Abstract: A hybrid airfoil for a gas turbine engine according to an exemplary embodiment of this disclosure can include a leading edge portion, a trailing edge portion, and an intermediate portion between the leading edge portion and the trailing edge portion. The leading edge portion can be made of a first material, the trailing edge portion can be made of a second material, and the intermediate portion can be made of a third material. At least two of the first material, the second material and the third material are different materials.

Abstract: An example multi-dimensional component building system includes a first chamber having at least one base disposed therein, a second chamber adjacent to and in fluid communication with the first chamber through a first door, and a third chamber adjacent to and in fluid communication with the second chamber through a second door. The second chamber is fluidly sealed from the first chamber if the first door is in a closed position. The second chamber is configured to receive the at least one base via a first transfer mechanism if the fluid parameters of the first chamber are approximately equal to the fluid parameters of the second chamber. The second chamber includes a directed heat source and a build-up material configured to form a component on the at least one base by melting or sintering. The third chamber is fluidly sealed from the second chamber if the first door is in a closed position.

Abstract: A monolithic composite turbine component includes at least one first region of a first material and one second region of a second material formed by solid freeform fabrication (SFF). The first material may be a metal and the second material may be a ceramic or a ceramic matrix composite. Transition regions between the metal region and ceramic region are functionally graded regions to minimize internal stress during temperature fluctuations.

Abstract: An example multi-dimensional component building system includes a first chamber having at least one base, a second chamber adjacent to and in fluid communication with the first chamber through a first door, and a third chamber adjacent to and in fluid communication with the second chamber through a second door. The second chamber is fluidly sealed from the first chamber if the first door is in a closed position. The second chamber includes a directed heat source, a build-up material and is configured to receive the at least one base if the fluid parameters of the first chamber and second chamber are approximately equal. The third chamber is fluidly sealed from the second chamber if the first door is in a closed position. The third chamber is configured to receive the at least one base, having a formed component disposed thereon, if the second door is in an open position.

Abstract: A powder-derived, non-finished work piece includes a first body section that has a wall that spans in a vertical direction. The wall has a relatively thin thickness with respect to a length and a width of the wall. A second body section is arranged next to, but spaced apart from, the first body section. A gusset connects the first body section and the second body section. The gusset extends obliquely from the wall of the first body section with respect to the vertical direction such that the gusset is self-supporting. The first body section has a geometry that corresponds to an end-use component exclusive of the gusset.

Abstract: A pulverant material supply system has an outer shell, an inner shell, and a plurality of openings to a passage within the inner shell to allow a reducing fluid into the pulverant material contained therein. The liner is made from a non-evaporable getter alloy.

Abstract: An apparatus and method for machining apertures into a conductive workpiece is disclosed. The apparatus has a tank capable of holding a dielectric fluid, and a fixture for holding the workpiece in the tank. An electric discharge machine with an electrode, a power supply connected to the electrode that produces machining pulses for electric discharge machining through the workpiece, and a controller for regulating the power supply and electrode position is also part of the apparatus. Finally, the apparatus has a pressure transducer connected to the fixture, and a process controller in communication with the electric discharge machine controller and pressure transducer.

Abstract: A method of forming a complex shaped part includes the steps of forming a polymer core by an additive manufacturing process. A metal is plated about surfaces of the polymer core, and the polymer core is removed, leaving hollows within a plate core. Metal powder is deposited within the hollows. An integral blade rotor is also disclosed.

Abstract: A method of component forming according to an exemplary aspect of the present disclosure includes, among other things, positioning a metal powder in a mold cavity, melting the metal powder within the mold cavity, and cooling the melted metal powder to form a component.

Abstract: A hybrid airfoil for a gas turbine engine according to an exemplary embodiment of this disclosure can include a leading edge portion, a trailing edge portion, and an intermediate portion between the leading edge portion and the trailing edge portion. The leading edge portion can be made of a first material, the trailing edge portion can be made of a second material, and the intermediate portion can be made of a third material. At least two of the first material, the second material and the third material are different materials.

Abstract: A system for airflow testing a turbine engine component having multiple cavities has a test fixture with a module for supporting a turbine engine component to be tested and a sliding element for sequentially allowing a pressurized fluid to flow through each of the multiple cavities in the turbine engine component. A method for performing the airflow testing is also described.

Abstract: A method of forming a leading edge protection component includes depositing particles using a cold spray process on a mandrel to form a leading edge protection component; and removing the leading edge protection structure from the mandrel. The leading edge protection can be formed in one or more pieces and involve using one or more mandrels.

Abstract: An example multi-dimensional component building system includes a first chamber having at least one base, a second chamber adjacent to and in fluid communication with the first chamber through a first door, and a third chamber adjacent to and in fluid communication with the second chamber through a second door. The second chamber is fluidly sealed from the first chamber if the first door is in a closed position. The second chamber includes a directed heat source, a build-up material and is configured to receive the at least one base if the fluid parameters of the first chamber and second chamber are approximately equal. The third chamber is fluidly sealed from the second chamber if the first door is in a closed position. The third chamber is configured to receive the at least one base, having a formed component disposed thereon, if the second door is in an open position.

Abstract: A Blade Outer Air Seal (BOAS) includes a body manufactured of a metal alloy, the body includes a face opposite a forward interface and an aft interface, the face includes a cavity. A non-metallic insert within the cavity such that the insert is flush with the face.

Abstract: A system for airflow testing a turbine engine component having multiple cavities has a test fixture with a module for supporting a turbine engine component to be tested and a sliding element for sequentially allowing a pressurized fluid to flow through each of the multiple cavities in the turbine engine component. A method for performing the airflow testing is also described.

Abstract: An apparatus and method for machining apertures into a conductive workpiece is disclosed. The apparatus has a tank capable of holding a dielectric fluid, and a fixture for holding the workpiece in the tank. An electric discharge machine with an electrode, a power supply connected to the electrode that produces machining pulses for electric discharge machining through the workpiece, and a controller for regulating the power supply and electrode position is also part of the apparatus. Finally, the apparatus has a pressure transducer connected to the fixture, and a process controller in communication with the electric discharge machine controller and pressure transducer.