Abstract: A heat exchanger arrangement includes walls defining at least two circuit passages for porting a first fluid, a first of the circuit passages defining a first passage length, and a second of the circuit passages defining a second passage length, the second passage length being different from the first passage length, the walls being in thermal communication with a second fluid while isolating the first fluid from the second fluid, at least one of the first circuit passage and the second circuit passage includes a flow control feature configured to decrease an imbalance in flow between the first circuit passage and the second circuit passage compared to if the flow control feature were not present.

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 method of forming a component by powder bed fusion includes depositing a bed of metal powder on a platform by moving a recoater blade across the platform at a first angle of approach. A layer of the component is formed by sintering at least a portion of the bed of metal powder. A subsequent bed of metal powder is deposited on the platform by moving the recoater blade across the platform and the bed of metal powder at a second angle of approach. A subsequent layer of the component is formed by sintering at least a portion of the subsequent bed of metal powder.

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 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 heat exchanger includes a core having a plurality of first layers for receiving a first fluid and at least one header arranged in fluid communication with the plurality of first layers. The at least one header is integrally formed ith the core via an additive manufacturing process. The header has a first microstructure and the core has a second, different microstructure.

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: 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 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 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: 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 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 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: 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.