A thrust chamber liner includes a metallic combustion chamber having an annular protrusion extending radially away from an exterior surface of the combustion chamber adjacent to its injector opening. A metallic nozzle is coupled to the combustion chamber at its throat opening. A composite material encases the exterior surface of the combustion chamber, but is only bonded to the annular protrusion.

A rocket engine includes a copper alloy combustion chamber, a non-copper weld transition ring welded to the copper alloy combustion chamber, and an injector assembly welded to the non-copper weld transition ring. The engine can be manufactured by forming the copper alloy combustion chamber using additive manufacturing, welding the non-copper weld transition ring to the copper alloy combustion chamber, and welding the injector assembly to the non-copper weld transition ring.

An assembly is provided for a gas turbine engine. This assembly includes a rotating structure, a stationary structure and a bushing. The rotating structure extends axially along and is rotatable about a centerline. The stationary structure extends circumferentially about the rotating structure. The stationary structure is configured from or otherwise includes stationary structure material with a coefficient of thermal expansion between 10 μin/in-° F. and 15 μin/in-° F. The bushing is radially between the rotating structure and the stationary structure. The bushing includes a mount and a bearing within the mount. The mount is configured from or otherwise includes mount material with a coefficient of thermal expansion between 9 μin/in-° F. and 10 μin/in-° F. The mount material contacts the stationary structure material. The bearing is configured from or otherwise includes bearing material, where the bearing material is engaged with and rotatably supports the rotating structure. The bearing material is or otherwise includes copper.

An assembly is provided for a gas turbine engine. This assembly includes a rotating structure, a stationary structure and a bushing. The rotating structure extends axially along and is rotatable about a centerline. The stationary structure extends circumferentially about the rotating structure. The stationary structure is configured from or otherwise includes stationary structure material with a coefficient of thermal expansion between 10 μin/in-° F. and 15 μin/in-° F. The bushing is radially between the rotating structure and the stationary structure. The bushing includes a mount and a bearing within the mount. The mount is configured from or otherwise includes mount material with a coefficient of thermal expansion between 9 μin/in-° F. and 10 μin/in-° F. The mount material contacts the stationary structure material. The bearing is configured from or otherwise includes bearing material, where the bearing material is engaged with and rotatably supports the rotating structure. The bearing material is or otherwise includes copper.

A rotor shaft for a high speed motor that has a coating that is secured to a shaft body. The coating and the shaft body are formed from dissimilar materials. More specifically, the coating may be an alloy material, such as, for example, a copper alloy, while the shaft body may be a steel material. According to certain embodiments, the alloy material of the coating may be secured to at least a portion of a rotor body blank in a solution treated condition via a low temperature welding procedure. Additionally, the coating may be hardened, such as for example, through the use of an age hardening process. The coating and the rotor body blank may be machined together to form the rotor shaft. According to certain embodiments, such machining may configure the rotor shaft for use with a turbo-compressor that is configured for air compression.

A rotor shaft for a high speed motor that has a coating that is secured to a shaft body. The coating and the shaft body are formed from dissimilar materials. More specifically, the coating may be an alloy material, such as, for example, a copper alloy, while the shaft body may be a steel material. According to certain embodiments, the alloy material of the coating may be secured to at least a portion of a rotor body blank in a solution treated condition via a low temperature welding procedure. Additionally, the coating may be hardened, such as for example, through the use of an age hardening process. The coating and the rotor body blank may be machined together to form the rotor shaft. According to certain embodiments, such machining may configure the rotor shaft for use with a turbo-compressor that is configured for air compression.

An abrasive coating for a substrate of a component in a gas path exposed to a maximum temperature of 1750 degree Fahrenheit, comprising a plurality of grit particles adapted to be placed on a top surface of the substrate; a matrix material bonded to the top surface; the matrix material partially surrounds the grit particles, wherein the grit particles extend above the matrix material relative to the top surface; a film of oxidant resistant coating applied over the plurality of grit particles and the matrix material and a thermal barrier coating material applied over said film of oxidant resistant coating.

Integrally bladed rotors (IBRs) are described. The IBRs include a central hub, an outer rim defining an outer circumference of the central hub, the outer rim defining a plurality of platforms, a plurality of circumferentially distributed blades, wherein a blade extends from each of the plurality of platforms, a rotor slot arranged between two adjacent blades, wherein the rotor slot is defined by a cut within the outer rim, and a rotor slot insert installed within the rotor slot, the rotor slot insert sized and shaped to fit within the rotor slot and prevent air leakage from a first side of the central hub to a second side of the central hub through the rotor slot during operation of the integrally bladed rotor.

A method of processing a joint, including forming an actively brazed joint in a vacuum furnace, wherein the actively brazed joint is formed from at least two components coupled together by a volume of a joining metal alloy having a solidus temperature and a liquidus temperature, wherein the joining metal alloy is heated to a first temperature that is higher than the liquidus temperature in the vacuum furnace. The method also includes cooling the actively brazed joint to a second temperature lower than the solidus temperature, and maintaining the second temperature within the vacuum furnace for a predefined duration to form at least one region of segregated crystallization within the volume of the joining metal alloy, the at least one region of segregated crystallization is configured to increase the liquidus temperature of a layer of brazed metal, formed from the joining metal alloy, between the at least two components.

A method for selectively irradiating a material layer in additive manufacturing, the method includes: providing a predetermined component geometry which contains geometrical information of individual layers of a component to be manufactured additively; and defining layer by layer an irradiation pattern in areas of a layer to be constructed for the manufacturing of the component, the irradiation pattern comprising irradiation vectors in each area; and, if a predefined irradiation vector length is not reached in a first area, lengthening irradiation vectors in a second area of the layer adjacent to the first area as far as a component contour.