Abstract: A compressor rotor, such as a fan, for a gas turbine engine is described which includes alternating at least first and second blade types. The leading edge of the second blade types includes a leading edge tip cutback extending to the blade tip thereof. The leading edge tip cutback of the second blade type defines a chord length at the blade tip of the second blade types that is less than that of the first blades types. The first and second blade types generate different shock patterns when the fan or compressor rotor operates in supersonic flow regimes.

Abstract: An inter-compressor case for a gas turbine engine is disclosed. The inter-compressor case comprises: an outer casing and an inner casing radially spaced apart relative to a longitudinal axis; a gas path extending from a plurality of radial inlets arranged in a circumferentially spaced apart array around the outer casing to an annular outlet defined by an axially extending downstream portion of the outer casing and an axially extending downstream portion of the inner casing; a plurality of struts having a gas path surface extending across the gas path between the outer casing and the inner casing; and a plurality of flow separators extending from the adjacent radial inlets. The flow separators have trailing edges disposed upstream of the annular outlet and include a plurality of full length flow separators and a plurality of truncated flow separators.

Abstract: A method of manufacturing a compressor stator having: a first stator blade with a first leading edge and a first trailing edge; a second stator blade disposed a circumferential distance from the first stator blade, the second stator blade having a second leading edge disposed an axial distance from the first leading edge and a second trailing edge disposed an axial distance from the first trailing edge; the method comprising: using additive manufacturing to deposit and fuse together progressive layers of metal material commencing at a substrate to form the first stator blade, the second stator blade, at least one intermediate support structure disposed between the first stator blade and the second stator blade, and at least one primary support structure disposed between the substrate and at least one of: the first stator blade; and the second stator blade; and removing the primary support structure and the intermediate support structure.

Abstract: An airfoil for a gas turbine engine including a tip extension disposed at the tip of the airfoil body. The tip extension extends from the suction side surface and/or the pressure side surface and defines a tip thickness that is larger than a true thickness of the airfoil body. The true thickness is defined within a plane perpendicular to a root axis and extending transversely to the airfoil chord around a midpoint thereof. The tip extension includes a side transitional surface forming a curve extending tangentially from the side surface and/or the pressure side surface. The tip thickness increases over a radial dimension in the plane that is at least 2 times the true thickness.

Abstract: A gas turbine engine is described having a rotor with a plurality of rotor blades each extending radially between a blade root to a blade tip and axially between a leading edge and a trailing edge. An annular casing body housing the rotor blades includes an abradable segment of the inner surface facing the blade tips and having an abradable member. The abradable segment having one or more annular grooves, extending into the casing body from an inner surface thereof, and including an edge groove axially aligned with and facing the leading edge or the trailing edge of the rotor blades. The edge groove extends axially between a first position on the inner surface upstream of the leading edge or the trailing edge, and a second position on the inner surface downstream of the leading edge or the trailing edge.

Abstract: A fan for a turbofan gas turbine engine having a low hub-to-tip ratio is disclosed. The fan includes a rotor hub and a plurality of radially extending fan blades. Each fan blade defines a hub radius (RHUB), which is the radius of the leading edge at the hub relative to a centerline of the fan, and a tip radius (RTIP), which is the radius of the leading edge at a tip of the fan blade relative to the centerline of the fan. The ratio of the hub radius to the tip radius (RHUB/RTIP) is less than 0.29. In a particular embodiment, this ratio is between 0.25 and 0.29. In another particular embodiment, this ratio is less than 0.25.

Abstract: A rotor for a gas turbine engine comprises a rotor having a hub and blades around the hub, and extending from the hub to tips. The tips include first and second tip portions between their respective tip leading edge and tip trailing edge. Tips are spaced from a rotational axis of the rotor by spans. A mean span of a first tip portion of a first blade is greater than a mean span of a corresponding first tip portion of a second blade. A mean span of a second tip portion the first blade is less than a mean span of a corresponding second tip portion of the second blade.

Abstract: A turbofan engine including an axially extending inlet wall surrounding an inlet flow path. A radial distance between the inlet wall and the inner wall adjacent the fan defines a downstream height of the inlet flow path. A plurality of vanes are circumferentially spaced around the inlet, each of the vanes extending radially inwardly from the inlet wall, a maximum radial distance between a tip of each of the vanes and the inlet wall defining a maximum height of the vane. The maximum height of the vane is at most 50% of the downstream height of the flow path. In another embodiment, the maximum height of the vane is at most 50% of the maximum fan blade span. A method of reducing a relative Mach number at fan blade tips is also discussed.

Abstract: A compressor rotor for a gas turbine engine is described which includes sets of blades having different airfoil thickness distributions, each including a frequency modifier forming a thickness differential relative to a baseline blade thickness. The frequency modifiers provide different natural vibration frequencies for each of the blades, and facilitate modifying natural vibration frequency separation between adjacent blades of the compressor rotor.

Abstract: A fan for a gas turbine engine comprises blades distributed around a hub. The blades include first and second blades, having geometric parameters and/or material properties that differ from each other to frequency mistune the fan. The blades are distributed about the hub with at least one second blade between adjacent first blades. The leading edge of the airfoil of the second blades is disposed axially aft of the corresponding leading edge of the first blades in at least a portion of the blade span.

Abstract: A turbofan engine including an axially extending inlet wall surrounding an inlet flow path. A radial distance between the inlet wall and the inner wall adjacent the fan defines a downstream height of the inlet flow path. A plurality of vanes are circumferentially spaced around the inlet, each of the vanes extending radially inwardly from the inlet wall, a maximum radial distance between a tip of each of the vanes and the inlet wall defining a maximum height of the vane. The maximum height of the vane is at most 50% of the downstream height of the flow path. In another embodiment, the maximum height of the vane is at most 50% of the maximum fan blade span. A method of reducing a relative Mach number at fan blade tips is also discussed.

Abstract: A rotor for a gas turbine engine. The rotor includes blades circumferentially distributed around a hub. The blades have airfoils with a span defined between a root and tip, a chord defined between a leading edge and a trailing edge, and a thickness defined between a pressure side surface and suction side surface. The blades include first blades and second blades. The airfoil of the first blades has a first thickness distribution defining a first natural vibration frequency of the airfoils of the first blades. The airfoil of the second blades has a second thickness distribution defining a second natural vibration frequency different than the first natural vibration frequency. The first thickness distribution is different than the second thickness distribution along a radially-inner half of the span, and the first thickness distribution matches the second thickness distribution along a radially-outer half of the span.

Abstract: A rotor for a gas turbine engine comprises a rotor having a hub and blades around the hub, and extending from the hub to tips. The tips include first and second tip portions between their respective tip leading edge and tip trailing edge. Tips are spaced from a rotational axis of the rotor by spans. A mean span of a first tip portion of a first blade is greater than a mean span of a corresponding first tip portion of a second blade. A mean span of a second tip portion the first blade is less than a mean span of a corresponding second tip portion of the second blade.

Abstract: An inlet for a turbofan engine, including an inlet wall surrounding an inlet flow path. The inlet wall extends axially from an upstream end to a downstream end adjacent the fan. The inlet wall has a shape defining a plurality of teeth circumferentially spaced around the inlet. The teeth extend axially and project radially inwardly toward the central longitudinal axis. A central portion of the inlet flow path has a cross-sectional dimension measured diametrically between opposed teeth, the cross-sectional dimension varying along the axial direction. The central portion defines a geometric throat at a minimum value of the cross-sectional dimension. The inlet wall is shaped so that the geometric throat is axially spaced from the upstream end and the downstream end. A gas turbine engine and a method of shielding tips of fan blades from impact by an object having a predetermined minimum dimension are also discussed.

Abstract: A compressor rotor for a gas turbine engine is described which includes sets of blades having different airfoil thickness distributions, each including a frequency modifier forming a thickness differential relative to a baseline blade thickness. The frequency modifiers provide different natural vibration frequencies for each of the blades, and facilitate modifying natural vibration frequency separation between adjacent blades of the compressor rotor.

Abstract: An inlet for a turbofan engine, including an inlet wall surrounding an inlet flow path. The inlet wall extends axially from an upstream end to a downstream end adjacent the fan. The inlet wall has a shape defining a plurality of teeth circumferentially spaced around the inlet. The teeth extend axially and project radially inwardly toward the central longitudinal axis. A central portion of the inlet flow path has a cross-sectional dimension measured diametrically between opposed teeth, the cross-sectional dimension varying along the axial direction. The central portion defines a geometric throat at a minimum value of the cross-sectional dimension. The inlet wall is shaped so that the geometric throat is axially spaced from the upstream end and the downstream end. A gas turbine engine and a method of shielding tips of fan blades from impact by an object having a predetermined minimum dimension are also discussed.

Abstract: A turbofan engine including an axially extending inlet wall surrounding an inlet flow path. A radial distance between the inlet wall and the inner wall adjacent the fan defines a downstream height of the inlet flow path. A plurality of vanes are circumferentially spaced around the inlet, each of the vanes extending radially inwardly from the inlet wall, a maximum radial distance between a tip of each of the vanes and the inlet wall defining a maximum height of the vane. The maximum height of the vane is at most 50% of the downstream height of the flow path. In another embodiment, the maximum height of the vane is at most 50% of the maximum fan blade span. A method of reducing a relative Mach number at fan blade tips is also discussed.

Abstract: An annular casing for a rotor of a gas turbine engine includes a casing treatment having at least one groove defined in the annular casing wall with an open end defined in an inner surface of the annular casing wall, and a perforated sheet overlapping the open end of the at least one groove. The perforated sheet includes a plurality of apertures therethrough in fluid communication with the at least one groove. A method of reducing flow losses through a flow path having a rotor with a plurality of rotating blades extending therethrough is also presented.

Abstract: An airfoil for a rotor blade or a stator vane of a gas turbine engine having a tip extension extending one or both of the suction and pressure side surfaces adjacent the tip. The tip extension defines a thickness at the tip larger than the true thickness of the airfoil. The tip extension includes a side transitional surface substantially defined along a curve extending tangentially from the corresponding side surface. The tip extension defines a gradual increase in the thickness over a portion of the airfoil having a radial dimension corresponding to at least 2 times the true thickness.

Abstract: A turbofan engine is disclosed which includes a nacelle assembly, having an interior surface for directing airflow, and a flow disruptor positioned on the interior surface upstream of the fan, the flow disruptor extending towards the axis a height greater than the anticipated boundary layer height of the airflow. A turbofan engine which includes an array of circumferentially disposed flow disruptors extending from a fan case inner surface is also disclosed. A method of mitigating fan flutter in a gas turbine engine by generating a circumferential asymmetrically in the airflow, upstream of the fan, is also described.