There is a described an aerofoil component for a turbomachine, the aerofoil component comprising: a central core formed from a metal matrix composite; and an external layer comprising a pressure surface, a suction surface, a leading edge, a trailing edge and a root, the external layer being formed by a metal which covers the metal matrix composite of the central core. Also described is a method of manufacturing such an aerofoil component.

The present application relates to a method for producing a housing for an axial turbomachine compressor having a metal sheet with annular rows of stator blades which are welded to the metal sheet. The method includes the steps of: (a) providing or producing a planar metal sheet with a step of machining in order to form blade stumps; (b) welding stator blades of friction to one of the planar faces of the metal sheet, the blades being arranged so as to form parallel straight rows of blades; (c) bending the metal sheet about a bending axis perpendicular to each row of blades, so as to form a half-tube with annular half-rows of blades which are axially spaced apart, and producing annular grooves by rolling; (d) welding annular flanges and axial flanges; (e) application of annular layers of abradable material.

Fan assemblies, and in particular fan wheels and stator assemblies for fan assemblies, are disclosed. In one embodiment, the fan wheel includes a wheel back having an outer surface forming one of a curved dome-shape and a truncated cone-shape. The fan wheel may also include a plurality of fan blades radially spaced about and mounted to the outer surface of the wheel back. In one embodiment, each of the fan blades is formed from a segment of an airfoil-shaped aluminum extrusion defining at least one internal cavity. The fan blade first ends can be provided with a compound cut profile with at least one curved cut such that the first end of the blade is mounted flush to the wheel back outer surface. The stator assembly can also be provided with a plurality of stator blades formed from airfoil-shaped aluminum extrusion segments and provided with compound cut profiles.

Aspects of the disclosure are directed to a seal configured to interface with at least a first component and a second component of a gas turbine engine. A method for forming the seal includes obtaining an ingot of a fine grained, or a coarse grained, or a columnar grained or a single crystal material from a precipitation hardened nickel base superalloy containing at least 40% by volume of the precipitate of the form Ni3(Al, X), where X is a metallic or refractory element, and processing the ingot to generate a sheet of the material, where the sheet has a thickness within a range of 0.010 inches and 0.050 inches inclusive.

A process of forming a turbine engine seal includes the steps of: providing a flat strip of material; roll forming the flat strip of material forming an asymmetric profile in the flat strip of material; coiling the formed asymmetric profile into an overlapping ring shape; cutting the circular shape to a predetermined length; and joining ends of the predetermined length forming the seal. The seal includes at least two peaks that are formed on opposing sides of a gap. The at least two peaks contact opposing sides of a U shaped profile at a zero radius. The asymmetric profile includes a circular shape and the ends are joined.

A system for deep rolling a fan blade including a shaft assembly disposed along a first axis; a hub connected to a distal end of the shaft assembly, the hub having an upper hub portion and a lower hub portion extending along a second axis, the second axis forming an angle relative to a first axis; a roller disk joined to the lower portion of the hub, the roller disk configured to contact a fan blade; a fixture supporting the fan blade; the fixture comprising a body supporting a pivot clamp attached to the body with a pivot; a support attached to the body, the support is configured to engage an airfoil portion of the fan blade; a receiver formed in the body for supporting a root of the fan blade; and a shoulder attached to the body configured to support a platform portion of the fan blade.

Aspects of the disclosure are directed to a seal configured to interface with at least a first component and a second component of a gas turbine engine. A method for forming the seal includes obtaining an ingot of a fine grained, or a coarse grained, or a columnar grained or a single crystal material from a precipitation hardened nickel base superalloy containing at least 40% by volume of the precipitate of the form Ni3(Al, X), where X is a metallic or refractory element, and processing the ingot to generate a sheet of the material, where the sheet has a thickness within a range of 0.010 inches and 0.050 inches inclusive.

A method for producing a contoured ring rolling product for a rotating application from a ring blank, with a ring rolling machine controlled in a process-monitored manner. At least one process window, extending over the rolling time, is defined in relation to preselected process parameters for the specific product on the basis of calibrating specimens brought into their final form by the ring rolling machine. The process window(s) monitored during the process is/are determined by the process parameters of calibrating specimens which produced rolled products meeting the requirements demanded of the ring rolling product. The preselected process parameters comprise at least two of ring growing rate, axial rolling force, radial rolling force, rolling time, and ring blank temperature. Ring blanks are subsequently rolled in a contoured manner with parameters of the rolled blanks being recorded with reference to the preselected process parameters and evaluated to ascertain whether they lie within the predefined process window(s), thereby determining whether they are accepted for further machining and/or processing.

An embodiment of a tool assembly includes a hub connected to a distal end of a spring-loaded shaft assembly disposed along a first axis. An upper hub portion is adjacent to the distal end of the spring-loaded shaft assembly aligned with the first axis, and a lower hub portion extends along a second axis, forming a nonzero angle relative to the first axis. A roller disk is joined to the lower portion of the hub, and is rotatable about the second axis parallel to the second portion of the hub. A load cell is disposed along the first axis between a proximal end of the shaft and the roller disk, and is adapted to measure a downward force applied along the shaft assembly.

A method of manufacturing a component from a nickel-based superalloy comprises the steps of: providing a vacuum induction casting furnace; positioning a component mould onto a chill plate within the furnace; casting a component blank; peening the surface of the component blank; applying a surface modification technique to the surface of the component blank; solution heat treating the component blank at or above the -solvus temperature for the superalloy; and precipitation heat treating the component blank.