Abstract: An article is provided and includes a first part having a first edge defined at an intersection of first and second surfaces where the first and second surfaces form a first angle, a second part having a second edge defined at an intersection of third and fourth surfaces where the third and fourth surfaces form a second angle which is different from the first angle and a weld joint formed at locations where the first surface contacts the third surface.

Abstract: An inlet shroud assembly includes a hub and a shroud for a ram air fan. The hub includes a center bore, a first frustoconical section, a plurality of slotted cooling holes located on the first frustoconical section, a second frustoconical section, a plurality of circular cooling holes located on the second frustoconical section, a rim, a central cavity, and an annular cavity. The shroud includes a central disk with a center bore, a circular flange located on a radially outer edge of the central disk, and an outer disk with a web portion and a tip portion, the tip portion having a curved lip.

Abstract: A diffuser for a ram air fan assembly includes a perforated cone, an inlet ring seal, and an outlet ring seal. The perforated cone has a frustoconical shape symmetrical about an axis of the diffuser. The inlet ring seal is attached to, and axially disposed about, a first end of the perforated cone. The inlet ring seal includes a fan housing connection having a cylindrical shape. The outlet ring seal is attached to, and axially disposed about, a second end of the perforated cone. An average external diameter of the second end is greater than an average external diameter of the first end such that the perforated cone extends away from the inlet ring seal and radially outward from the axis of the diffuser.

Abstract: A fan housing has a radially outer surface. A pair of radially intermediate surfaces includes a first surface spaced towards a first axial end, which has an inner bore positioned radially outward of an inner bore of a second surface. Vanes extend between the radially outer surface and an outer periphery of the pair of radially intermediate surfaces. A bearing bore extends radially inwardly of the first surface. A mounting lug nub is formed on an outer periphery of the radially outer surface. A first distance is defined between the first axial one end of the fan housing and an opposed axial end. A second distance is defined between the first axial end and a center of the mounting lug. A ratio of the first distance to the second distance is between 2.13 and 2.11. An intermediate part, a ram air fan and a method are also disclosed.

Abstract: An article is provided and includes a first part having a first edge defined at an intersection of first and second surfaces where the first and second surfaces form a first angle, a second part having a second edge defined at an intersection of third and fourth surfaces where the third and fourth surfaces form a second angle which is different from the first angle and a weld joint formed at locations where the first surface contacts the third surface.

Abstract: A ram air fan inlet housing for containing a ram air fan rotor. The inlet housing includes a flanged surface and an interior surface. The flanged surface is perpendicular to an axis of the inlet housing and defines a flange plane at an axial end of the inlet housing. The interior surface is symmetric about the axis of the inlet housing and includes a flange section, a transition section, an outlet section, a rotor section, and an inlet section.

Abstract: A compressor rotor compresses and delivers compressed air across a turbine rotor. The turbine rotor is connected to the compressor rotor such that rotation of the turbine rotor drives the compressor rotor. A shaft is connected to rotate with the turbine rotor and the compressor rotor. A thrust bearing is provided by a member extending perpendicular and radially outwardly of the shaft. The member rotates with the shaft and faces a first housing wall. A hollow chamber is formed on an opposed side of the first housing wall. A cooling air path supplies air across a thrust bearing surface, and between the member and the first housing wall. The first housing wall has a communication hole for communicating cooling air from the cooling air path into the hollow cavity to drive air within the hollow chamber. Also, a housing incorporating the communication hole is disclosed.

Abstract: An air cycle machine includes a bearing housing with a shaft bore. A rotor shaft is arranged in the shaft bore and includes knife edges extending from the rotor shaft. A seal engages the shaft bore and includes an outer diameter and an inner diameter providing a seal land axially aligned with the knife edges. A radial clearance between the seal land and the knife edges is nominally 0.006 inch. The inner diameter is arranged between lateral sides of the seal that define a width. In one example, a tapered surface extending at an angle relative to the outer diameter from the lateral side to the seal land, the tapered surface facing the large end. The outer diameter to the inner diameter provides a first ratio of 1.25-1.28, and the inner diameter to the width provides a second ratio of 4.33-5.58.

Abstract: An example shaft support includes a cylindrical body establishing a bore extending along an axis. The bore is configured to receive a shaft. Openings are provided in the cylindrical body and distributed circumferentially about the axis. The openings are positioned radially outward of the bore. Each of the openings has a cross-sectional area. The ratio of a total cross sectional area of the openings to a diameter of the cylindrical body is between 0.0963 and 0.0964.

Abstract: A fan housing has a radially outer surface. A pair of radially intermediate surfaces includes a first surface spaced towards a first axial end, which has an inner bore positioned radially outward of an inner bore of a second surface. Vanes extend between the radially outer surface and an outer periphery of the pair of radially intermediate surfaces. A bearing bore extends radially inwardly of the first surface. A mounting lug nub is formed on an outer periphery of the radially outer surface. A first distance is defined between the first axial one end of the fan housing and an opposed axial end. A second distance is defined between the first axial end and a center of the mounting lug. A ratio of the first distance to the second distance is between 2.13 and 2.11. An intermediate part, a ram air fan and a method are also disclosed.

Abstract: An inlet shroud assembly includes a hub and a shroud for a ram air fan. The hub includes a center bore, a first frustoconical section, a plurality of slotted cooling holes located on the first frustoconical section, a second frustoconical section, a plurality of circular cooling holes located on the second frustoconical section, a rim, a central cavity, and an annular cavity. The shroud includes a central disk with a center bore, a circular flange located on a radially outer edge of the central disk, and an outer disk with a web portion and a tip portion, the tip portion having a curved lip.

Abstract: A disclosed ram air assembly includes a housing that defines an inlet and an inner cavity. A fan disposed at the inlet generates air flow and is driven by an electric motor. Airflow through the ram air fan assembly is directed through a passageway defined by a diffuser. The diffuser includes a first diameter at a forward end, and a second diameter at an aft end with the second diameter being larger than the forward end to diffuse airflow and increase fan efficiency.

Abstract: An article is provided and includes a first part having a first edge defined at an intersection of first and second surfaces where the first and second surfaces form a first angle, a second part having a second edge defined at an intersection of third and fourth surfaces where the third and fourth surfaces form a second angle which is different from the first angle and a weld joint formed at locations where the first surface contacts the third surface.

Abstract: A compressor rotor compresses and delivers compressed air across a turbine rotor. The turbine rotor is connected to the compressor rotor such that rotation of the turbine rotor drives the compressor rotor. A shaft is connected to rotate with the turbine rotor and the compressor rotor. A thrust bearing is provided by a member extending perpendicular and radially outwardly of the shaft. The member rotates with the shaft and faces a first housing wall. A hollow chamber is formed on an opposed side of the first housing wall. A cooling air path supplies air across a thrust bearing surface, and between the member and the first housing wall. The first housing wall has a communication hole for communicating cooling air from the cooling air path into the hollow cavity to drive air within the hollow chamber. Also, a housing incorporating the communication hole is disclosed.

Abstract: A ram air fan inlet housing for containing a ram air fan rotor. The inlet housing includes a flanged surface and an interior surface. The flanged surface is perpendicular to an axis of the inlet housing and defines a flange plane at an axial end of the inlet housing. The interior surface is symmetric about the axis of the inlet housing and includes a flange section, a transition section, an outlet section, a rotor section, and an inlet section.

Abstract: A diffuser for a ram air fan assembly includes a perforated cone, an inlet ring seal, and an outlet ring seal. The perforated cone has a frustoconical shape symmetrical about an axis of the diffuser. The inlet ring seal is attached to, and axially disposed about, a first end of the perforated cone. The inlet ring seal includes a fan housing connection having a cylindrical shape. The outlet ring seal is attached to, and axially disposed about, a second end of the perforated cone. An average external diameter of the second end is greater than an average external diameter of the first end such that the perforated cone extends away from the inlet ring seal and radially outward from the axis of the diffuser.

Abstract: A fan rotor ring for an air cycle machine includes a ring body that defines a main bore having a main bore diameter and central axis. An annular flange extends axially from the ring body over a length and defines a fan ring bore having a fan ring bore inner diameter. A ratio of the fan ring bore inner diameter to the length of the annular flange is 1.63-1.69.

Abstract: An air cycle machine includes a bearing housing with a shaft bore. A rotor shaft is arranged in the shaft bore and includes knife edges extending from the rotor shaft. A seal engages the shaft bore and includes an outer diameter and an inner diameter providing a seal land axially aligned with the knife edges. A radial clearance between the seal land and the knife edges is nominally 0.006 inch. The inner diameter is arranged between lateral sides of the seal that define a width. In one example, a tapered surface extending at an angle relative to the outer diameter from the lateral side to the seal land, the tapered surface facing the large end. The outer diameter to the inner diameter provides a first ratio of 1.25-1.28, and the inner diameter to the width provides a second ratio of 4.33-5.58.

Abstract: An example shaft support includes a cylindrical body establishing a bore extending along an axis. The bore is configured to receive a shaft. Openings are provided in the cylindrical body and distributed circumferentially about the axis. The openings are positioned radially outward of the bore. Each of the openings has a cross-sectional area. The ratio of a total cross sectional area of the openings to a diameter of the cylindrical body is between 0.0963 and 0.0964.

Abstract: A compressor rotor compresses and delivers compressed air across a turbine rotor. The turbine rotor is connected to the compressor rotor such that rotation of the turbine rotor drives the compressor rotor. A shaft is connected to rotate with the turbine rotor and the compressor rotor. A thrust bearing is provided by a member extending perpendicular and radially outwardly of the shaft. The member rotates with the shaft and faces a first housing wall. A hollow chamber is formed on an opposed side of the first housing wall. A cooling air path supplies air across a thrust bearing surface, and between the member and the first housing wall. The first housing wall has a communication hole for communicating cooling air from the cooling air path into the hollow cavity to drive air within the hollow chamber. Also, a housing incorporating the communication hole is disclosed.