact one another at a first point of tangency. A first tangent intersects the first lobe at the first point of tangency and a second tangent intersects the second lobe at the first point of tangency. The first tangent and the second tangent are separated by about 120 degrees.

Abstract: A winding configuration for an electric machine includes a stator core with a plurality of winding slots, a plurality of conductor strands distributed in a winding slot of the plurality of winding slots, and an insulation matrix that surrounds each of the plurality of the conductor strands. The winding slot includes a slot cavity with a cross-section area and the plurality of distributed conductor strands are configured to maximize slot fill factor.

Abstract: A component to generate a magnetic field and a method of designing windings, comprised of a plurality of strands, within each slot of the component, are described. The component includes a plurality of slots. The component also includes sets of a plurality of strands that form windings, each set of the plurality of strands being enclosed in a respective one of the plurality of slots, each set of the plurality of strands being divided into a plurality of a collection of strands configured to be twisted over a portion of a length of the respective one of the plurality of slots. Each of the collection of strands changes cross sectional shape over the portion.

Abstract: A process is provided involving an agitator. This process includes steps of: (a) disposing an object with the agitator, which object includes an aperture therein; (b) disposing abrasive material within the aperture; and (c) agitating the abrasive material by moving the object using the agitator.

Abstract: A ceramic component retention system includes a metallic component, a ceramic component, and at least one spring element arranged between the metallic component and the ceramic component. The metallic component has a first coefficient of thermal expansion, and the ceramic component has a second coefficient of thermal expansion. The at least one spring element is configured to mechanically couple the ceramic component to the metallic component.

Abstract: An electric machine includes a laminated stack. The laminated stack includes first and second additively manufactured conductive phase coils. Each of the first and second additively manufactured phase coils includes of a plurality of conductive strands. An additively manufactured end winding conductively couples the first and second phase coils. The end winding has a non-circular cross-sectional geometry.