Abstract: A method includes building a tubular object by a layer-by-layer additive manufacturing process. A structure integrally connected to the tubular object for supporting a portion of the tubular object is formed during building of the tubular object. The structure provides vibration dampening, heat shielding, heat transfer, stiffening, energy absorption, or mounting after the tubular object is built.

Abstract: A damper-seal assembly for a gas turbine engine includes an additively manufactured seal and an additively manufactured damper inseparably assembled with the additively manufactured seal.

Abstract: A method includes designing a part. The part includes at least one internal structure. The internal structure is designed to provide strain mitigation, energy dissipation, or impact resistance for the part during an emergency condition. The part is built by a layer-by-layer additive manufacturing process. While building the part, the internal structure is connected to the part.

Abstract: An example multi-dimensional component building system includes a first chamber having at least one base disposed therein, a second chamber adjacent to and in fluid communication with the first chamber through a first door, and a third chamber adjacent to and in fluid communication with the second chamber through a second door. The second chamber is fluidly sealed from the first chamber if the first door is in a closed position. The second chamber is configured to receive the at least one base via a first transfer mechanism if the fluid parameters of the first chamber are approximately equal to the fluid parameters of the second chamber. The second chamber includes a directed heat source and a build-up material configured to form a component on the at least one base by melting or sintering. The third chamber is fluidly sealed from the second chamber if the first door is in a closed position.

Abstract: A multi-component fastener is provided having a body and a sleeve. The body has a shank that extends lengthwise between a head and a distal end. The shank includes a first outer surface. The body includes a first material. The sleeve has a wall defined by an outer surface and an inner surface. The inner surface defines an interior cavity. The wall extends lengthwise between a first end and a second end. At least a portion of the sleeve outer surface contiguous with the first end is threaded. The sleeve includes a second material that is dissimilar to the first material. A portion of the shank including the distal end is disposed within the interior cavity of the sleeve. The sleeve and the shank are fixed to one another.

Abstract: An apparatus includes first, second, and third layers. The first layer includes a plurality of flanges. The second layer includes a deformable membrane. The second layer is connected to the first layer along a first major surface of the deformable membrane. The third layer is connected to the second layer along a second major surface of the deformable membrane opposite the first major surface. The third layer includes a first series of internal structures.

Abstract: A component includes an additively manufactured component with an internal passage; and an additively manufactured elongated member within the internal passage. A method of additively manufacturing a component including additively manufacturing a component with an internal passage; and additively manufacturing an elongated member within the internal passage concurrent with additively manufacturing the component.

Abstract: A method of removing partially sintered powder from an internal passage in a metal component formed by electron beam additive manufacturing (EBAM) includes co-forming a solid wire cutter in the passage during the EBAM forming process and removing partially sintered powder from the cavity by extracting the cutter from the cavity.

Abstract: A method of making a part including a solid portion with an internal passage includes building the part using an additive manufacturing process that builds the part on a layer-by-layer basis. The solid portion of the part is formed. A solid core is formed within at least a portion of the internal passage. Forming the solid core includes forming an attachment feature and forming a shearing feature. Material that is not fused, either semi-sintered or un-sintered, is positioned between the solid portion and the solid core. A force selected from the group consisting of a tensile, compressive, vibratory, and torsional force is applied to the solid core at the attachment feature. The material is then shorn with the shearing feature.

Abstract: A method of making a part including a solid portion with an internal passage includes building the part using an additive manufacturing process that builds the part on a layer-by-layer basis. The solid portion of the part is formed. Forming the solid portion includes fusing the solid portion. A solid core is formed within at least a portion of the internal passage. Forming the solid core includes fusing the solid core and forming an attachment feature on the solid core. Material that is not fused, either semi-sintered or un-sintered, is positioned between the solid portion and the solid core. At least a tensile, compressive, vibratory, or torsional force is applied to the solid core at the attachment feature. The solid core is then removed from the part.

Abstract: A thermal energy exchange system for cooling air of a gas turbine engine includes a heat exchanger located at a diffuser of the gas turbine engine. The diffuser is positioned axially between a compressor and a combustor of the gas turbine engine. A fuel source is operably connected to the heat exchanger to direct a flow of fuel through the heat exchanger via a fuel pipe and toward a fuel nozzle of the combustor. An airflow inlet directs a cooling airflow through the heat exchanger to reduce an airflow temperature via thermal energy exchange between the cooling airflow and the flow of fuel. An airflow outlet directs the cooling airflow from the heat exchanger toward one or more of components of the turbine to cool the one or more components.

Abstract: A component comprises a non-metallic core having an outer surface, a first catalyst deposited onto at least a first portion of the outer surface of the non-metallic core, a second catalyst deposited onto at least a second portion of the outer surface of the non-metallic core, an electrical interface, and a metallic coating. The electrical interface is plated onto the first catalyst, and includes a first interface layer electroless plated onto the first catalyst. The metallic coating is plated onto the second catalyst.

Abstract: A tool includes a head that extends form the flexible section, an emitter within the head; and a nozzle to eject a cooling fluid therefrom. A method of additively manufacturing a component including delivering series of thermal shocks to a conglomerated powder within an internal passage of an additively manufactured component to facilitate removal of the conglomerated powder.

Abstract: A tool includes a flexible section; a head that extends form the flexible section; and an exciter within the head. A method of additively manufacturing a component including burrowing a tool into a conglomerated powder within an internal passage of an additively manufactured component, the tool vibrating in a manner to facilitate removal of the conglomerated powder.

Abstract: A method of forming an object includes installing multiple foil drums within a processing chamber of an ultrasonic consolidation system. The multiple foil drums each include different materials than the other foil drums. The multiple foil drums are positioned so that one of the foils is selected to be placed on top of the build platform. The selected foil is welded onto the build platform or onto a previously processed layer. A portion of the welded foil is then cut. The multiple foil drums are retracted away from the build platform. The portion of the welded foil that was just cut is then consolidated to the object. The build platform is incrementally lowered before the process is repeated to form the next layer of the object.

Abstract: A powder bed deposition apparatus comprises a movable build plate, a powder delivery system, an energy beam apparatus capable of selectively steering at least one focused energy beam over successive quantities of metal powder, a non-metallic barrier layer, and an anchor removably secured to the build plate. The non-metallic barrier layer is disposed over a metal upper surface of the build plate. The anchor has a metal bonding surface flush with the non-metallic barrier layer, the non-metallic barrier layer and the anchor defining a removable build assembly with a powder bed working surface.

Abstract: A method of monitoring the residual stress in surface and near surface regions of a component includes identifying predetermined locations on the surface of a component that are expected to experience high stress during normal operating conditions of the component. Marker particles are introduced into the component during additive manufacture of the component at the predetermined locations. Then, the residual stress of the component is measured at a location corresponding with the marker material using x-ray techniques.

Abstract: An embodiment of an apparatus includes a centrifugal drive unit, an arm assembly, an optional dynamic balancing ring, and a workpiece fixture. The arm assembly is operatively connected to the centrifugal drive unit and configured to revolve about a primary axis perpendicular to the arm. The workpiece fixture is mounted to the arm assembly, and is configured to rotate at least one workpiece about at least one secondary axis outboard of the primary axis.

Abstract: A blade is provided for a gas turbine engine. The blade includes an airfoil portion with at least one internal cavity and a damper located within the internal cavity. The damper includes a cantilever spring arm. A fan blade is provided for a gas turbine engine. The fan blade includes an airfoil portion with at least one internal cavity; and a damper located within the internal cavity. The damper includes a cantilever spring arm that terminates with a rub surface pad adjacent to a friction bridge between a concave pressure side and a convex suction side of the airfoil portion. A method is also provided for damping a blade of a gas turbine engine. The method includes deflecting a cantilever spring arm to contact a rub surface pad with a friction bridge between a concave pressure side and a convex suction side of an airfoil portion of the blade.

Abstract: A method of forming a metal component with two and three dimensional internal functionally graded alloy composition gradients includes forming the component by a powder based layer-by-layer additive manufacturing process. The areal composition distribution of each powder layer is determined by simultaneously depositing different powders and powder mixtures through a mixing valve attached to a single nozzle during powder deposition. The layers are then sintered with a directed energy source to form a forging preform. The preform is then forged to form a component.