A composite fan casing for a gas turbine engine defining a central axis is generally provided. The composite fan casing includes a core having a plurality of core layers of reinforcing fibers bonded together with a thermosetting polymeric resin and having an outer surface. The composite fan casing further includes at least one stiffener integrally coupled to an aft portion of the outer surface of the core relative to the central axis. Additionally, the at least one stiffener comprises an elastic material.

A fan has a fan housing and an impeller mounted in the fan housing. The fan housing has a main case, and a foamed metal plate securely mounted in an air inlet aperture of the main case. Hot air inhaled into the main case is forced to flow through pores in the foamed metal plate. Thus, heat in the hot air is conducted to the foamed metal plate and then to the main case. The heat in the hot air is dissipated to reduce temperature of the hot air in advance. Accordingly, heat dissipation efficiency of the fan is improved. Since the foamed metal plate hinders flow of the hot air, the hot air flowing into the main case is reduced. Therefore, air pressure and flowing speed of the hot air flowing into the main case is reduced, such that noise made by the fan is also reduced.

A compressor section or a turbine section of a gas turbine engine having an axis includes a drum. The compressor section or the turbine section also includes a plurality of bores extending radially inward from the drum including a first bore and a second bore. The compressor section or the turbine section also includes a first bore basket at least partially defining a first cavity such that the first bore has at least one surface located in the first cavity. The compressor section or the turbine section also includes a second bore basket at least partially defining a second cavity that is isolated from the first cavity such that the second bore has at least one surface located in the second cavity.

An air cooled integrally bladed rotor with single crystals turbine rotor blades having cooling air passages formed into an equiax rotor disk, where a mold having expendable Molybdenum tooling and reusable molybdenum tooling is used to form the IBR. An annular blade ring with openings is used to secure the single crystal rotor blades within the mold, and a number of tube tools are inserted into a bottom end of each blade that forms a cooling air supply passage within the rotor disk. Two molybdenum circular shaped hubs are used to secure a bottom end of the tube tools with the mold. The mold is filled with metal powder and high pressure is used to solidify the powder to form the IBR. Expendable tooling is removed using sublimation when exposed to oxygen. Reusable tooling is reused to form additional IBRs.

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 turbine vane assembly adapted for use in a gas turbine engine includes a support and a turbine vane arranged around the support. The support is made of metallic materials. The turbine vane is made of ceramic matrix composite materials to insulate the metallic materials of the support.

An air cooled integrally bladed rotor with single crystals turbine rotor blades having cooling air passages formed into an equiax rotor disk, where a mold having expendable Molybdenum tooling and reusable molybdenum tooling is used to form the IBR. An annular blade ring with openings is used to secure the single crystal rotor blades within the mold, and a number of tube tools are inserted into a bottom end of each blade that forms a cooling air supply passage within the rotor disk. Two molybdenum circular shaped hubs are used to secure a bottom end of the tube tools with the mold. The mold is filled with metal powder and high pressure is used to solidify the powder to form the IBR. Expendable tooling is removed using sublimation when exposed to oxygen. Reusable tooling is reused to form additional IBRs.

A blade outer airseal has a body comprising: an inner diameter (ID) surface; an outer diameter (OD) surface; a leading end; and a trailing end. The airseal body has a metallic substrate and a coating system atop the substrate along at least a portion of the inner diameter surface. At least over a first area of the inner diameter surface, the coating system comprises an abradable layer comprising a metallic matrix and a solid lubricant; and the metallic matrix comprises, by weight, 35% copper, 30.0-45.0% combined nickel, cobalt, and iron with combined iron and cobalt content at most one-third of the nickel content, 2.0-8.0% aluminum, and 5.0-15.0% chromium.

A blade for a gas turbine engine includes a body that includes an airfoil that extends in a radial direction from a 0% span position near an airfoil base to a 100% span position at an airfoil tip. The airfoil has a leading edge and a trailing edge that define the true chord length. The airfoil includes a first portion near the airfoil base with a first density and a second portion near the airfoil tip with a second density. The second density is less than the first density. The second portion includes an increasing true chord length in the radial direction. The second portion is in the range of 90% span to 100% span.

A fan has a fan housing and an impeller mounted in the fan housing. The fan housing has a main case, and a foamed metal plate securely mounted in an air inlet of the main case. Hot air inhaled into the main case is forced to flow through pores in the foamed metal plate. Thus, heat in the hot air is conducted to the foamed metal plate and then to the main case. The heat in the hot air is dissipated to reduce temperature of the hot air in advance. Accordingly, heat dissipation efficiency of the fan is improved. Since the foamed metal plate hinders flow of the hot air, the hot air flowing into the main case is reduced. Therefore, air pressure and flowing speed of the hot air flowing into the main case is reduced, such that noise made by the fan is also reduced.