Abstract: A hybrid torque box comprising a plurality of composite tubes and metal fittings attached together in alternating succession and configured to attach a thrust reverser to an engine fan case of an aircraft. The hybrid torque box may be substantially hollow and may comprise two V-blades for attaching the torque box to the engine fan case. The hybrid torque box may also be attached to or integral with a bull nose fairing configured for attachment with a cascade of the thrust reverser. Furthermore, the hybrid torque box may comprise and/or attach to a cowl interface flange configured for interfacing with an outer cowl of the thrust reverser.

Abstract: A method for manufacturing a regeneratively cooled nozzle extension of a rocket combustion chamber, the nozzle extension including a first wall and a second wall arranged coaxially to each other and between which a number of cooling channels is configured that are laterally delimited by cooling channel webs. The first wall and the second wall are connected to each other by a positive fit by cooling channel webs of the first wall engaging with corresponding recesses of the second wall for forming the positive fit. The positive fit is produced by a forming process in the region of the cooling channels of the second wall having the recesses.

Abstract: A combustion liner cap assembly includes a cylindrical outer sleeve. The cylindrical outer sleeve includes a center fuel nozzle opening and a plurality of outer fuel nozzle openings spaced around the center fuel nozzle. A mounting flange assembly concentrically surrounds the cylindrical outer sleeve. A plurality of struts on an outer surface of the cylindrical outer sleeve support the mounting flange assembly. A plurality of flanges are on the outer surface of the cylindrical outer sleeve; and a plurality of support rods having first ends are adjustably supported by respective flanges. A combustor for a gas turbine includes a combustion liner cap assembly, a plurality of outer fuel nozzles supported in the plurality of outer fuel nozzle openings, and a center fuel nozzle supported in the center fuel nozzle opening. Second ends of the plurality of support rods adjustably contact the center fuel nozzle.

Abstract: A process for making a fluid ejector head for a micro-fluid ejection device. In one embodiment, the process comprises depositing a thin film resistive layer on a substrate to provide a plurality of thin film heaters. The thin film resistive layer comprises a tantalum-aluminum-nitride material consisting essentially of AlN, TaN, and TaAl alloys, and containing from about 30 to about 70 atomic % tantalum, from about 10 to about 40 atomic % aluminum and from about 5 to about 30 atomic % nitrogen.

Abstract: A method for determining sensor locations in a gas turbine engine is provided. The said method includes providing a turbine rear frame including a radially inner surface, a radially outer surface and a plurality of circumferentially-spaced struts extending between the inner and outer surfaces, wherein a strut sector is defined between each pair of circumferentially-adjacent struts, providing a plurality of fuel nozzles that are each aligned with a strut sector, selecting one of the plurality of fuel nozzles as a primary index nozzle and positioning each of a plurality of sensors relative to one of the plurality of nozzles using a corresponding positioning angle such that each of the plurality of sensors coincides with a gas flow temperature distribution profile between each pair of circumferentially-spaced nozzles.

Abstract: Multiple-use rocket engines and associated systems and methods are disclosed. A method in accordance with a particular embodiment includes launching a two-stage vehicle have a first stage and a second stage carried by the first stage. The first stage can be powered with a first rocket engine having first rocket engine components, including a first combustion chamber, arranged in a first component configuration. The method can further include separating the second stage from the first stage, and powering the second stage with a second rocket engine having second engine components arranged in a second component configuration. The second rocket engine components can include a second combustion chamber that is interchangeable with the first combustion chamber. In further particular embodiments, recovered engine components from the first stage may be used to power the second stage of the same or a different two-stage vehicle.

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 ion thruster includes an accelerator grid proximate to an ionization chamber for drawing and accelerating ions from the chamber. The accelerator grid include a core and an overlying layer that is made of a material having a mass less than that of the propellant.

Abstract: The fluid and heat transfer theory for regenerative cooling of a rocket combustion chamber with a porous media coolant jacket is presented. This model is used to design a regeneratively cooled rocket or other high temperature engine cooling jacket. Cooling jackets comprising impermeable inner and outer walls, and porous media channels are disclosed. Also disclosed are porous media coolant jackets with additional structures designed to transfer heat directly from the inner wall to the outer wall, and structures designed to direct movement of the coolant fluid from the inner wall to the outer wall. Methods of making such jackets are also disclosed.

Abstract: An engine wall structure includes an inner wall to which hot gas is admitted during engine operation, an outer wall, which is colder than the inner wall during engine operation, and at least two webs that connect the inner wall with the outer wall and delimit a cooling duct between the walls. The webs are mainly formed by a first material and the inner wall is mainly formed by a second material of other composition and other heat conductivity than the first material.

Abstract: The invention provides a method of fabricating a turbine stator casing, the method comprising the operations consisting in: between the walls of portions of a mold, forming a cavity of shape corresponding to the shape of the shroud of said casing, securing soluble cores to at least one of said mold portions, said cores being held at a distance from the wall of said mold portion and representing empty spaces that are to be formed inside said shroud; putting soluble inserts into place between the cores to represent flow paths between said empty spaces; filling said cavity with a metal alloy powder; sintering said powder by hot isostatic pressing; eliminating the cores and the inserts by dissolving them; and extracting the shroud as molded in this way. The invention is applicable to fabricating a turbine stator casing for an airplane turbojet.

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: A rocket motor for one or more of limited re-use or single use, including a rocket motor housing, the motor housing adapted to contain propellant; an aft closure with a nozzle, the aft closure connected or connectable to the housing; a forward closure connected or connectable to the housing; wherein one or both of the aft closure and the forward closure are connectable to the housing in manner adapted for one or both of limited re-use or single use.

Abstract: A rocket motor may include a case, a plurality of pellet cells disposed within the case, an igniter disposed to ignite at least one of the pellet cells, and a nozzle coupled to the case. Each pellet cell may contain a corresponding plurality of propellant pellets.

Abstract: A gas turbine exhaust component, such as an exhaust nozzle, is provided that includes circumferential ribs arranged along a longitudinal axis. Longitudinal strakes are supported by the circumferential ribs and arranged about the longitudinal axis. Fastening elements are used to secure the longitudinal strakes to one another to provide a desired exhaust component contour. In one example, fastening elements are used to secure the longitudinal strakes to the circumferential ribs using a bracket. The longitudinal strakes are preformed into the desired exhaust component contour, using low cost forming methods. The longitudinal strakes are formed to fit the circumferential ribs and provide the desired exhaust component contour. The longitudinal strakes are secured to one another to maintain the desired exhaust component contour. The longitudinal strakes may be provided by a low cost steel, in one example.

Abstract: A method for producing an integrated monolithic aluminum structure, including the steps of: (a) providing an aluminum alloy plate from an aluminum alloy with a predetermined thickness (y), (b) shaping or forming the alloy plate to obtain a predetermined shaped structure, (c) heat-treating the shaped structure, (d) machining, e.g. high velocity machining, the shaped structure to obtain an integrated monolithic aluminum structure.

Abstract: A combustor of a turbine, a method of retro-fitting a combustor of a turbine and a method of building a combustor of a turbine are each provided. The combustor includes a combustion chamber along which a dilution breach is defined, a casing perimetrically surrounding the combustion chamber so as to define an airflow between the casing and the combustion chamber, the airflow being configured to supply dilution air to the combustion chamber via the dilution breach, and an easy to adjust dilution airflow tuning part disposed on the casing and in communication with the airflow. The dilution airflow tuning part is configured to increase and/or decrease an available amount of the dilution air to be supplied to the combustion chamber.

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: Systems and methods for positioning fairing sheaths are provided. In this regard, a representative method includes using vacuum pressure to assist in moving opposing portions of a fairing sheath away from each other.

Abstract: There is disclosed a solid fuel rocket motor which may include a case and a nozzle coupled to the case. A plurality of fuel pellets may be disposed within the case. An igniter may be disposed to ignite at least a portion of the fuel pellets. A pellet retainer may be positioned within the case to retain the plurality of fuel pellets within the case.

Abstract: A combustion chamber louver assembly includes an aft louver having a forward panel 24 that extends axially from a louver leading edge 26 to a corner 28, and a forward louver joined to the forward panel of the aft louver. A lip 48 defined by a portion of the forward louver that extends axially past the corner to a louver trailing edge 36 includes circumferentially distributed trailing edge slots 60 extending forwardly from the trailing edge a nominal distance equal to about 88% to 95% of the length L of the lip.

Abstract: A full width array printhead is provided having a continuous maintainable printhead surface and method of forming the same. The printhead includes a substrate and an array of die modules mounted thereon with a front face of each die module exposed. A hardened fill material surrounds the array of die modules to define a continuous surface coplanar with the front face of the array of die modules.

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 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: A method for repairing a damaged portion of a combustor inner liner assembly. The method includes removing the combustor from a gas turbine engine. After inspecting the combustor to determine whether cracks exists in portions of the inner liner assembly, the method includes removing a cracked inner liner assembly from the combustor. Then the portion of the inner liner assembly, comprising a multi-hole panel region, an aft lip region, an aft seal flange region and an aft panel support leg are separated from the inner liner assembly. The multi-hole panel region and aft lip, where fatigue damage typically exists, along with the aft seal flange region, are discarded and a new aft lip region/aft seal flange region and multi-hole panel region are provided. The new parts are joined to the aft panel support leg and the inner liner assembly aft of forward bolt flange region after these parts are refurbished. The inner liner assembly is then reattached to the combustor and reassembled into the engine.

Abstract: Microthruster includes a combustion chamber comprising a substrate material, a fuel inlet, and a gas outlet. A first resistance heater is arranged in the combustion chamber. A catalyst is structured and arranged to decompose fuel entering the combustion chamber. First substrate material sections are heated by the first resistance heater to at least one of a predetermined temperature and a predetermined temperature range. This Abstract is not intended to define the invention disclosed in the specification, nor intended to limit the scope of the invention in any way.

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: A hot gas valve disc for a divert and attitude control disc switching element used in a propelled craft. The hot gas valve disc comprises a first layer comprising a first metal material having a first grain size and a first grain orientation, and at least one additional layer comprising a second metal material having a second grain size that differs from the first grain size, or a second grain orientation that differs from the first grain orientation. A method of manufacturing the hot gas valve disc comprises the steps of fabricating a first metal layer using a solid-free-form fabrication process, the first metal layer having a set of grain characteristics comprising grain size and grain structure, followed by heating the first layer and thereby changing at least one of the grain characteristics.

Abstract: A method is provided for manufacturing a missile component for use in a high temperature environment, where the missile component has a flow passage therethrough and the flow passage has a shape. An apparatus manufactured by the inventive method is provided as well. The method includes the steps of depositing a first metal onto a mandrel having the shape of the flow passage to create a first metal layer, applying an insulating material on to the first metal layer to create an insulating layer, machining a predetermined shape into at least a portion of the insulating layer, and applying a second metal onto the machined insulating layer to create an outer shell layer.

Abstract: Parachute signaling rockets in which the parachute (18) is connected to the effect charge (14) in the form a plug connection (16). This plug connection (16) can be made automatically, so that there is no longer any need for the previous manual connection of the parachute (18) to the pyrotechnic effect charge (14) for the parachute signaling rocket according to the invention.

Abstract: An engine wall structure includes an inner wall to which hot gas is admitted during engine operation, an outer wall, which is colder than the inner wall during engine operation, and at least two webs that connect the inner wall with the outer wall and delimit a cooling duct between the walls. The webs are mainly formed by a first material and the inner wall is mainly formed by a second material of other composition and other heat conductivity than the first material.

Abstract: A method of assembling a gas turbine engine is provided. The method includes coupling at least one turbine nozzle segment within the gas turbine engine. The at least one turbine nozzle segment includes at least one airfoil vane extending between an inner band and an outer band that includes an aft flange and a radial inner surface.

Abstract: A piezoelectric actuator includes a first ceramic sheet having individual inner-electrodes formed thereon, a second ceramic sheet having a common inner-electrode formed thereon, a third ceramic sheet having individual surface-electrodes formed thereon, and a fourth ceramic sheet having a plurality of connection electrodes connecting the individual surface-electrodes and the individual inner-electrodes respectively. The connection electrodes have first portions, second portions and third portions respectively, the first portions facing the individual surface-electrodes and arranged at a pitch in a row in a row-direction, the second portions facing the individual inner-electrodes and being arranged in the row-direction to be shifted with respect to the first portions by half the pitch respectively; and the third portions connecting the first portions and the second portions respectively.

Abstract: Method and arrangement for providing a liquid fuel rocket engine member having a load bearing wall structure (11,14) including a plurality of cooling channels (11) for handling a coolant flow. Each cooling channel (11) is provided with a flow guiding surface (15) extending at an angle to the cooling channel axis, for providing the axial coolant flow with an added flow component in the radial direction.

Abstract: An improved engine construction, such as a rocket engine construction is provided. The engine construction comprises a combustion chamber, a smooth wall nozzle, and a transition zone between the chamber and the smooth wall nozzle. The transition zone has a coolant system which includes a manifold formed from a non-copper material through which a coolant flows. In a high heat transfer embodiment, the transition zone includes an additional manifold formed from a copper based material.

Abstract: A process for the production of a panel with a protective acoustic damping layer. The protective layer includes at least one porous core covered, on the one side, with a porous acoustic damping layer and on the other side with a total acoustic reflector. The porous damping layer is emplaced by striping or draping. The porous damping layer consists of parallel strips. Edges of the strips of the porous damping layer are positioned facing a strip deposited by striping or draping and containing a thermoplastic, thermosetting or thermofusible material adapted, by subsequent heating, to ensure the securement of the edges of said strips of the porous damping layer with the adjacent strip of thermoplastic, thermosetting or thermofusible material.

Abstract: A solid propellant rocket engine includes: a propellant formed into a predetermined shape having a combustion cavity and capable of deflagrating into hot, high-pressure gas upon ignition; and a nozzle configured and positioned to expand the hot, high-pressure gas into the atmosphere, where the propellant forms the nozzle as a part of the predetermined shape. A multi-stage rocket unit, a multi-engine rocket stage, and a super-staged rocket each has many rocket engines.

Abstract: Method and arrangement for providing an outlet nozzle (10) for use in a liquid fuel rocket engine. The nozzle forms a body of revolution having an axis (11) of revolution and a cross section that varies in diameter along said axis. The nozzle has a wall structure having a plurality of mutually adjacent cooling channels, helically extending substantially in parallel from the inlet end (13) of the nozzle to its outlet end (14). The nozzle includes at least two longitudinally arranged sections (10a, 10b, 10c). A shift between a positive and a negative channel angle in the transition from one section to an adjacent section balances any roll momentum generated by friction of rocket exhausts against the nozzle wall.

Abstract: A fluid flow nozzle is formed by a plurality of adjacent L-shaped channels forming successive channel pairs. Each channel has a linking member joined to a radial member. Each linking member is welded to an adjacent linking member forming a contiguous surface of linking members. Each radial member is oriented approximately perpendicular to a first side of the contiguous surface. A circumferentially enclosed chamber is formed on a second side of the contiguous surface. Each radial member is laser welded to a jacket at a distal end of each radial member. The jacket is oriented approximately parallel with the contiguous surface and separably spaced from the contiguous surface by the radial members. Each radial member forms one of a plurality of flow chambers between its adjacent radial member, the jacket and the contiguous surface. The flow chambers advantageously contain fluid in the event of a radial member rupture.

Abstract: A method of manufacturing an ink jet print head is provided. The method forms, on a silicon monocrystailine substrate, a first etching pattern for forming pressure generating chambers and a second etching pattern located opposite to the first etching pattern with respect to ink supply ports. The second etching pattern is narrower than the first etching pattern and is located within opposite lines defining the first etching pattern. The method also anisotropically etches the silicon monocrystailline from the surface thereof, on which the first and second etching patterns are formed, to the other surface thereof and anisotropically etches areas of the silicon monocrystalline substrate. Also, each of the areas is located between the first and second etching patterns, to a depth suitable for the ink supply ports.

Abstract: A method for controlling combustor liner carbon formation on repaired combustors includes making modular effusion panel subassemblies remote from the combustor liner; removing a non-effusion or damaged panel from the combustor liner; and replacing the non-effusion or damaged panel with the modular effusion panel.

Abstract: The present invention provides methods for integrating structural members inside the body of a propulsion vehicle with tankage used to store fluid propellant and the like. Propulsion vehicles may be made lighter, more compact, cheaper, and easier to manufacture by using pressurized membranes of the tankage to accomplish other structural purposes. More specifically, tanks may be integrated with thrust structures to transfer thrust loads from the engine to the main body of the vehicle. Alternatively, the tanks may be integrated with the vehicle engine. One tank may be integrated with one or more other tanks to form a single pressure vessel with multiple interior chambers. Methods of manufacturing a metallic integrated tank assembly include weld fabrication, machining, spinning, hydroforming, casting, forging, plating, metal deposition, or some combination thereof. Methods of manufacturing a composite integrated tank assembly include filament winding, fiber placement, hand-lay-up, or some combination.

Abstract: A printhead assembly for an A4 pagewidth drop on demand printer includes a number of printhead modules situated along a metal channel. The metal channel is typically of a special alloy called “Invar 36”. Preferably the channel is nickel plated to help match it to the coefficient of thermal expansion of silicon, being the major component of each individual printhead module. The channel captures the printhead modules in a precise alignment relative to each other and the similar coefficient of thermal expansion of the “Invar” channel to the silicon chips allows similar relative movement during temperature changes.

Abstract: A method for forming a coolant system for a rocket engine combustion chamber is provided. The method comprises the steps of providing a plurality of tubes formed and shaped into the profile of a nozzle with each of the tubes having a constantly expanding cross section in an upper chamber area, providing an inlet manifold and an exit manifold with a plurality of holes for receiving an end of each tube, inserting a brazing preform into each hole, inserting a first end of each tube into the inlet manifold and a second end of each tube into the outlet manifold so that the first end is surrounded by a first brazing preform and the second end is surrounded by a second brazing preform, and brazing the inlet and outlet manifolds to the tubes. The brazing step forms a series of brazed joints between the tubes and the manifolds. The method further includes the steps of forming a layer of coating material on exposed portions of the tubes and forming a single piece jacket construction around the tubes.

Abstract: A gas turbine engine including a gas exhaust duct assembly which comprises an annular shroud forming at least a section of an inner wall of a gas exhaust duct, a plurality of strut members radially projecting from the shroud, and a plurality of insert members. The strut members are disposed in a circumferentially, substantially equally spaced-apart relationship, and extend in a substantially axial direction. The insert members each define a circumferential section of an outer wall of the gas exhaust duct and are positioned in a space between adjacent strut members, and are secured to same.

Abstract: A method enables replacement of a gas turbine engine combustor liner. The combustor has a combustion zone formed by inner and outer liners. A plurality of cooling features are formed by overhanging portions of the inner and outer liner liners. The method comprises cutting through at least one of the combustor inner and outer liner aft of an overhanging portion, wherein the portion of the combustor liner upstream from the cut remains coupled within the combustor, removing the portion of the combustor liner that is aft of the cut, and installing a replacement liner within the combustor such that the replacement liner extends aftward from the portion of the combustor liner that is upstream from the cut.

Abstract: A method facilitates assembling a gas turbine engine. The method comprises providing an engine frame including an integrally formed outer band, an inner band, and a plurality of circumferentially-spaced apart struts extending radially therebetween, and providing at least one fairing that is formed as an integral single piece casting and includes a first sidewall and a second sidewall connected at a leading edge and a trailing edge such that at least one cooling chamber is defined therebetween. The method also comprises coupling the at least one fairing around at least one strut such that the strut extends through the fairing at least one cooling chamber and such that during the coupling process the fairing is only transitioned axially around the strut rather being slid radially along the strut.

Abstract: A turbine engine combustor member, for example a deflector including an inner surface at a combustor interior and an outer surface away from such interior includes a body of a high temperature alloy having properties combining resistance to hot corrosion in March=1 flows and oxidation to avoid coating the outer surface. In one embodiment, the inner surface includes an environmental resistant coating comprising a ceramic-base thermal barrier coating. In some forms such coating includes an inner coating including Al under the ceramic-base coating. In another embodiment, the member includes air cooling passages and is substantially uncoated. Provision of such a member enables complete combustor assembly including a plurality of members and then coating all inner surfaces concurrently rather than individually before assembly.

Abstract: Variations in dilution air leakage paths in a gas turbine combustion liner assembly are minimized or eliminated to reduce emissions and variations in emissions from combustor to combustor. Leakage paths between the liner sleeve and venturi outer liner are minimized by using additional rivets at that joint. The leakage paths between the outer and inner sleeves of the venturi are eliminated by applying a peripheral weld to the end edges of the flanges of the outer and inner sleeves. The leakage paths between the venturi and outer liner are minimized while simultaneously maintaining accurate venturi throat area relative to the cap centerbody by match drilling holes through the liner sleeve and the overlapped flanges of the venturi and followed by riveting the parts together.

Abstract: A wall structure capable of withstanding high thermal load, including a wall structure with an inner wall, an outer wall positioned about the inner wall, and distancing elements located between the inner and outer walls. The distancing elements are joined to at least one of the inner and outer walls by means of laser welding and thereby establishing a plurality of cooling ducts between the inner and outer walls and a weld joint formed by the laser welding and having a cross-section taken through the wall structure that is substantially T-shaped and which displays a rounded shape towards an inside one of the plurality of cooling ducts.