A method and apparatus for producing AlN whiskers includes reduced incorporation of metal particles, an AlN whisker body, AlN whiskers, a resin molded body, and a method for producing the resin molded body. The method for producing AlN whiskers includes heating an Al-containing material in a material accommodation unit to thereby generate Al gas; and introducing the Al gas into a reaction chamber through a communication portion while introducing nitrogen gas into the reaction chamber through a gas inlet port, to thereby grow AlN whiskers on the surface of an Al.sub.2O.sub.3 substrate placed in the reaction chamber.

Systems and methods for thermally processing composite components are provided. In one exemplary aspect, a system includes a thermal system, a mover device, and a control system. The system also includes a plurality of vessels in which one or more components may be placed. The vessels are similarly shaped and configured. A vessel containing the one or more components therein may be mounted into a chamber defined by the thermal system during thermal processing. The thermal system and vessels include features that allow components to be thermally processed, e.g., compacted, burnt-out, and densified via a melt-infiltration process, a polymer impregnation and pyrolyzing process, or a chemical vapor infiltration process. utilizing the same thermal system and common vessel design. The control system may control the thermal system and mover device to automate thermal processing of the composite components.

Ply layups and methods for forming composite components are provided. For example, a method for forming a composite component comprises laying up a plurality of composite plies to form a composite ply layup; partially processing the composite ply layup to form a green state layup; machining the green state layup; assembling the green state layup with one or more sub-assemblies; and processing the green state layup and the one or more sub-assemblies to form the composite component. In an exemplary embodiment, the composite component is a turbine nozzle airfoil. Another exemplary method comprises laying up a plurality of composite plies to form a composite ply layup; compacting the composite ply layup to form a green state layup; machining the green state layup; assembling the green state layup with one or more sub-assemblies; and processing the green state layup and the one or more sub-assemblies to form the composite component.

One embodiment of the present invention provides a conductive ceramic composition comprising: conductive non-oxide ceramic particles; oxide ceramic particles electrostatically bonded or co-dispersed with the non-oxide ceramic particles; and a binder resin.

Carbon powders are homogeneous powders derived from mesophase pitch. Additive Manufacturing (AM) use these powders in two basic classes of AM to produce manufactured articles: 1) Low temperature 3D printers suitable for plastics, polymers, binders and resins, and 2) High temperature 3D printers suitable for direct 3D metal-fusion printing. There are three categories of carbon powders used for AM: a) Powders derived directly from mesophase carbon pitches with a low melting point. These powders can be printed, without binders; b) Carbon powders, that blend with polymers, binders or resins of similar melting temperatures; and c) Carbon powders that have been graphitized and/or carbonized, that can sustain their form above 3000 C. and are compounded with metal or ceramic matrix powders, which can be printed in high temperature environment 3D printers.

A method and apparatus for producing AlN whiskers includes reduced incorporation of metal particles, an AlN whisker body, AlN whiskers, a resin molded body, and a method for producing the resin molded body. The method for producing AlN whiskers includes heating an Al-containing material in a material accommodation unit to thereby generate Al gas; and introducing the Al gas into a reaction chamber through a communication portion while introducing nitrogen gas into the reaction chamber through a gas inlet port, to thereby grow AlN whiskers on the surface of an Al.sub.2O.sub.3 substrate placed in the reaction chamber.

An aluminum borate whisker reinforced and toughened non-metallic matrix composite is provided, which specifically includes a non-metallic material reinforced and toughened with aluminum borate whiskers. The composite exhibits a higher bending strength and fracture toughness and a higher wear resistance. A method for preparing the composite is also provided. The method includes mixing the aluminum borate whiskers and the non-metallic material to form a mixture; and sintering the mixture by a vacuum hot press method, or molding the mixture.

Rotor assemblies and methods for manufacturing airfoils for rotor assemblies are provided. For example, a rotor assembly comprises a rotary structure extending circumferentially about an axial centerline of a gas turbine engine, an airfoil having a root and a tip, and a pin extending through the root. The root is coupled to the rotary structure and has a bulbous shape, and the airfoil is formed from a plurality of composite plies. The pin defines both a planar first surface and a planar second surface on a pin body having a generally circular cross-section. Further, the pin includes a first end and a second end that contact the rotary structure. The first and second surfaces together form a point that is oriented toward the tip of the airfoil. In one embodiment, the rotary structure is an outer rotor of an interdigitated rotor assembly and the airfoil extends radially inward.

Rotor assemblies and methods for manufacturing airfoils for rotor assemblies are provided. For example, a rotor assembly comprises a rotary structure extending circumferentially about an axial centerline of a gas turbine engine and an airfoil having a root and a tip. The root is coupled to the rotary structure and has a bulbous shape. The airfoil is formed from a plurality of composite plies, a portion of which defines at the root first and second end surfaces, which are in contact with the rotary structure and together define a chisel-shaped end of the root. In another embodiment, a rotor assembly comprises an outer rotor extending circumferentially about an axial centerline of a gas turbine engine and a composite outer rotor blade having a root and a tip. The blade root is coupled to the outer rotor and extends inward along a radial direction toward the axial centerline.

A process for producing a process for producing a LnM.sub.2Cu.sub.3O.sub.x high-temperature superconductive powder, the process comprising: i) providing an aqueous solution of Ln, M and Cu and at least one mineral acid; ii) adding at least one sequestrating agent and, optionally, at least one dispersant to the solution to form a precipitate; iii) recovering the precipitate from the solution; and iv) heating the precipitate in a flow of oxygen to form the LnM.sub.2Cu.sub.3O.sub.x powder, wherein Ln is a rare earth element, preferably Y, Ce, Dy, Er, Gd, La, Nd, Pr, Sm, Sc, Yb, or a mixture of two or more thereof, and wherein M is selected from Ca, Sr, and Ba.