Abstract: The present disclosure is directed to an apparatus for manufacturing a composite component. The apparatus includes a mold onto which the composite component is formed. The mold is disposed within a grid defined by a first axis and a second axis. The apparatus further includes a first frame assembly disposed above the mold, and a plurality of printheads coupled to the first frame assembly within the grid in an adjacent arrangement along the first axis. At least one of the mold or the plurality of printheads is moveable along the first axis, the second axis, or both. At least one of the printheads of the plurality of printheads is moveable independently of one another along a third axis.

Abstract: Methods for manufacturing composite components having complex geometries are provided. In one exemplary aspect, a method includes laying up each of a plurality of laminates to an initial shape with a substantially planar geometry or a gently curved geometry. Then, a laid up laminate is formed to a final shape for each predefined section defined by the composite component to be manufactured. Thereafter, the laminates formed to their respective final shapes are stacked to build up the complex geometry of the composite component. Next, the composite component can be cured and finish machined as necessary to form the completed composite component.

Abstract: Rotor blade panels, along with methods of their formation, are provided. The rotor blade panel may include one or more fiber-reinforced outer skins having an inner surface; and, a plurality of reinforcement structures on the inner surface of the one or more fiber-reinforced outer skins, where the reinforcement structure bonds to the one or more fiber-reinforced outer skins as the reinforcement structure is being deposited. The reinforcement structure includes, at least, a first composition and a second composition, with the first composition being different than the second composition.

Abstract: Rotor blade panels, along with methods of their formation, are provided. The rotor blade panel may include one or more fiber-reinforced outer skins having an inner surface; and, a plurality of reinforcement structures on the inner surface of the one or more fiber-reinforced outer skins, where the reinforcement structure bonds to the one or more fiber-reinforced outer skins as the reinforcement structure is being deposited. The reinforcement structure includes, at least, a first composition and a second composition, with the first composition being different than the second composition.

Abstract: According to present embodiments or aspects thereof, a composite booster spool with separable composite blades is provided. The blades are inserted radially from within the inner circumference of the spool and extend outwardly through the spool. The system provides a reduced weight assembly as compared to prior art metallic or composite/metallic combination systems. Additionally, the blades are separable which results in a more field-serviceable assembly over a fully integral system wherein the blades and spool are integrally formed from composites or combination of metal and composites.

Abstract: Rotor blade panels, along with methods of their formation, are provided. The rotor blade panel may include one or more fiber-reinforced outer skins having an inner surface; and, a plurality of reinforcement structures on the inner surface of the one or more fiber-reinforced outer skins, where the reinforcement structure bonds to the one or more fiber-reinforced outer skins as the reinforcement structure is being deposited. The reinforcement structure includes, at least, a first composition and a second composition, with the first composition being different than the second composition.

Abstract: Methods for manufacturing composite components having complex geometries are provided. In one exemplary aspect, a method includes laying up each of a plurality of laminates to an initial shape with a substantially planar geometry or a gently curved geometry. Then, a laid up laminate is formed to a final shape for each predefined section defined by the composite component to be manufactured. Thereafter, the laminates formed to their respective final shapes are stacked to build up the complex geometry of the composite component. Next, the composite component can be cured and finish machined as necessary to form the completed composite component.

Abstract: A rotor assembly for use in a turbofan engine is provided. The rotor assembly includes an annular spool including a blade opening defined therein, and a rotor blade radially insertable through the blade opening. The rotor blade includes a rotor blade radially insertable through the blade opening. The rotor blade includes a root portion having a dovetail shape, and the root portion is undersized relative to the blade opening. At least one secondary dovetail member is positioned within the blade opening and configured to couple the root portion within the blade opening with an interference fit.

Abstract: An airfoil structure is presented. The airfoil structure includes an outer casing substantially surrounding a composite core. The composite core includes a plurality of fiber bands, each of the plurality of fiber bands is placed at a predetermined position and orientation at a time, wherein the plurality of fiber bands are interwoven in an in-plane and out-of-plane orientation by interleaving each of the plurality of fiber bands placed in a plane with one or more of the plurality of fiber bands of an adjacent plane to define an interleaved structure. A method for manufacturing an airfoil structure including the composite core is also presented.

Abstract: A rotor assembly for use in a turbofan engine is provided. The rotor assembly includes an annular spool including a first blade opening defined therein, a first rotor blade configured to be radially inserted through the first blade opening, and a fairing positioned on a radially outer side of the annular spool. The first rotor blade includes a blade portion and a flange portion that extends substantially perpendicularly relative to the blade portion such that the flange portion is positioned on a radially inner side of the annular spool. The fairing is configured to receive a fastener radially inserted through the flange portion and the annular spool such that the first rotor blade is secured to the annular spool.

Abstract: In one embodiment, the present invention provides a central core element for a reverse osmosis separator assembly, the central core element comprising a pair of central core element components, each of said core element components comprising at least one porous exhaust conduit and at least one friction coupling, the friction couplings being configured to join said core element components to form a central core element defining a cavity configured to accommodate a first portion of a membrane stack assembly; wherein each core element component comprises a first section defining an exhaust cavity and a second section comprising a porous exhaust conduit, wherein said porous exhaust conduit comprises a removable wall member configured to form a substantial portion of a porous exhaust conduit wall.

Abstract: A hybrid metal and composite spool includes metal rings on an outer diameter of a composite spool shell. Metal rings may include features such as annular or axial dovetail slots. Adhesive layers may be between the metal rings and composite shell which may be connected by a shrink bonded joint. The metal rings may include a single seal tooth ring with an annular radially extending seal tooth. A method for fabricating the spool may include fabricating one or more metal rings with the features therein, positioning the metal rings in place on an outer surface of an uncured composite spool shell of the spool before curing the shell, and curing the shell with the one or more metal rings positioned in place. Alternatively, rings may be heated to a temperature at least sufficient to slide rings over a cured composite shell, and allowed to cool and shrink onto shell.

Abstract: A rotor assembly for use in a turbofan engine is provided. The rotor assembly includes an annular spool including a first blade opening defined therein, a first rotor blade configured to be radially inserted through the first blade opening, and a fairing positioned on a radially outer side of the annular spool. The first rotor blade includes a blade portion and a flange portion that extends substantially perpendicularly relative to the blade portion such that the flange portion is positioned on a radially inner side of the annular spool. The fairing is configured to receive a fastener radially inserted through the flange portion and the annular spool such that the first rotor blade is secured to the annular spool.

Abstract: A rotor assembly for use in a turbofan engine is provided. The rotor assembly includes an annular spool including a blade opening defined therein, and a rotor blade radially insertable through the blade opening. The rotor blade includes a rotor blade radially insertable through the blade opening. The rotor blade includes a root portion having a dovetail shape, and the root portion is undersized relative to the blade opening. At least one secondary dovetail member is positioned within the blade opening and configured to couple the root portion within the blade opening with an interference fit.

Abstract: A liquid pumping system comprises a plurality of liquid pumps and a hydraulic drive unit. Each liquid pump is driven by a separate hydraulic cylinder. The hydraulic cylinders are powered by a shared hydraulic pump through a valve set. A valve set controller is configured to operate the valve set. A liquid pumping process comprises distributing an initial flow of pressurized hydraulic fluid between the hydraulic cylinders. The hydraulic cylinders move through a cycle in a phased relationship to provide a constant sum of flow rates from the liquid pumps. A membrane filtration system combines the liquid pumping system with a membrane unit. In a water treating process, feed water is pumped through the membrane unit. Brine from the membrane unit is returned to each liquid pump while that liquid pump is feeding water to the membrane unit.

Abstract: According to present embodiments or aspects thereof, a composite booster spool with separable composite blades is provided. The blades are inserted radially from within the inner circumference of the spool and extend outwardly through the spool. The system provides a reduced weight assembly as compared to prior art metallic or composite/metallic combination systems. Additionally, the blades are separable which results in a more field-serviceable assembly over a fully integral system wherein the blades and spool are integrally formed from composites or combination of metal and composites.

Abstract: A method includes driving a fluid pumping unit having a plurality of pumping cylinders via a plurality of hydraulic cylinders respectively of a hydraulic power unit. The method further includes controlling activation of the hydraulic power unit such that each stroke of the corresponding piston assembly between the top dead center and the bottom dead center follows a corresponding trapezoidal velocity profile with respect to a time duration. Controlling activation includes controlling flow of a hydraulic fluid in the hydraulic power unit so as to control the corresponding trapezoidal velocity profile with respect to the time duration of the corresponding piston assembly to obtain a predefined flow rate of the fluid medium from the pumping unit.

Abstract: A system and a method for recovering oil from an oil-bearing formation wherein the method includes providing a reverse osmosis (RO) unit comprising at least one membrane; feeding a first feed stream having a first salinity content to a first side of the membrane; and feeding a second feed stream having a second salinity content to a second side of the membrane. The method further includes discharging a retentate stream from the first side of the membrane, and discharging a product stream having a controlled salinity content from the second side of the membrane. The method furthermore includes injecting at least a portion of the product stream into the oil-bearing formation, and recovering at least a portion of the oil from the oil-bearing formation.

Abstract: A hybrid metal and composite spool includes metal rings on an outer diameter of a composite spool shell. Metal rings may include features such as annular or axial dovetail slots. Adhesive layers may be between the metal rings and composite shell which may be connected by a shrink bonded joint. The metal rings may include a single seal tooth ring with an annular radially extending seal tooth. A method for fabricating the spool may include fabricating one or more metal rings with the features therein, positioning the metal rings in place on an outer surface of an uncured composite spool shell of the spool before curing the shell, and curing the shell with the one or more metal rings positioned in place. Alternatively, rings may be heated to a temperature at least sufficient to slide rings over a cured composite shell, and allowed to cool and shrink onto shell.

Abstract: The present invention provides a method and apparatus for fabricating a separator assembly. The method comprises: providing a central core element comprising at least one concentrate exhaust conduit and at least one permeate exhaust conduit; disposing a first portion of a membrane stack assembly comprising a permeate carrier layer, a membrane layer, and a feed carrier layer within the central core element such that the concentrate exhaust conduit and permeate exhaust conduit are separated by the first portion of the membrane stack assembly; radially winding a second portion of the membrane stack assembly around the central core element; and sealing the wound assembly comprising two opposing end surfaces made of the membrane stack assembly by applying an adhesive on both end surfaces of the wound assembly; and applying a negative pressure inside the central core element so that the adhesive penetrates into the membrane stack assembly.