Abstract: A method of forming a heat exchanger for use with a rotating component configured to rotate about an axis of rotation is provided including generating a stereolithography file of the surface geometry of the heat exchanger. The surface geometry of the heat exchanger includes a cylindrical base having a plurality of fins extending generally radially therefrom. The surface geometry defined in the stereolithography file is ‘sliced’ into a plurality of axisymmetric layers, perpendicular to the axis of rotation. Energy from an energy source is applied to a powdered material causing the powdered material to fuse and form the plurality of axisymmetric thin layers. Each of the axisymmetric thin layers is integrally formed with an adjacent axisymmetric thin layer to create a unitary heat exchanger.

Abstract: An impeller including a blade section, a shroud section, and a hub is made of a monolithic structure. The impeller is made by loading a 3D image file into an additive manufacturing device, using it to generate 2D files which correspond to a plurality of cross-sectional layers of the impeller, and solidifying corresponding portions of pulverant material layers to create the impeller.

Abstract: An emission treatment system includes a first separation device that is operable to introduce one or more sorbents into an exhaust stream having emission products. The sorbent captures the emission products such that the exhaust stream includes sorbent with captured emission products. A second separation device located downstream from the first separation device receives the exhaust stream and utilizes an electrostatic potential to separate the sorbent with captured emission products from the exhaust stream into a discharge stream to produce a clean stream.

Abstract: A bond coat system for silicon based substrates wherein a compliant layer having an elastic modulus of between 30 and 130 GPa is provided between the silicon based substrate and a silicon metal containing oxygen gettering layer.

Abstract: An emission treatment system includes a first separation device that is operable to introduce one or more sorbents into an exhaust stream having emission products. The sorbent captures the emission products such that the exhaust stream includes sorbent with captured emission products. A second separation device located downstream from the first separation device receives the exhaust stream and utilizes an electrostatic potential to separate the sorbent with captured emission products from the exhaust stream into a discharge stream to produce a clean stream.

Abstract: A fuel cell stack includes a plurality of fuel cells each having an anode layer, an electrolyte layer, and a cathode layer, the fuel cells each having a first effective thermal expansion coefficient; a plurality of bipolar plates positioned between adjacent fuel cells having an anode interconnect, a separator plate, and a cathode interconnect, the bipolar plates being positioned between adjacent fuel cells, wherein the anode interconnect is in electrical communication with the anode layer of one adjacent fuel cell, wherein the cathode interconnect is in electrical communication with the cathode layer of another adjacent fuel cell, and wherein at least one interconnect of the cathode interconnect and the anode interconnect has a second thermal expansion coefficient and is adapted to reduce strain between the at least one interconnect and an adjacent fuel cell due to differences between the first and second thermal expansion coefficients over repeated thermal cycles.

Abstract: An interconnect for a solid oxide fuel cell includes a compliant superstructure having a first portion defining a separator plate contact zone and a second portion defining an electrode contact zone, wherein the super structure is porous. In one embodiment, the superstructure is defined by a plurality of compliant substructures provided in a first direction and a plurality of compliant substructures provided in second direction to define a woven structure.

Abstract: A fuel cell stack includes a plurality of fuel cells each having an anode layer, an electrolyte layer, and a cathode layer, the fuel cells each having a first effective thermal expansion coefficient; a plurality of bipolar plates positioned between adjacent fuel cells having an anode interconnect, a separator plate, and a cathode interconnect, the bipolar plates being positioned between adjacent fuel cells, wherein the anode interconnect is in electrical communication with the anode layer of one adjacent fuel cell, wherein the cathode interconnect is in electrical communication with the cathode layer of another adjacent fuel cell, and wherein at least one interconnect of the cathode interconnect and the anode interconnect has a second thermal expansion coefficient and is adapted to reduce strain between the at least one interconnect and an adjacent fuel cell due to differences between the first and second thermal expansion coefficients over repeated thermal cycles.