Abstract: A method of additively manufacturing includes generating a thermal model driven scan map that identifies an equiaxed cap region, a single crystal (SX) region, and a columnar to equiaxed transition (CET) region; and forming an active melt pool with respect to the thermal model driven scan map such that a depth of the active melt pool is greater than a thickness of the equiaxed transition (CET) region.

Abstract: An attritable gas turbine engine casing unitary charging volume comprising a casing having an interior wall and an exterior wall opposite the interior wall; a unitary charging volume formed between the exterior wall and the interior wall.

Abstract: A unitary rub strip comprises a casing having an inner surface and an outer surface opposite the inner surface; a unitary rub strip is formed integral with the casing proximate the inner surface, wherein the unitary rub strip comprises a modified structure within the casing configured to abrade responsive to an interaction with a rotating element.

Abstract: A process for additively controlled surface features of a gas turbine engine casing. The process comprises forming the casing having an inner surface and an outer surface opposite the inner surface; forming a surface feature on the casing proximate the inner surface, wherein the surface feature comprises a structure on the inner surface configured to align or misalign with respect to a flow direction of a working fluid in a flow path of the casing.

Abstract: A vehicle structure with unitary casing for an attritable gas turbine engine comprising a vehicle structure forming a unitary casing having a casing wall opposite the vehicle structure; a bypass duct formed between the casing wall and the vehicle structure, wherein the unitary casing is configured to receive a core of the attritable gas turbine engine.

Abstract: An additively-manufactured heat exchanger includes fluidly-separated alternating first and second layers having respective flow channels which can include one or more features that is either a riblet or a turbulator. A riblet includes a riblet peak and/or a riblet valley, which has a riblet slope, and the riblet peak and/or riblet valley has a riblet axis that is generally parallel to either the first fluid flow direction or the second fluid flow direction. A turbulator includes a turbulator peak and/or a turbulator valley, which has a turbulator slope, and the turbulator peak and/or turbulator valley has a turbulator axis that is generally perpendicular to either the first fluid flow direction or the second fluid flow direction. The respective slope angles are generally 25-65 deg. relative to build-axis, thereby resulting in improved surface roughness and uniformity control during the build process.

Abstract: A propulsion system according to an example of the present disclosure, includes a core engine and an outer casing surrounding the core engine. The outer casing includes an integral injector assembly. The injector assembly includes a wall that defines a cavity, the wall being integral with the outer casing. A method of operating a propulsion system and method of making a component of a propulsion system are also disclosed.

Abstract: A method of making an article using an additive manufacturing technique includes depositing a powder. The powder includes particles formed from an article material and having particle surfaces. A coating formed from a sacrificial coating is deposited over the particle surface. The sacrificial material has a composition that is different from the composition of the article material and is separated from the article material during fusing of the article material into a layer of an additively manufactured article.

Abstract: A rotary component may comprising a first structure configured to rotate about an axis and a second structure configured to rotate about the axis. A support structure may be coupled to the first structure at a first attachment location and to the second structure at a second attachment location. The support structure may be configured to separate from the first structure and the second structure in response to a centrifugal force generated by the first structure and the second structure rotating about the axis.

Abstract: An additively manufactured thermally insulating structure comprising a base layer and a fire-resistant layer adjacent to the base layer that forms an air gap therebetween. A method for assembling a miniature gas turbine engine includes additively manufacturing an additively manufactured thermally insulating structure onto a static structure of the miniature gas turbine engine.

Abstract: A gas turbine engine is provided that includes a compressor section, a turbine section, and a unitary structure. The compressor section has at least one compressor rotor stage. The turbine section has at least one turbine rotor stage. The compressor rotor stage and the turbine rotor stage are in rotational communication with each other. The unitary structure includes an outer case portion, a combustor section, a turbine nozzle, and an exhaust duct. The unitary structure configured for attachment with the turbine section and compressor section.

Abstract: An assembly for use in an attritable engine includes a hub and a blade. The hub is configured to rotate about a centerline axis passing through a center of the hub and is formed with a first type of layer-by-layer additive manufacturing process. The blade is connected to and extends radially outward from the hub. The blade is formed with a second type of layer-by-layer additive manufacturing process that is different than the first layer-by-layer additive manufacturing process. The hub and the blade are integrally formed together as a single piece of material with a layer-by-layer additive manufacturing process. The blade includes a root of a first material, a platform connected to the root, an airfoil connected to and extending from the platform, and a tip connected on a distal end of the airfoil opposite from the root. The platform includes a material that is different from the first.

Abstract: A component for a gas turbine engine is disclosed. In various embodiments, the component includes a diffuser ring, a combustor and a spring element connecting the diffuser ring to the combustor.

Abstract: A process for additive manufacturing of a metal alloy material is provided that includes: a) providing a feedstock powder comprising base powder particles with nanoparticles attached to surfaces of the base powder particles; b) providing an additive manufacturing system with a laser power source relatively movable at a scan speed; c) wherein the additive manufacturing system has a process window for the feedstock powder; and d) exposing the feedstock powder to a predetermined power input from the laser power source at a predetermined scan speed to produce the metal alloy material. The concentration by volume of nanoparticles within the feedstock powder is such that independent first and second microstructures may be produced within the metal alloy material.

Abstract: An additive manufacturing (AM) system comprising a process distortion compensation computing system configured to determine a digital nominal model that represents a physical target object excluding a distortion, and a digital distortion model that represents the physical target object including at least one distortion. The AM system further comprises an AM peripheral device configured to form a three-dimensional physical object based on a digital compensation model. The process distortion compensation computing system determines a material volume difference between the digital nominal model and the digital distortion model, and generates the digital compensation model that compensates for the material volume difference.

Abstract: An additively manufactured heat exchanger can include a plurality of vertically built fins, and a plurality of non-horizontally built parting sheets. The plurality of vertically built fins can extend between and connect to the plurality of parting sheets. The heat exchanger can include a plurality of layers of fins and parting sheets. The heat exchanger can include first and second flow circuits for allowing separate fluid flows to flow through the heat exchanger to exchange heat therebetween.

Abstract: An additive manufacturing (AM) system comprising a process distortion compensation computing system configured to determine a digital nominal model that represents a physical target object excluding a distortion, and a digital distortion model that represents the physical target object including at least one distortion. The AM system further comprises an AM peripheral device configured to form a three-dimensional physical object based on a digital compensation model. The process distortion compensation computing system determines a material volume difference between the digital nominal model and the digital distortion model, and generates the digital compensation model that compensates for the material volume difference.

Abstract: A method includes accessing a first model defining a shape of a part. The shape of the part is segregated into a plurality of predefined shapes selected from a library of predefined shapes. The predefined models for each of plurality of predefined shapes are assembled into a second model defining the shape of the part. The part is additively manufactured according to the second model.

Abstract: A method of manufacturing a component susceptible to multiple failure modes includes generating a stereolithography file including a geometry of the component. The geometry of the stereolithography file is divided into a plurality of layers. Each of the layers includes a first portion and a second portion of the component. Energy from an energy source is applied to a powdered material such that the powdered material fuses to form the first portion and the second portion of each of the plurality of layers. Applying energy from the energy source to form the first portion of the plurality of layers includes operating the energy source with a first set of parameters and applying energy from the energy source to form the second portion of the plurality of layers includes operating the energy source with a second set of parameters. The first set and second set of parameters are different.

Abstract: A method of manufacturing a component susceptible to multiple failure modes includes generating a stereolithography file including a geometry of the component. The geometry of the stereolithography file is divided into a plurality of layers. Each of the layers includes a first portion and a second portion of the component. Energy from an energy source is applied to a powdered material such that the powdered material fuses to form the first portion and the second portion of each of the plurality of layers. Applying energy from the energy source to form the first portion of the plurality of layers includes operating the energy source with a first set of parameters and applying energy from the energy source to form the second portion of the plurality of layers includes operating the energy source with a second set of parameters. The first set and second set of parameters are different.