Abstract: Non-contact strain measurement systems and their method of use to detect strain on rotating components are disclosed. A non-contact strain measurement system comprises magnetic materials plated onto a rotatable component in addition to appropriate encoders and controller. The magnetic materials are spaced apart a first distance D1 when the component is not rotating, and a second distance D2 when the component is rotating. The encoders and controller are utilized to detect strain on the rotating component. A method of using the system to detect strain on a rotating component includes detecting the first distance D1 then detecting the second distance D2, and calculating the strain imparted onto the component from a difference between D1 and D2.

Abstract: A heat exchanger includes an additively manufactured manifold. The manifold includes an inlet feed manifold and an outlet feed manifold, and a plurality of hypotubes fluidly coupled to the manifold. The hypotubes are round in cross-section, wherein each of the hypotubes has a diameter that has a first value between 0.03 inches and 0.3 inches, and wherein each of the hypotubes has a wall thickness that has a second value between 0.001 inches and 0.0.015 inches.

Abstract: An additive manufacturing system for fabricating a hybrid component includes a build platform having a platform surface at a first elevation and at least one preform structure secured proximate to the build platform. The preform structure includes a first preform surface located at a second elevation. The system further includes a powder deposition device disposed above the build platform at a third elevation, the third elevation being greater than the first and second elevations.

Abstract: A septum-tied tube pack is provided that includes a first outer wall formed by a multiple of first connected radiuses. A second outer wall is formed by a multiple of second connected radiuses. A first end radius connects the first outer wall and the second outer wall. A second end radius connects the first outer wall and the second outer wall. A multiple of septum elements extend between the first outer wall and the second outer wall. A gas turbine engine is also provided that includes an engine case structure and a fluid conduit mounted to the engine case structure. The fluid conduit includes a septum-tied tube pack section.

Abstract: A damper includes a damper body that is configured to be attached to a workpiece during a machining process. A first side of the damper body is configured to abut a first side of the workpiece. The damper body includes a frame forming an outer periphery of the damper body, a plurality of damper nodes with a cavity in each damper node positioned in the frame, and a plurality of ribs extending between the frame and the damper nodes. A damping material is positioned in the cavity of each damper node.

Abstract: An apparatus for finishing a component includes at least one articulating arm having a shot peening apparatus and at least one laser source. A plurality of laser redirectors are configured to redirect a laser originating from the laser source. Each laser redirector in the plurality of laser redirectors is mounted to a first rail and a second rail. A controller is controllably coupled to the articulating arm and each of the rails such that output signals from the controller control a position of the articulating arm, and a position of each laser redirector in the plurality of laser redirectors.

Abstract: An apparatus for finishing a component includes at least one articulating arm, at least one plasma gun disposed at an end of a first articulating arm of the at least one articulating arm, at least one shot peen nozzle maintained in a fixed positioned relative to the plasma gun, and a controller controllably coupled to the articulating arm such that output signals from the controller control motions of the articulating arm.

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: An electrochemical machining system comprises a component having a passage, the passage has an opening and an internal surface formed along the passage, a conductive wire has insulation covering portions of the conductive wire forming gaps having exposed wire; the conductive wire is inserted in the passage; a power source is coupled to the component and the conductive wire forms an electrical circuit, wherein the component comprises an anode and the conductive wire comprises a cathode; and an electrolyte within the passage contacting the internal surface and the exposed wire, wherein the electrolyte comprises a charge-carrying liquid configured to complete the electrical circuit between the cathode and anode.

Abstract: A system for dispersing a catalyst in a fuel includes a first reservoir containing the fuel, and a second reservoir including an agitator and containing a quantity of the catalyst suspended in the fuel. The system also includes a first conduit extending from the first reservoir, a second conduit extending from the second reservoir, and a mixing nozzle connected to the first conduit and the second conduit. The mixing nozzle includes a first meter positioned within the first conduit, a second meter positioned within the second conduit, a valve positioned upstream from the second meter within the second conduit, a junction in flow communication with the first conduit and the second conduit, a mixer downstream from the junction, a sensor positioned between the mixer and an outlet; and a controller connected to the valve and the first and second meters, the controller receiving feedback from the sensor.

Abstract: An additive manufacturing system includes a build plate; a deposition system operable to dispense material as a melt pool to grow a workpiece on the build plate; a sensor system operable to determine a temperature of the workpiece being grown on the build plate adjacent to the melt pool; and a heater system operable to selectively heat the workpiece between the melt pool and the build plate.

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: An exemplary method of adjustably mounting a first component to a second component includes, among other things, securing the first component to the second component with a linking member, and selectively adjusting the temperature of a variable portion of the linking member to change a size of the linking member.

Abstract: An airfoil is disclosed. The airfoil may comprise a leading edge, a body portion and a trailing edge formed from a high-modulus plating. The body portion of the airfoil may be formed from a material having a lower elastic modulus than the high-modulus plating. The high-modulus plating may improve the stiffness of the trailing edge, allowing for thinner trailing edges with improved fatigue life to be formed.

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 machine for fabricating a fiber-reinforced component by additive manufacture is disclosed. The machine may have a surface, a matrix feed configured to deposit a plurality of matrix layers on the surface, and a fiber feed configured to deposit a fiber layer on at least one of the plurality of matrix layers. The deposition of the plurality of matrix layers and the fiber layer may be controlled by a computer.

Abstract: A thin-walled heat exchanger includes a component having at least one thermal transfer structure. The thermal transfer structure includes a wall having a thickness ranging from about 0.003 in to about 0.010 in.

Abstract: An additively manufactured component includes a planar sheet and a coating applied to the planar sheet to form the component. The component is configured for attachment to a non-planar surface of a workpiece.

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.