Abstract: A three-dimensional additive manufactured product includes a body portion and a male screw portion integrally disposed on a surface of the body portion so as to protrude therefrom. The male screw portion includes a following side flank forming a first flank angle with respect to a vertical plane to an axis thereof. The first flank angle is not less than 45 degrees.

Abstract: A combustor heat shield has lips with fins distributed on the lips. The lip-fins have an extended end portion projecting rearwardly from the back face of the heat shield. Impingement jets may be directed against the rearwardly extended end portions of the lip-fins to enhance cooling. The heat shield may define a fuel nozzle opening surrounded by a rail on the back side of the heat shield. Impingement holes or slots may be defined in the rail for allowing cooling air passing therethrough to impinge upon the lip-fins.

Abstract: Embodiments of the invention relate to systems and methods for casting hybrid rocket motor fuel grains. In one embodiment, a method for casting a rocket motor fuel grain can be provided. The method can include providing a positive image of a port made from at least one material. The method can further include disposing at least one fuel material around at least a portion of the positive image of the port. Further, the method can include removing the at least one material, wherein a negative image of the port is formed in the at least one fuel material.

Abstract: The construction of an internal/external single expansion ramp nozzle (nxSERN), and method of designing the same, is provided. Initial design parameters for primary stream construction are selected and additional parameters are determined by isentropic relations using the selected design parameters and Prandtl-Meyer function. The nozzle throat input and output angles are determined and used to define an initial portion of the nozzle primary stream lower expansion surface. The nozzle primary stream upper expansion surface and an aft portion of the primary stream lower expansion surface are defined using a method of characteristics. Initial and aft portions of the primary stream lower expansion surface are then connected by a straight line to define the primary stream nozzle.

Abstract: A method for removing an end cap assembly from a combustor cap assembly includes inserting a push rod through an opening in a back plate portion of the cap assembly. One end of the push rod is engaged with a radial support feature of the end cap assembly and a substantially linear force is applied to the push rod. The force is distributed to the radial support feature, thereby preventing damage to a cap plate portion of the end cap assembly.

Abstract: In various embodiments, a jet engine, as described herein, may include a fan case, a fan cowl, and an air inlet. Further, in various embodiments, at least one of the fan case and the fan cowl may be directly coupled to the air inlet. In addition, in various embodiments, the fan case, the fan cowl, and the air inlet may be manufactured as a single, unitary, engine part.

Abstract: A novel and improved combustion liner for use in a gas turbine engine is provided in which the premixer assembly is removably fastened to the combustion liner. Apparatus and method for removably securing the premixer assembly to the combustion liner is provided. A combustor dome plate, swirler assembly and inlet ring basket are coupled together by a plurality of removable fasteners in order to increase accessibility to portions of the combustion liner for inspection and repair processes.

Abstract: A system and method are provided for altering the natural frequency of a dome plate portion of a premixer assembly of a gas turbine combustor. The plate assembly has a dome plate with a central pilot mixer and a plurality of extension tabs extending radially outward from the pilot mixer. A plurality of radially extending struts are secured to the extension tabs in order to alter the natural frequency of the dome plate.

Abstract: A hybrid rocket motor is manufactured by photopolymerizing the solid fuel grain in a stereolithography method, wherein fuel grains in a plastic matrix are deposited in layers for building a solid fuel rocket body in three dimensions for improved performance and for a compact design,

Abstract: Methods and apparatus of an improved cooling structure having cooling passages are provided. A method includes forming pilot holes with an electrical discharge machine (EDM) drill near a heated flow surface. The pilot holes are then shaped with a wire EDM into cooling passages having a desired shape.

Abstract: A transverse splicing plate for producing a fuselage of an aircraft by connecting several CFP fuselage sections that have in particular been produced in the winding method, in each case by forming a transverse seam, wherein the flexible transverse splicing plate is of a multilayer construction, in other words it comprises a multitude of plate segments arranged one above the other, wherein each of the plate segments comprises a multitude of longitudinal slits, each being able independently of each other to make small radial bending movements in order to cause tolerance compensation in radial direction between the fuselage sections to be joined, in which tolerance compensation a sliding movement between the sub-plates of the plate segments arranged one above the other takes place in axial direction of the barrel-shaped fuselage sections, and wherein on the inside the ends of the fuselage sections comprise chamfers; as well as a method for producing a connection between two CFP fuselage sections, which have pref

Abstract: An apparatus includes a slotted multi-nozzle grid with a plate having multiple elongated slotlettes through the plate. Each of at least some of the slotlettes has a convergent input, a divergent output, and a narrower throat portion separating the convergent input and the divergent output. At least some of the slotlettes are arranged in multiple rows. The plate further includes multiple cooling channels through the plate. At least some of the cooling channels are located between the rows of slotlettes. Each cooling channel is configured to transport coolant through the plate in order to cool the plate, such as to cool the plate as hot combustion gases pass through the plate. Each of at least some of the rows may include at least two slotlettes, and two adjacent slotlettes in one row may be separated by a structural ligament (which may have a tear-drop cross-sectional shape).

Abstract: A method of forming an internal combustion engine component having a multi-panel outer wall. The multi-panel outer wall has an inner panel (16) with an inner surface (18) and an outer surface (37). The inner panel outer surface (37) has discrete pockets (23) formed by integral structural ribs (38). Each pocket (23) has a film cooling hole (31) between the pocket (23) and the plenum (20). The method includes: forming dimples (40) in the intermediate panel (22), at least one dimple (40) having a nozzle (29); securing the intermediate panel (22) to the inner panel outer surface (37), thereby enclosing at least one pocket (23); and ensuring a respective dimple (40) having a nozzle (29) protrudes into a respective enclosed pocket (24) and a respective nozzle (29) is configured to direct a respective jet (35) of cooling fluid onto the inner panel outer surface within the respective enclosed pocket (23).

Abstract: A discharge system of a separated twin-flow turbojet for an aircraft, supported by a suspension mast, is disclosed. The system includes a main nozzle delimited by an annular cowl with a slot of annular shape defining upstream and downstream portions of the cowl and which is traversed by the suspension mast. The downstream portion of the cowl of the main nozzle includes a first part extending downstream from the upstream portion of the cowl to a trailing edge of the main nozzle, on either side of the suspension mast along two predefined angular sectors; and a second part formed from an internal contour of the slot and having a trailing edge with a diameter smaller than that of the trailing edge associated with the first part of the downstream portion of the cowl. Connecting walls laterally connect the first and second parts of the downstream portion.

Abstract: A simplified and less costly manufacture process of a print head can be effective in preventing the peeling-off between a substrate and a flow passage forming member. In the print head, a protective layer is formed between the flow passage forming member and a heat generating portion. The protective layer contains a noble metal. On a side of the flow passage forming member, the surface of the protective layer is made of an oxide of a noble metal, except in a portion corresponding to the heat generating portion, while in the portion corresponding to the heat generating portion on the flow passage forming member side, the surface thereof is made of the noble metal.

Abstract: A fiber preform is obtained by conforming panels of fiber texture on a former having a surface that reproduces the shape desired for a surface of the nozzle or the nozzle divergent section that is to be made. The panels are bonded together via their mutually contacting edges. A consolidated fiber reinforcement is formed by shaping the fiber preform impregnated with a consolidation composition including a resin. The shaping of the fiber preform is performed between the former and a jacket applied against the impregnated fiber preform so as the consolidated fiber reinforcement has a fiber volume percentage of at least 35%, and a thickness of less than 5 mm over at least a major fraction of its axial dimension. The densification of the fiber reinforcement is continued by chemical vapor infiltration after pyrolyzing the resin so that once densified, a part is obtained that has practically the shape and the wall thickness of the nozzle or the nozzle divergent section that is to be made.

Abstract: A method for manufacturing an air-intake structure for a turbojet-engine nacelle includes two component parts, i.e. one air-intake lip structure and one outer cowl for the air-intake structure. In particular, the method includes the following steps: separately manufacturing the component parts such that each integrates one overlapping portion with a part to which is to be attached. The overlapping portion is configured such that an outer surface of the outer overlapping portion provides continuity with an outer surface of the outer cowl associated with the inner overlapping portion. To secure the overlapping portions, glue or a fastener may be used.

Abstract: A combustor generally includes a liner that at least partially defines a combustion chamber within the combustor. The liner may generally include a hole that extends through the liner and that at least partially defines a mating surface. An insert having an outer surface extends at least partially through the hole. A projection that at least partially defines a mating surface at least partially circumferentially surrounds the insert outer surface. A joint between the projection mating surface and the hole mating surface provides a connection point between the projection mating surface and the liner hole mating surface.

Abstract: A method for producing a combustion chamber includes providing a combustion chamber wall; forming a plurality of milled recesses in the combustion chamber wall, along a longitudinal axis and in an area of the longitudinal axis transverse to the longitudinal axis; and forming a cooling channel having a substantially rectangular cross section and opposite web walls inside the combustion chamber wall along the longitudinal axis and configured to receive a flow a cooling medium along the longitudinal axis, wherein the plurality of milled recesses form depressions in the web walls.

Abstract: An injector assembly for a rocket engine includes a thermal insulating layer adjacent to an oxidizer cavity.

Abstract: A method of manufacturing a wall structure includes producing at least one elongated web in a workpiece by feeding a machining tool along the workpiece, wherein the machining tool simultaneously machines a first side surface of the web, a second side surface of the web and a top surface of the web.

Abstract: Hydroelectric turbines in confined spaces depend heavily on nozzles and relationships involving nozzles and related turbine components in order to obtain maximal efficiencies for a wide range of flow conditions.

Abstract: A nozzle arrangement is disclosed herein for use with a supersonic jet engine that is configured to produce a plume of exhaust gases. The nozzle arrangement includes, but is not limited to, a nozzle having a trailing edge and a plug body partially positioned within the nozzle. The plug body has an expansion surface and a compression surface downstream of the expansion surface. A protruding portion of the plug body extends downstream of the trailing edge for a length greater than a conventional plug body length. The plug body is configured to shape the exhaust gases to flow substantially parallel to a free stream of air flowing off of the trailing edge of the nozzle and to cause the plume of exhaust gases to isentropically turn the free stream of air to move in a direction parallel to a longitudinal axis of the plug body.

Abstract: A method of repairing an annular sheet metal combustor liner of a gas turbine engine includes cutting circumferentially around combustor liner bands bounding an effusion patch extending circumferentially around the liner, the effusion patch having effusion cooling holes and being bounded on either side by at least one effusionless band free from effusion cooling holes, to thereby remove a portion of the combustor liner having the effusion patch. A replacement liner portion including an effusion patch is provided and welded to the liner assembly, the weld extending circumferentially around the cut band to provide a welded effusionless band. The welded effusionless bands is cooled during engine use using one of film cooling of an inner surface of the welded effusionless band and impingement cooling of an outer surface of the welded effusionless band.

Abstract: A method for mounting a piezoelectric transducer layer to a diaphragm layer exposes an electrode for each piezoelectric transducer after thermoset polymer filling the interstitial space between the piezoelectric transducers has been cured. The method includes bonding a polymer layer to a diaphragm layer having a plurality of openings, bonding piezoelectric transducers to the diaphragm layer, filling areas between the piezoelectric transducers on the diaphragm layer with thermoset polymer, and removing the thermoset polymer from the piezoelectric transducers with a laser to expose a metal electrode on each piezoelectric transducer.

Abstract: Certain embodiments of the invention may include systems, methods, and apparatus for providing a multi-fuel hybrid rocket motor. According to an example embodiment of the invention, a method is provided for producing a multi-fuel hybrid motor. The method can include forming a body, where the body includes one or more intake ports; one or more exit nozzles; one or more channels connecting the one or more intake ports with the one or more exit nozzles; and a plurality of cavities comprising segment walls in communication with the one or more channels. The method also includes depositing a propellant fuel within the plurality of cavities, wherein at least a portion of the propellant fuel is exposed to the one or more channels and wherein the propellant fuel has a higher burn consumption rate than the segment walls.

Abstract: Thruster devices for use with a lateral thrust module and/or a flight body are adapted to achieve short action times with relatively slow burning propellant materials. Such thruster devices include a combustion chamber with a plurality of propellant grains disposed therein. At least some of the plurality of propellant grains are formed into a selected shape. Methods of making thruster devices include forming a housing comprising a first longitudinal end and an opposing second longitudinal end. The housing is formed to define a combustion chamber. A plurality of propellant grains are disposed in the combustion chamber of the housing, where each propellant grain comprises a selected shape. An igniter is coupled to the housing, which igniter is adapted to initiate a combustion of the plurality of propellant grains during deployment of the thruster device.

Abstract: A nozzle arrangement for use in a gas thruster is presented. At least one heater micro structure (20) is arranged in a stagnation chamber (12) of the gas thruster. The heater microstructure (20) comprises a core of silicon or a silicon compound coated by a surface metal or metal compound coating. The heater microstructure (20) is manufactured in silicon or a silicon compound and covered by a surface metal coating. The heater microstructure (20) is mounted in the stagnation chamber (12) before or after the coverage of the surface metal or metal compound coating. The coverage is performed by heating the heater microstructure and flowing a gas comprising low quantities of a metal compound. The compound decomposes at the heated heater microstructure (20), forming the surface metal or metal compound coating. The same principles of coating can be used for repairing the heater microstructure (20) in situ.

Abstract: A turbomachine combustor assembly includes a combustor housing and a combustor body. The combustor body defines a combustor liner having a first end portion that extends to a second end portion through a combustion chamber. A cap assembly is mounted at the combustor housing. The cap assembly includes an endcover, a plurality of fuel nozzles supported by the end cover, and an outer barrel member. The outer barrel member extends about the plurality of fuel nozzles. A liner stop is arranged on one of the outer barrel member and the first end portion of the combustor liner. The liner stop includes a stepped lip portion that receives the other of the outer barrel member and the first end portion of the combustor liner to form substantially smooth liner to outer barrel interface. The liner stop restricts axial movement of the combustor liner relative to the outer barrel member.

Abstract: An actuator that includes a substrate; first conductive layers provided so as to extend in a first direction and to be disposed adjacent to each other on the substrate; a piezoelectric body layer having a first portion formed so as to cover the first conductive layers and openings between the first conductive layers, a second portion other than the first portions, and a contact to the first conductive layer; a second conductive layer having a third portion which overlap with the first conductive layers in the second direction, a fourth portion connected to the third portion being formed over the second portion of the piezoelectric body layer, and a fifth portion connected to the first conductive layer in the contact; and a wiring having a sixth portion which is formed over the fourth portion of the second conductive layer and a seventh portion connected to the fifth portion.

Abstract: A hybrid rocket motor is manufactured by photopolymerizing the solid fuel grain in a stereolithography method, wherein fuel grains in a plastic matrix are deposited in layers for building a solid fuel rocket body in three dimensions for improved performance and for a compact design,

Abstract: A method for producing a missile nose cone is disclosed. The method consists of manufacturing a first missile nose cone from a first lot of polymeric material and determining a first rupture value. The method further consists of manufacturing a second missile nose cone from a second lot of polymeric material and determining a second rupture value of the second missile nose cone. Both first and second lots of material are mixed into a test batch with one another based on their associated rupture values. An evaluation missile nose cone is then manufactured from the test batch and a determination is made as to whether the evaluation missile nose cone has a desired rupture value. If a desired rupture value is not obtained, then the mixing and evaluation steps are repeated.

Abstract: A combustor assembly that includes a casing that includes a plenum, a combustor liner positioned within the plenum and defining a combustion chamber there within, and a transition piece that includes a forward portion that is coupled to the combustion liner and an aft portion that extends from the forward portion. The aft portion includes a transition piece frame. The transition piece frame includes an upstream surface, a downstream surface, and a radially inner surface extending between the upstream and downstream surfaces. The radially inner surface includes a leading edge that extends between the radially inner surface and the upstream surface. A plurality of first cooling passages extend from the upstream surface to the downstream surface. Each of the first cooling passages is oriented obliquely with respect to the leading edge from the upstream surface towards the downstream surface.

Abstract: A toroid pressure vessel includes a toroid body having an inner shell and an outer shell. The toroid body includes a toroid outer perimeter. The outer shell extends along the toroid outer perimeter. A planar exterior face extends along at least a portion of the outer shell and the toroid outer perimeter. A support belt circumscribes the toroid outer perimeter and is coupled along the planar exterior face. The support belt braces and supports the pressure vessel along the toroid outer perimeter against bulging force (and hoop stress) generated by pressurized fluids within the vessel. The support belt facilitates the use of thinner pressure vessel shells and thereby decreases the weight of the pressure vessel while providing a support to the outer shell that substantially prevents deformation of the planar exterior face.

Abstract: A hybrid rocket motor is manufactured by photopolymerizing the solid fuel grain in a stereolithography method, wherein fuel grains in a plastic matrix are deposited in layers for building a solid fuel rocket body in three dimensions for improved performance and for a compact design.

Abstract: A combustor heat shield comprises a heat shield member defining at least one opening for receiving a fuel nozzle. A louver is received in the opening. The louver has a flow diverting portion extending radially outwardly from the opening for directing air along the hot side of the heat shield member.

Abstract: A thruster stack assembly and method for manufacturing the same is provided. The thruster stack assembly includes a plurality of grain elements having a common core region (e.g., a channel or passageway), where each grain element comprises a volume of electrically ignitable propellant. The thruster stack assembly further includes electrodes associated with the plurality of grain elements, the electrodes adapted for selectively igniting the plurality of grain elements. In one example, one or more of the grain elements may be ignited and combusted without igniting or damaging adjacent grain elements of the stack. The core region serves to channel combustion gases and exhaust from the thruster stack. Multiple stacks may be assembled together to form three-dimensional thruster arrays.

Abstract: Embodiments of a flight vehicle are provided, as are embodiments of a method for manufacturing a flight vehicle. In one embodiment, the flight vehicle includes a solid-propellant rocket motor, control circuitry, and an electrically-interconnective support structure. The electrically-interconnective support structure includes a load-bearing frame and a plurality of electrical conductors embedded within the load-bearing frame. The solid-propellant rocket motor is mounted to the load-bearing frame, and the plurality of electrical conductors embedded within the frame electrically couples the solid-propellant rocket motor to the control circuitry.

Abstract: A projectile propulsion system includes a launch tube, multiphase material, and a membrane. The launch tube has an interior cavity, the multiphase material disposed therein. The launch tube also has an opening to receive the multiphase material. The membrane seals the opening while the multiphase material is disposed in the interior cavity of the launch tube so as to allow the launch tube to be pressurized. When the membrane is broken, a supersonic wave thrusts the contents of the interior cavity, such as a projectile, outwards with a high velocity and force.

Abstract: A method is provided for repairing a turbine nozzle assembly with an insert and a support structure. The method includes positioning the insert on the support structure of the turbine nozzle assembly; and plug welding the insert to the support structure of the turbine nozzle assembly.

Abstract: A method of fabrication of a rocket engine nozzle assembly using pressure brazing generally includes initially assembling a rocket engine nozzle liner into a rocket engine nozzle jacket for a rocket engine nozzle assembly. The rocket engine nozzle assembly may then be sealed. Prior to pressure brazing the rocket engine nozzle assembly, pressure brazing parameters may be determined. The pressure brazing may be performed with the determined pressure brazing parameters to complete the fabrication of the rocket engine nozzle. The rocket engine nozzle assembly may include a rocket engine nozzle jacket and a rocket engine nozzle liner having a plurality of channels, with the space between each channel defining a land, and the rocket engine nozzle liner having at least a pair of endlands disposed at each end thereof. The rocket engine nozzle liner is bonded to the rocket engine nozzle jacket by the endlands being bonded to the nozzle jacket and the lands being pressure brazed to the nozzle jacket.

Abstract: In order to provide a manufacturing method for a heating resistor element component, with which an insulating film (undercoat) can be easily handled, damage caused in the insulating film can be reduced, and a high yield can be ensured, the manufacturing method comprises the steps of: processing, on a surface of a supporting substrate (2), a plurality of concave portions (8) each forming a hollow portion (7) at intervals; processing, on the surface of the supporting substrate (2), a concave part (10) for each region straddling the plurality of concave portions (8) in an arrangement direction of the concave portions (8); placing an insulating film (3) made of sheet glass in each concave part (10); and bonding the insulating film (3) to the supporting substrate (2).

Abstract: Embodiments of a solid propellant rocket motor are provided. In one embodiment, the solid propellant rocket motor includes a pressure vessel having a cavity therein, a solid propellant disposed within the cavity, a nozzle fluidly coupled to the cavity, and a tungsten alloy burst disc positioned proximate the nozzle. The tungsten alloy burst disc is configured to block gas flow through the nozzle when the tungsten alloy burst disc is intact and to fragment at a predetermined burst pressure. Embodiments of a method are further provided for manufacturing a burst disc. In one embodiment, the method comprises the step of forming a burst disc from a tungsten alloy. Embodiments of a burst disc are still further provided. In one embodiment, the burst disc includes an outer annular portion, and a central portion comprising a tungsten alloy.

Abstract: A method of fabricating a rolling bladder propellant tank assembly includes providing a pair of half-domes comprising a nanophase metallic material and a bladder formed of a ductile metallic material. A bladder support ring extends from at least one of the pair of half-domes. The pair of half-domes are positioned together to form a cavity therein with a portion of the bladder trapped between the pair of half-domes adjacent to the bladder support ring, wherein the bladder is positioned within the cavity. A seal is formed between the pair of half-domes and the bladder by friction stir welding. A friction stir welding pin used to form the seal is aligned with the bladder support ring during the friction stir welding operation.

Abstract: The invention relates to a honeycomb core structure (202) for use in a structural panel for a jet engine nacelle, comprising at least one block with a honeycomb core (A, B) having a central part (5a, 5b) with core honeycomb cells (7a, 7b) and at least two lateral parts (9a, 9b) each comprising a number of honeycomb joining cells (11a, 11b) of which at least one part of the honeycomb joining cells (11a, 11b) has at least one additional wall (201a, 201b) to form a join, the honeycomb core block(s) (A, B) being connected by at least one joint zone (213) formed by punching two additional walls (201a, 201b) superimposed one o the other and provided by honeycomb joining cells (11a, 11b) belonging to the distinct lateral parts (9a, 9b). The invention further relates to a structural panel and a nacelle comprising such a structure (202) and a method for producing such a structure (202).

Abstract: A turbomachine includes a compressor, a turbine, and a combustor operatively coupled to the compressor and the turbine. The combustor includes a combustor casing having a flange, an outer surface and an inner surface that defines an internal passage. The combustor casing includes an extruded fluid manifold mounted to the outer surface. The extruded fluid manifold includes first and second walls integrally formed with a third, connecting, wall. The first wall includes a first mounting element and the second wall includes a second mounting element. The first mounting element extends axially along the combustor casing away from the first wall and the second mounting element extends axially along the combustor casing away from the second wall and the first mounting element. The extruded fluid manifold is joined to the outer surface of the combustor casing through the first and second mounting elements.

Abstract: A method of repairing an annular sheet metal combustor liner of a gas turbine engine includes cutting circumferentially around combustor liner bands bounding an effusion patch extending circumferentially around the liner, the effusion patch having effusion cooling holes and being bounded on either side by at least one effusionless band free from effusion cooling holes, to thereby remove a portion of the combustor liner having the effusion patch. A replacement liner portion including an effusion patch is provided and welded to the liner assembly, the weld extending circumferentially around the cut band to provide a welded effusionless band. The welded effusionless bands is cooled during engine use using one of film cooling of an inner surface of the welded effusionless band and impingement cooling of an outer surface of the welded effusionless band.

Abstract: An external jet nozzle mixer includes identically formed lobes. The external mixer works with the internal mixer further to mix the engine internal bypass flow with the internal jet engine core flow to level the disparate flow velocities, to reduce the peak velocities from the jet engine core and increase the lower bypass velocities of the engine internal bypass flow, and thereby reduce noise. The internal lobe contours act as lifting flutes, causing mixing of the primary hot and cold flows to mix before exiting the nozzle. The external lobe contours act as venturi chutes, accelerating the cooler ambient secondary air flow. The lobes thus act collectively as an injector to force the cooler ambient secondary flow into the previously mixed primary flow as it exits the nozzle. Also obtained is an increased thrust efficiency and, consequently, decreased fuel consumption and engine emissions.

Abstract: A method of providing a floating collar for a gas turbine engine combustor is provided, and comprises providing an annular sheet metal blank and bending the blank to provide the floating collar with an axial extending annular collar portion, an annular flange portion extending radially from the collar portion and a smooth transition portion between the collar and flange portions. The arrangement offers reduced cost, and simplicity, and therefore facilitates manufacturing.

Abstract: A welded assembly of combustion chamber elements is disclosed. Two subassemblies of the combustion chamber are fabricated by butt-welding, and a first subassembly has an intermediate connection ring welded thereto suitable for performing final welding with the second subassembly.