Abstract: A method for assembling a rotor assembly and a rotor assembly are provided. The method comprises providing a rotor blade including a first sidewall, a second sidewall, where the first and second sidewalls are connected at a leading edge and a trailing edge and extend in span from a root portion to a tip portion, removing blade material from the tip portion to form a tip portion rake angle that enables the tip portion to extend obliquely between the first and second sidewalls, and coupling the rotor blade to a shaft such that during tip rubs the tip portion rake angle facilitates reducing radial loading induced to the blade during tip rubs.

Abstract: In the manufacture of integrally designed rotor wheels (BLISKs), the natural frequency of each blade is measured after forming by conventional shaping methods and the respective blade mass and its divergence from the smallest blade mass is calculated therefrom. The mass of each blade exceeding the smallest blade mass is removed by means of an etchant, so that all blades have essentially corresponding thickness, chord length, mass and natural frequency and are evenly loaded in operation. BLISKs manufactured in this way feature a long service life.

Abstract: A rotor blade for a turbine engine includes a first side that defines a first contact face with a hardcoat and a second side that defines a second contact face without a hardcoat.

Abstract: Overlapping twisted radial aerofoil blades or vanes (70) are formed on a compressor rotor or turbine disk or the like (68) by electro-discharge machining with a curved round section wire tool electrode (72) which is turned by a tool holder (28) as it is advanced on a helical path to form the inner surface of each blade or vane with the outer curve of the wire, or the outer surface of each blade or vane with the inner curve of the wire, the disk being indexed to a next rotary position after each blade surface is machined.

Abstract: A turbocharger system for an internal combustion engine includes at least one compressor wheel. The at least one compressor wheel of a single stage or multiple stage turbocharger system is formed, such as by pressure casting, from at least one of an aluminum metal matrix composite and an aluminum alloy containing up to 5 weight percent scandium.

Abstract: A method and apparatus for forming a closely spaced radial array of overlapping twisted airfoil blades or vanes. The apparatus comprises an electro-discharge machine that articulates an electrode (150), electrode (150) being in the form of an elongate and substantially rigid (non-wire) curved element which is turned by a tool holder (130) as it is advanced on a helical path. As the electrode (150) is advanced toward the edge surface of the blank it forms the inner surface of each airfoil blade with its outer curve, and forms the outer surface of each airfoil blade with its inner curve. As the electrode (150) is advanced through the blank it is twisted to give the first groove a helical form, thereby forming a twisted airfoil blade.

Abstract: An impeller assembly is for a fluid machine, such as a compressor, and includes a first, main body and a second body. The main body includes a first section providing at least a substantial portion of either an impeller disc or an impeller cover and a second section spaced generally axially from the first section and providing a portion of the other one of the disc or the cover. A plurality of integrally formed blades extend between and connect the main body first and second sections such that the main body is generally of one piece construction. A plurality of flow channels are defined between the blades and a plurality of access openings extend into the flow channels. The second body provides a remainder of the disc or cover and is attachable to the main body to substantially form an impeller and to close all of the access openings.

Abstract: The present invention provides an impeller in which a metallic bush can be inserted correctly into a synthetic resin impeller main body manufactured by resin molding using a die, and a determination as to whether or not the impeller has been manufactured correctly can be made easily. The impeller comprises: a metallic bush comprising a circumferential boss portion having a substantially truncated cone-shaped throttle portion positioned on a front surface axial end side, a periaxial support boss portion positioned in an axial center, and a circumferential protruding portion positioned on a back surface axial end side; and an impeller main body made of synthetic resin and formed with a V-shaped bulging portion that bulges axially in the center of a front surface side of a disk-shaped vane portion fulcrum, in which a plurality of vanes are formed integrally on the periphery of the V-shaped bulging portion.

Abstract: A method of machining a rotor disk includes the step of detecting accessible contact areas on a rotor surface and corresponding abrasive disk orientations at contact points within that contact area. The detected accessible area and orientations are then utilized to map a machining path and corresponding abrasive disk movements. Machine tool executable instructions are generated using the mapped machining path and corresponding abrasive disk movement for removing material on a rotor surface between two airfoils.

Abstract: The invention relates to a method for contour grinding wide blades at high speed, according to which a wheel (1) is used the grinding contour of which has a width dimension that is less than the width of the tip of the blades to be ground, said contour being defined by a straight area followed by an arched area at one end, with the straight area of which a straight grinding is carried out to deburr the tip of the blades, whereas with the arched area the contour grinding is carried out by the interpolation of axes.

Abstract: The present invention relates to a machine tool and a corresponding method for machining, in particular for turning and milling, a workpiece having a central bore, said machine tool comprising a tool holder for holding a tool, a work rest for seating the workpiece, a work mounting for holding the workpiece in place, and a drive means for rotating the workpiece about a central rotation axis, wherein the work rest has an arbor for attaching the workpiece, such that a section of the arbor projects into the central bore on a first side of the workpiece, and wherein the work mounting has a counter-holder movable in the direction of the bore axis of the central bore for applying a contact pressure, acting in the direction of the bore axis, to the workpiece on a second side opposite the first side.

Abstract: A method is provided for the production of gas turbine rotors with integrated blading. In a first step, rotating blades are produced. Subsequently, at least one of the produced rotating blade blanks is connected to the rotor bearing, then the or each of the rotating blade blanks connected to the rotor bearing are processed to form a nominal shape of the or each rotating blade. Consequently, the end contours of the gar turbine rotor with integrated balding are finely processed.

Abstract: A process for manufacturing a single-piece blisk, including: using an abrasive water jet to cut a block of material, so as to create blade preforms extending radially outwards from a disk, while keeping material forming a connecting mechanism between at least two directly consecutive blade preforms; then milling on the blade preforms so as to obtain profiled blade blanks; then a finishing by milling of the blade blanks, so as to obtain blades with a final profile; then removing the connecting mechanism.

Abstract: A process for manufacturing a single-piece bladed disk, including: using an abrasive water jet to cut a block of material, so as to create blade preforms extending radially outwards from a disk, while keeping material forming a connecting mechanism between at least two directly consecutive blade preforms, the connecting mechanism being at a radial spacing from the disk; then removing the connecting mechanism; then milling the blade preforms.

Abstract: A process for manufacturing a single-piece blisk, including: using an abrasive water jet to cut a block of material, so as to create blade preforms extending radially outwards from a disk, while keeping material to form a connecting mechanism between directly consecutive blade preforms, the cutting being done such that the connecting mechanism approximately forms a ring at a radial spacing from the disk, connecting the blade preforms together at a radially inwards distance from their tips, and then removing the connecting mechanism.

Abstract: A process for manufacturing a single-piece bladed disk, including: using an abrasive water jet to cut a block of material so as to create blade preforms extending radially outwards from a disk, while keeping material to form a connecting mechanism between at least two directly consecutive blade preforms; then milling on the blade preforms so as to obtain profiled blade blanks; then removing the connecting mechanism; then a finishing by milling of the blade blanks, so as to obtain blades with a final profile.

Abstract: A process for manufacturing a single-piece blisk, including: using an abrasive water jet to cut a block of material, so as to create blade preforms extending radially from a disk, then milling the blade preforms.

Abstract: A method of making an ice dispense agitator of a type as may be used in ice and beverage dispensing machines is characterized by manufacturing the agitator as an integral unit by cutting the agitator from flat metal stock and then bending the agitator into a desired final shape.

Abstract: The present invention is an apparatus that includes a chamber rotor with a chamber and an extension rotor with an extension. The rotors are housed in a rotor case. A pressure cavity is at least transiently formed by the extension rotor and the chamber rotor. The present invention also includes a compressor that includes a chamber rotor with a chamber and an extension rotor with an extension where the extension is adapted to be received in the chamber when the rotors are synchronously rotated. The compressor also includes a power input shaft attached to the extension rotor and a gear assembly attached to the rotors that is adapted to insure the synchronous rotation of the rotors. A rotor case houses the rotors and has an intake port and an exhaust port. The present invention also includes an engine that is similar to the compressor and includes a spark plug. Methods of compressing, pumping and generating electricity and mechanical power are also part of the present invention.

Abstract: A metal leading edge of a turbine fan blade is manufactured by cutting and shaping an elongated metal part. The metal part has front and rear edges extending lengthwise of the part, and has a generally wedge-shaped transverse cross-section with opposite sides diverging from the front edge toward the rear edge. A cavity is cut inward from the rear edge toward the front edge. This provides the part with a generally V-shaped transverse cross-section having opposite side walls diverging rearwardly from the front edge. A mandrel is inserted into the cavity, and the side walls of the V-shaped part are deflected toward each other to constrict the cavity into the configuration of the mandrel. The part is then mounted as a metal leading edge by inserting a turbine fan blade component into the constricted cavity and fastening the part to the component.

Abstract: A process for manufacturing an integrally bladed disk for a turbomachine rotor by friction welding is disclosed. The manufacturing process includes arranging a plurality of blades in the form of a ring in a mold having symmetry of revolution; casting a degradable material, preheated to a temperature above its melting point, onto the ring of blades in the mold; extracting the molded ring which is obtained after the degradable material has solidified; welding the molded ring onto a disk; and eliminating the degradable material.

Abstract: A processing method of a semi-processed product for obtaining a rotor equipped with a series of blades integral therewith by using a rotating tool such as a cutter, integral or with inserts. The processing method includes a) forming a hole into the semi-processed product; b) forming a series of cavities in the semi-processed product by removing material with the rotating tool to create the series of blades, starting from the hole and following predetermined paths; and c) removing material from the semi-processed product by advancing the rotating tool along its rotation axis and not removing material when the rotating tool advances along the predetermined paths. The rotation axis of the rotating tool is misaligned with respect to an axis of the hole.

Abstract: A system for manufacturing an integrally bladed rotor is provided. This system includes a ring component, wherein the ring component further includes at least one metal matrix composite and a continuous radially outwardly facing blade conical surface; an airfoil component, wherein the at least one airfoil component has been created from a single, unitary piece of material and further includes a plurality of individual airfoil blades and a continuous radially inwardly facing blade conical surface; and inertia welding means for frictionally engaging under an axially applied weld load the ring component and the airfoil component to effect an inertia weld therebetween along the conical surfaces.

Abstract: A method for the milling machining of components is disclosed. The method produces recesses with one or more lateral walls, in particular for the production of integrally bladed rotors for gas turbines, the recesses forming flow channels and the lateral walls forming blade surfaces of an integrally bladed rotor. The component to be machined by milling is clamped in a locating device for the milling machining. To adjust the vibrational properties of the component to be machined by milling, areas of the component are embedded in and/or filled with a machinable plastic.

Abstract: Method for manufacturing a stator component or rotor component (10) including at least one ring element (3). A joining material is provided in contact with at least one of the blade (2) and the ring element (3). The blade and the ring element are arranged in relation to one another in such a way that they are joined together via a butt joint when heated, and when such heat-treatment is subsequently carried out, the joining material forms a melt that joins the parts together upon solidification.

Abstract: A disk for a turbine engine is disclosed herein. The disk includes a rotatable body extending along a longitudinal axis between a forward side and an aft side. The disk also includes a plurality of slots disposed about a periphery of the body. Each of the slots extends between the forward and aft sides along a respective slot axis. The sides of each of the slots are asymmetrical relative to one another in a cross-section normal to the slot axis.

Abstract: A system for manufacturing an integrally bladed rotor is provided. This system includes a ring component, wherein the ring component further includes at least one metal matrix composite and a continuous radially outwardly facing conical surface; an airfoil component, wherein the airfoil component further includes a plurality of individual airfoil blades, wherein at least a portion of each individual airfoil blade has been reinforced with at least one metal matrix composite, and wherein each of the plurality of airfoil blades further includes a radially inwardly facing blade conical surface; and inertia welding means for frictionally engaging under an axially applied weld load the ring component and the airfoil component to effect an inertia weld therebetween along the conical surfaces.

Abstract: The invention relates to a process for preparing rotors or stators of a turbomolecular pump with rotor blades made of a specific aluminum alloy.

Abstract: A turbine blade including a root section at an end of the turbine blade, a first airfoil section adjacent to the root section, and a tip section adjacent to the airfoil section and including a material block that is incongruous with the airfoil section. A midspan section may also include a material block. Each material block can be selectively machined to customize the length of the turbine blade and the position of a tip shroud connection or midspan connection. The turbine blade can be sized for retrofitting last stage blades of older turbines. A radial position of the root mounts for the turbine blade may also be adjusted to provide further customization.

Abstract: A system for manufacturing an integrally bladed rotor is provided. This system includes a ring component, wherein the ring component further includes at least one metal matrix composite and a plurality of radially outwardly facing blade conical surfaces; an airfoil component, wherein the airfoil component further includes: a plurality of individual airfoil blades, wherein each of the plurality of airfoil blades further includes a radially inwardly facing blade conical surface; and inertia welding means for frictionally engaging under an axially applied weld load the ring component and the airfoil component to effect an inertia weld therebetween along the conical surfaces.

Abstract: An extrusion die for radial extrusion of a rotor shaft for a wind turbine generator has a body and a mandrel received in the body. The mandrel and body cooperatively define a tubular interior chamber. A punch is received in the tubular interior chamber and is moveable with respect to body and mandrel. A radial extrusion insert has a radial interior chamber in communication with the tubular interior chamber. The radial extrusion insert includes an arcuate edge disposed in a transition area between the tubular interior chamber and the radial interior chamber.

Abstract: A system and method for reconfiguring an airfoil of a turbine vane segment. In at least one embodiment, the system may be used to straighten an airfoil of a turbine vane segment to remove lean, twist, or racking, or any combination thereof. The airfoil may be straightened by applying a load to an inner shroud in a direction that is generally tangential to an outer shroud of the turbine vane segment. Orifices may be cut into the airfoil suction side, inboard of the outer shroud, to facilitate the straightening process. The orifices may be sealed upon completion of the process.

Abstract: In order to create titanium components with a titanium composite insert, a method is provided whereby an initial pre form 1 has a groove 2 formed in it. An encapsulating member 4 is then provided about the groove 2 in order to create a cavity 5 which is filled with titanium alloy powder 6. This titanium alloy powder 6 is densified and then accurately machined in order to create a groove insert form 7 which can accommodate a titanium composite material pre form insert 8 and further titanium alloy powder 9 such that through a high temperature isostatic pressing (HIP) process, the insert 8 is embedded. The original component form 1 can then be machined in order to create the final component elements such as aerofoils 13.

Abstract: A method and device for the surface peening, especially ultrasonic shot-peening, of at least one partial element of a component of a gas turbine, is disclosed. The partial element, e.g., a sealing fin, and at least one surface of a vibration device impinging the blasting material are positioned relative to each other at an angle between 70° and 90° based on the direction of extension of the sealing fin.

Abstract: With an integrally bladed rotor, material removal is performed from the annulus (5) on a wide, even machining path (8) using the front-side cutting area of an essentially cylindrical cutter head (7). The tool shank (9) is shaped and dimensioned such that it does not collide with the opposite lateral surfaces of the differently curved and twisted blades (4). This type of machining enables an essentially even, smooth annulus surface to be obtained with a reduced number of overlapping machining paths (8). The time required for machining the annulus and the tool wear are reduced. With an annulus machined in accordance with the present invention, the rotor will satisfy high requirements on aerodynamics.

Abstract: A rotor element includes at least one irregularity with regard to rotational properties in its circumferential direction and the irregularity is positioned so as to separate the mechanical natural frequencies of the rotor element.

Abstract: A method for machining a blank includes machining a first pocket in the blank having a first sidewall, machining a second pocket in the blank, machining a groove within material located between the first and second pockets to expose a second sidewall opposite the first sidewall, machining the first and second sidewalls, and alternately repeating machining the grove and the sidewalls to step mill the groove deeper in the blank and form a third pocket along which the second sidewall extends.

Abstract: With the fabrication of integrally bladed rotors or stators (blisks) for gas-turbine engines, where the space confined by the pressure and suction side as well as the annulus surface is shaped by cutting and machining from the solid material, starting at the periphery of a ring or disk, a stiffness-optimized pre-machining contour is cut out in a cutting process at a certain distance from the pressure and suction side along straight control surfaces at a cutting angle varying in correspondence with the blade twist and along a conical surface extending at a certain distance from the annulus surface as well as along transition surfaces between the conical and the control surfaces, and subsequently finish machined by finish milling to produce the final contour of the blade, annulus and transition surfaces. The method reduces tool wear and is cost-effective.

Abstract: A method of manufacturing an integral bladed rotor is disclosed. The method includes calculating a cutting path in an area of a blank between adjacent blade locations to approximate contours of adjacent blades. A cutter is plunged into the area at an initial angle and depth that extends from an outer perimeter to the blank to an inner perimeter of the blank, in one example. The blade roots extend from the inner perimeter, and the blade tips terminate near the outer perimeter. The cutter is plunged into the area at an original angle that, in one example, is different than the initial angle. The cutter is rotated about an axis in a spiral-like fashion as the cutter extends further into the blank, along the cutting path.

Abstract: In a method for manufacturing a hollow blade for a turbomachine, the blade is made from a preform derived from external primary parts. Each primary part comprising a root part is formed by flattening a blank cut out from a ring with a large diameter provided with a protuberance, in order to reduce costs.

Abstract: The turbine includes a plurality of successive stages each having a rotatable disk and blades carried thereby. A pair of adjacent rotatable disks define an annular gap therebetween and have respective opposing sealing band receiving slots aligned with the annular gap. At least one of the rotatable disks has at least one notch therein coupled to the respective sealing band receiving slot, and a sealing band is in the opposing sealing band receiving slots to seal the corresponding annular gap. The sealing band includes at least one sealing strip and at least one movable locking tang carried thereby and extending into the at least one notch to define an anti-rotational feature for the sealing band.

Abstract: In a vane-type camshaft phaser, one vane extends over a much larger internal angle than the other two vanes. Because of its size and strength, the large vane is the vane designated for contact with the stator. The other vanes and lobes have extra clearance to prevent contact regardless of rotor position. In one embodiment, a first surface of the large vane engages a surface of a first adjacent lobe at one extreme rotor rotation, and a second surface of the large vane engages a surface of a second adjacent lobe at the opposite extreme of rotation. The contact surfaces of the lobes and the vane may be equipped with hardened wear pads. One or more wear pads may be machined to provide a desired rotor displacement angle.

Abstract: A method of manufacturing a rotor to be used in a dual-rotor lobe pump system for pumping a material at a periodic rate is provided. The method includes selecting a desired periodic flow rate for the material, selecting a number of lobes for the rotor, and selecting either a thickness of the rotor or a spacing between the dual-rotors' axes of rotation in the lobe pump. The method also includes determining the profile for the rotor based on the desired periodic flow rate, so that when the rotor is operated within the dual-rotor lobe pump system, the material can be pumped at substantially the desired periodic flow rate. In another embodiment of the invention, a lobe pump rotor profile is formed by the method described above.

Abstract: In the manufacture of integrally designed rotor wheels (BLISKs), the natural frequency of each blade is measured after forming by conventional shaping methods and the respective blade mass and its divergence from the smallest blade mass is calculated therefrom. The mass of each blade exceeding the smallest blade mass is removed by means of an etchant, so that all blades have essentially corresponding thickness, chord length, mass and natural frequency and are evenly loaded in operation. BLISKs manufactured in this way feature a long service life.

Abstract: A method for reconfiguring an airfoil of a turbine vane segment. In at least one embodiment, the method may be used to straighten an airfoil of a turbine vane segment to remove lean, twist, or racking, or any combination thereof. The airfoil may be straightened by heating the airfoil to no more than 750 degrees F. while applying a load to an inner shroud in a direction that is generally tangential to an outer shroud of the turbine vane segment. The load is up to 6000 lbf. Orifices may be cut into the airfoil suction side, inboard of the outer shroud, to facilitate the straightening process. The orifices may be sealed upon completion of the process.

Abstract: A compositionally graded gas turbine disk is made by placing a cylindrically symmetric slip case concentrically into an interior of a cylindrically symmetric outer container. A first nickel-base superalloy powder is loaded into a radially inner first portion of the interior and a second nickel-base superalloy powder is loaded into a radially outer second portion of the interior. The slip case is removed so that the first nickel-base superalloy powder and the second nickel-base superalloy powder contact in the transition region and form a non-compacted powder mass. The non-compacted powder mass is processed into a gas turbine disk, typically by compacting the non-compacted powder mass to form a compacted powder mass, and thereafter heat treating the compacted powder mass.

Abstract: A method of determining optimal parameters for machining a workpiece comprises performing a first computer simulation to determine parameters for machining a workpiece, including a tool nose radius and a tool rake angle, performing a second computer simulation to determine additional parameters for machining a workpiece, including a tool rotational speed and tool feed speed, and performing a third computer simulation to optimize the parameters for a desired tool path. A method of machining a green or bisque ceramic workpiece contacts the workpiece with a tool using a negative rake angle.

Abstract: A method of manufacturing a rotating component (110), the method comprising the following steps: providing a component comprising a first portion (20, 40, 60, 80, 100, 116), which first portion defines a first cavity (26, 46, 66, 86, 106), characterised by; identifying a first inertial property of the first portion and/or the entire component, introducing material (28, 48, 68, 88, 108) into the first cavity to achieve an adjusted inertial property of the first portion and hence a desired inertial property of the component. A rotating component (110) comprising: a first portion (20, 40, 60, 80, 100, 116) defining a first cavity (26, 46, 66, 86, 106), a second portion (118) defining a second cavity, the second portion being circumferentially spaced from said first portion, characterised in that the first cavity has a first material (28) deposit therein, said material having predetermined inertial characteristics so as to adjust the centre of mass (Z) of the rotating component.

Abstract: An integrally bladed rotor disk, commonly referred to as an IBR or a blisk, includes partial cuts in the rotor disk extending from the rotor disk surface and along side the blades to form a partial root portion below each blade. A damaged blade can be removed from the rotor disk by breaking off the partial root portion from the disk or additionally cutting the disk to join the two cuts forming the partial root portion of the damaged blade. A replacement blade having a root already formed on the blade can then be inserted into the remaining slot of the rotor disk and secured to the rotor disk by any known means. The partial formed root of the blade can be in the shape of a dove tail root or a fir tree root.

Abstract: A method for finishing a part having excess material includes generating one or more surfaces on a model of the part to be machined, creating a machining tool path drive geometry, using the machine tool path drive geometry and one or more surfaces on the model to be machined to generate machining tool paths on the surfaces; and running tool paths on the part in a fixture.