A nanocellular single crystal nickel based material is provided having a thermal diffusivity in the range of 0.0002 cm{circumflex over ()}2/s to 0.02 cm{circumflex over ()}2/s and a thermal conductivity in the range of 0.024 W/mK to 9.4 W/mK. The nanocellular single crystal nickel based material may be used to form turbine engine components. The nanocellular single crystal nickel based material may be produced by providing a first solution containing a nickel precursor and deionized water, providing a second solution containing a structure controlling polymer/surfactant and an alcohol, mixing the first and second solutions into a solution containing a reducing agent to form a third solution, and processing the third solution to create the nanocellular single crystal based material.

A single-crystal turbine blade and a method of making such single-crystal turbine blade are disclosed. During manufacturing, a secondary crystallographic orientation of the material of the single-crystal turbine blade is controlled based on a parameter of a root fillet between an airfoil of the single-crystal turbine blade and a platform of the single-crystal turbine blade. The parameter can be a location of peak stress in the root fillet expected during use of the turbine blade.

A gas turbine engine according to an example of the present disclosure includes, among other things, a fan section, and a compressor section including at least a first compressor section and a second compressor section. A power ratio is provided by the combination of the first compressor section and the second compressor section. A method of design a gas turbine engine is also disclosed.

A method for epitaxial addition of repair material onto a process surface (38) of a directionally solidified component (30). The component is positioned in a fluidized bed (34) to drift particles of a repair material over the process surface as laser energy (36) is rastered across the surface to melt the particles and to fuse repair material onto the entire surface simultaneously. The component is moved downward (39) in the bed in a direction parallel to the grain orientation in the component as material is added to the surface, thereby providing continuous epitaxial addition of material to the surface without recrystallization.

A blade for a gas turbine engine includes an airfoil that extends a span from a root to a tip. The airfoil is provided by a first portion near the root and has a metallic alloy. A third portion near the tip has a refractory material. A second portion joins the first and third portions and has a functional graded material.

An article includes a body that has a first section and a second section bonded with the first section. The first section is formed with a first material that has a first microstructure and the second section is formed of a second material that has a second, different microstructure.

Dual alloy turbine rotors and methods for manufacturing the same are provided. The dual alloy turbine rotor comprises an assembled blade ring and a hub bonded to the assembled blade ring. The assembled blade ring comprises a first alloy selected from the group consisting of a single crystal alloy, a directionally solidified alloy, or an equi-axed alloy. The hub comprises a second alloy. The method comprises positioning a hub within a blade ring to define an interface between the hub and the blade ring. The interface is a non-contacting interface or a contacting interface. The interface is enclosed by a pair of diaphragms. The interface is vacuum sealed. The blade ring is bonded to the hub after the vacuum sealing step.

Methods for processing bonded dual alloy rotors are provided. In one embodiment, the method includes obtaining a bonded dual alloy rotor including rotor blades bonded to a hub disk. The rotor blades and hub disk are composed of different alloys. A minimum processing temperature (T.sub.DISK.sub._.sub.PROCESS.sub._.sub.MIN) for the hub disk and a maximum critical temperature for the rotor blades (T.sub.BLADE.sub._.sub.MAX) is established such that T.sub.BLADE.sub._.sub.MAX is less than T.sub.DISK.sub._.sub.PROCESS.sub._.sub.MIN. A differential heat treatment process is then performed during which the hub disk is heated to processing temperatures equal to or greater than T.sub.DISK.sub._.sub.PROCESS.sub._.sub.MIN, while at least a volumetric majority of each of the rotor blades is maintained at temperatures below T.sub.BLADE.sub._.sub.MAX. Such a targeted differential heat treatment process enables desired metallurgical properties (e.g., precipitate hardening) to be created within the hub disk, while preserving the high temperature properties of the rotor blades and any blade coating present thereon.

An airfoil includes an airfoil body that extends at least between leading and trailing edges, first and second sides, and radially inner and outer ends. The airfoil body includes an aluminum alloy that has a controlled crystallographic texture with respect to a predefined three-dimensional coordinate system. The airfoil can be used in the fan of a gas turbine engine.

A dual wall component includes a first outer wall extending from a leading edge to a trailing edge, a first inner wall spaced from the first outer wall by a plurality of first cavities and first ribs, a second inner wall spaced from the first inner wall by a plurality of second cavities and second ribs, and a second outer wall extending from the leading edge to the trailing edge and spaced from the second inner wall by a plurality of third cavities and third ribs. Portions of the first and second outer walls have thicknesses less than about 0.018 (0.457 mm). In a method for forming a dual wall component, component walls are formed by additive manufacturing and without using cores to form the cavities.