Abstract: A rotor blade formed via additive manufacturing is provided. The rotor blade includes an airfoil and a coupled component. The airfoil includes a plurality of fused layers of a first material formed via additive manufacturing and defines a leading edge and a tip at a distal end. The coupled component includes a plurality of fused layers of a second material formed via additive manufacturing. An interlocking transition zone includes a plurality of projections alternately extending from the airfoil and the coupled component, respectively, to undetachably couple the airfoil and the coupled component.

Abstract: Turbine nozzles are provided for gas turbine engines. The turbine nozzle includes an arcuate inner band; an arcuate outer band; and a nozzle vane disposed between the arcuate inner band and the arcuate outer band. The radially inner end of the nozzle vane is attached to the arcuate inner band through an interlocking transition zone including a plurality of projections alternately extending from the radially inner end of the nozzle vane and the arcuate inner band, respectively, to undetachably couple the nozzle vane and the arcuate inner band. Optionally, the radially outer end of each nozzle vane is also attached to the arcuate outer band through an interlocking transition zone.

Abstract: A bladed disk for a gas turbine engine is provided. The bladed disk includes a rotor disk, a plurality of rotor blades, and an interlocking transition zone. The rotor disk includes a plurality of fused layers of a first material formed via additive manufacturing and defines an outer rim. The plurality of rotor blades includes a plurality of fused layers of a second material formed via additive manufacturing. The interlocking transition zone includes a plurality of projections alternately extending from the outer rim of the rotor disk and the plurality of rotor blades, respectively, to undetachably couple the rotor disk and the plurality of rotor blades.

Abstract: A nozzle for a gas turbine engine, including an airfoil having an exterior surface, flange and radially compressive contact face. Also included is an airfoil support frame having a mating face positioned in engagement with the contact face. A non-orthogonal engagement angle is provided in order to transmit a compressive force to the airfoil.

Abstract: A clearance control apparatus for a gas turbine engine including an annular turbine case having opposed inner and outer surfaces; an annular manifold surrounding a portion of the turbine case, the manifold including: an inlet port in fluid communication with the manifold and the outer surface of the turbine case, and an exit port; and a bypass pipe having an upstream end coupled to the exit port, a downstream end coupled to a low-pressure sink, and a valve disposed between upstream and downstream ends, the valve selectively moveable between a first position which blocks flow between the upstream and downstream ends, and a second position which permits flow between the upstream and downstream ends.

Abstract: A method of joining two components using additive manufacturing is provided. The method includes forming a first component made of a first material; forming an interlocking transition zone from the first material and a second material; and forming a second component made of the second material. The interlocking transition zone includes a plurality of projections alternately extending from the first component and the second component, respectively, to undetachably couple the first component and the second component.

Abstract: Methods for repairing surface of a metal substrate are provided, which can include preparing the surface of the metal substrate for repair; melt attaching a base layer onto the surface of the metal substrate; fusing a plurality of first layers of a first material via additive manufacturing to the base coating; forming an interlocking transition zone via additive manufacturing from the first material and a second material; and fusing a plurality of second layers of the second material via additive manufacturing on the interlocking transition zone. The interlocking transition zone can have a plurality of projections alternately extending from the plurality of first layers and the plurality of second layers, respectively, to undetachably couple the plurality of first layers to the plurality of second layers. A repaired metal substrate is also provided.

Abstract: The present invention relates to a ceramic or metallic component including a first region having a first porosity ranging between 1 and 30%. The component includes a second region having a second porosity that is less than the first porosity. The component includes at least one graded transition between the first and second regions.

Abstract: An edge guard apparatus for an airfoil includes: a body having a nose with spaced-apart first and second wings extending therefrom, the body defining a cavity between the first and second wings; and an energy absorbing structure disposed in the cavity.

Abstract: A rotor blade formed via additive manufacturing is provided. The rotor blade includes an airfoil and a coupled component. The airfoil includes a plurality of fused layers of a first material formed via additive manufacturing and defines a leading edge and a tip at a distal end. The coupled component includes a plurality of fused layers of a second material formed via additive manufacturing. An interlocking transition zone includes a plurality of projections alternately extending from the airfoil and the coupled component, respectively, to undetachably couple the airfoil and the coupled component.

Abstract: Turbine nozzles are provided for gas turbine engines. The turbine nozzle includes an arcuate inner band; an arcuate outer band; and a nozzle vane disposed between the arcuate inner band and the arcuate outer band. The radially inner end of the nozzle vane is attached to the arcuate inner band through an interlocking transition zone comprising a plurality of projections alternately extending from the radially inner end of the nozzle vane and the arcuate inner band, respectively, to undetachably couple the nozzle vane and the arcuate inner band. Optionally, the radially outer end of each nozzle vane is also attached to the arcuate outer band through an interlocking transition zone.

Abstract: A method of joining two components using additive manufacturing is provided. The method includes forming a first component made of a first material; forming an interlocking transition zone from the first material and a second material; and forming a second component made of the second material. The interlocking transition zone includes a plurality of projections alternately extending from the first component and the second component, respectively, to undetachably couple the first component and the second component.

Abstract: A bladed disk for a gas turbine engine is provided. The bladed disk includes a rotor disk, a plurality of rotor blades, and an interlocking transition zone. The rotor disk includes a plurality of fused layers of a first material formed via additive manufacturing and defines an outer rim. The plurality of rotor blades includes a plurality of fused layers of a second material formed via additive manufacturing. The interlocking transition zone includes a plurality of projections alternately extending from the outer rim of the rotor disk and the plurality of rotor blades, respectively, to undetachably couple the rotor disk and the plurality of rotor blades.

Abstract: Methods for repairing surface of a metal substrate are provided, which can include preparing the surface of the metal substrate for repair; melt attaching a base layer onto the surface of the metal substrate; fusing a plurality of first layers of a first material via additive manufacturing to the base coating; forming an interlocking transition zone via additive manufacturing from the first material and a second material; and fusing a plurality of second layers of the second material via additive manufacturing on the interlocking transition zone. The interlocking transition zone can have a plurality of projections alternately extending from the plurality of first layers and the plurality of second layers, respectively, to undetachably couple the plurality of first layers to the plurality of second layers. A repaired metal substrate is also provided.

Abstract: A nozzle for a gas turbine engine, including an airfoil having an exterior surface, flange and radially compressive contact face. Also included is an airfoil support frame having a mating face positioned in engagement with the contact face. A non-orthogonal engagement angle is provided in order to transmit a compressive force to the airfoil.

Abstract: A clearance control apparatus for a gas turbine engine including an annular turbine case having opposed inner and outer surfaces; an annular manifold surrounding a portion of the turbine case, the manifold including: an inlet port in fluid communication with the manifold and the outer surface of the turbine case, and an exit port; and a bypass pipe having an upstream end coupled to the exit port, a downstream end coupled to a low-pressure sink, and a valve disposed between upstream and downstream ends, the valve selectively moveable between a first position which blocks flow between the upstream and downstream ends, and a second position which permits flow between the upstream and downstream ends.

Abstract: A sump pressurization system for a gas turbine engine comprises a first hollow shaft and a second hollow shaft disposed within the first hollow shaft and defining a cavity therebetween. Each of the first and second hollow shafts has a common axis of rotation. Also included is a source of pressurized air to pressurize the cavity and a plurality of hollow tubes disposed in the cavity. The tubes are oriented perpendicular to the axis of rotation and are connected to and rotatable with the first hollow shaft. A plurality of apertures in the second hollow shaft are in fluid communication with the tubes, such that pressurized air flowing through the tubes passes through the apertures into the interior of the second hollow shaft.

Abstract: A sump pressurization system for a gas turbine engine comprises a first hollow shaft and a second hollow shaft disposed within the first hollow shaft and defining a cavity therebetween. Each of the first and second hollow shafts has a common axis of rotation. Also included is a source of pressurized air to pressurize the cavity and a plurality of hollow tubes disposed in the cavity. The tubes are oriented perpendicular to the axis of rotation and are connected to and rotatable with the first hollow shaft. A plurality of apertures in the second hollow shaft are in fluid communication with the tubes, such that pressurized air flowing through the tubes passes through the apertures into the interior of the second hollow shaft.

Abstract: A first stage turbine disk section for a gas turbine engine, including a centrally disposed disk hub having an integrally-formed, radially outwardly extending web terminating at an outer end. The disk hub has a convex, curved hub surface exposed to high pressure, high temperature compressor bleed and discharge gases during engine operation, and the convex, curved hub surface acts to reduce the axial constraint at the location of peak axial stress, thereby mitigating the formation of undesirable axial stress in the disk hub and allows separation of the peak axial and hoop stresses, thereby reducing the magnitude of the peak hub surface effective stress.

Abstract: Methods and apparatus for cooling gas turbine rotor blades is provided. The blade includes an airfoil having an internal three pass serpentine cooling circuit having radially extending first, second, and third serpentine cooling cavities partially separated by, in axially aft succession, a first radially extending internal rib and a second radially extending internal rib. The serpentine cooling circuit includes a first inlet in flow communication with the first cavity and a second inlet in flow communication with at least one of the second and third cavities wherein the first and second inlets are formed during casting of the airfoil.