Abstract: Methods for manufacturing a composite fan inlet housing are disclosed. The methods include inserting a first piece of composite material and a second piece of composite material into a molding tool, inserting an inflatable bladder between the first piece and the second piece, and pressurizing the inflatable bladder to a curing pressure for a length of time sufficient to allow the first piece and second piece to cure.

Abstract: Methods for manufacturing a composite fan inlet housing are disclosed. The methods include inserting a first piece of composite material and a second piece of composite material into a molding tool, inserting an inflatable bladder between the first piece and the second piece, and pressurizing the inflatable bladder to a curing pressure for a length of time sufficient to allow the first piece and second piece to cure.

Abstract: Methods and apparatus are provided for a fan containment system for a gas turbine engine having a plurality of fan blades includes a cylindrical casing with an inner surface surrounding the plurality of fan blades and an opposing outer surface; a first layer of fabric material positioned on the exterior surface of the cylindrical casing; and a shear thickening fluid impregnated within the first layer of fabric material.

Abstract: Abradable wall structures for high temperature applications, such as in turbine housings and the like. The wall structures comprise a superalloy metal base plate supporting a superalloy metallic cellular structure, the cells of which are filled to a substantial extent with at least one ceramic core material providing high heat resistance, oxygen barrier and low thermal expansion properties. The invention involves the application of a porous or pore-forming surface composition to provide a corrosion-resistant, erosion-resistant abradable outer surface layer, the softness or porosity of which can be tailored to improve the abradability of the wall structure, while imparting oxidation-, corrosion- and erosion-resistance to the structure. The surface layer composition may comprise metal superalloy, ceramic or cermet base compositions containing fugitive or retained inert filler materials.

Abstract: Abradable wall structures for high temperature applications, such as in turbine housings and the like. The wall structures comprise a superalloy metal base plate supporting a superalloy metallic cellular structure, the cells of which are filled to a substantial extent with at least one ceramic core material providing high heat resistance, oxygen barrier and low thermal expansion properties. The invention involves the application of a porous or pore-forming surface composition to provide a corrosion-resistant, erosion-resistant abradable outer surface layer, the softness or porosity of which can be tailored to improve the abradability of the wall structure, while imparting oxidation-, corrosion- and erosion-resistance to the structure. The surface layer composition may comprise metal superalloy, ceramic or cermet base compositions containing fugitive or retained inert filler materials.

Abstract: A powder feed system with a recirculator is provided for a plasma spray apparatus so that spraying operations may be started and stopped abruptly. The subject system utilizes a pressurized gas to direct a powdered material from a powder feed hopper to the plasma spray applicator. A diverter valve is located intermediate the powder feed hopper and the plasma spray applicator and in close proximity to the plasma spray applicator for selectively diverting the powdered material toward or away from the plasma spray applicator. Powdered material diverted away from the plasma spray applicator is directed to a powder accumulator for subsequent reuse. The powdered material is kept in continuous motion during both spraying and diverting operations thereby avoiding the need to overcome inertia each time spraying operations are commenced.