A method for forming a component for a gas turbine engine may include forming a first portion of the component that includes a cast metal or metal alloy, forming a second portion of the component that includes presintered preform defining at least one support structure, positioning the second portion on the first portion to define an assembly such that the first portion and the second portion define at least one cooling channel therebetween, and heating the assembly to join the first portion and the second portion and form the component.

Methods for manufacturing combustor panels of gas turbine engines and combustor panels are described. The methods include defining a particle deposit near-steady state for at least a portion of a combustor panel, the particle deposit near-steady state representative of a build-up of particles on the at least a portion of the combustor panel during use, generating a template based on the defined particle deposit near-steady state, wherein the template includes one or more augmentation elements based on the representative of build-up of particles, and forming a combustor panel based on the template, wherein the formed combustor panel includes one or more augmentation elements defined in the template.

A method for manufacturing small adaptive engines uses a battlefield repository having cloud services that is configured to enable additive manufacturing (AM) of engine parts and assemblies. The method also uses a compilation of recipes/signatures for building the engine parts and the assemblies using additive manufacturing (AM) processes and machine learning programs. An additive manufacturing system and an alloy powder suitable for performing the additive manufacturing (AM) processes can be provided. In addition, the engine parts can be built using the additive manufacturing (AM) system, the alloy powder, the battlefield repository and the compilation of recipes/signatures. A system for manufacturing small adaptive engines includes the battlefield repository, the compilation of recipes/signatures, a foundry system for providing the alloy powder and an additive manufacturing (AM) system configured to perform the additive manufacturing (AM) processes.

A method of electropolishing an internal passageway of a component, wherein the passageway has an inlet and an outlet; including: providing an electrode assembly including a flexible electrode, a shuttle and a guide cable extending between the flexible electrode and the shuttle; inserting the shuttle into the inlet; causing fluid to flow through the passageway to transport the shuttle through the passageway from the inlet towards the outlet; pulling the guide cable through the passageway to position the electrode in the passageway adjacent to a region of the passageway to be polished; and electropolishing the passageway using the electrode while moving the electrode within the passageway. Also, an electrode assembly for electropolishing an internal passageway of a component, including: a flexible electrode, a shuttle, and a guide cable extending between the flexible electrode and the shuttle.

A method for producing a thin-walled metal part with complex geometry includes mixing a metal powder with a polymer binder in order to obtain a composite mixture, producing a flexible composite sheet from the composite mixture, cutting, in the flexible composite sheet, a preform based on a contour of the metal part, applying the preform in a mold having a surface configured with a relief of the metal part, and debinding and sintering the preform in order to obtain the metal part.

A method for producing a thin-walled metal part with complex geometry includes mixing a metal powder with a polymer binder in order to obtain a composite mixture, producing a flexible composite sheet from the composite mixture, cutting, in the flexible composite sheet, a preform based on a contour of the metal part, applying the preform in a mold having a surface configured with a relief of the metal part, and debinding and sintering the preform in order to obtain the metal part.

A method for obtaining, by additive manufacture, a component including at least one recess, this method including: a step of forming, by additive manufacture, a one-piece blank component, in which the at least one recess contains a support including a core in the form of a block of material and cellular elements that connect the core to the recess; and a step of detaching the support from the rest of the blank component in order to expose the recess.

The present invention provides a bladed rotor wheel for a gas turbine engine comprising at least a rotatable forged disc, the rotatable forged disc comprising a front surface and a back surface, at least one rim surface, and a plurality of projections located on at least a portion of at least one of the front or back surface and/or on the rim surface; wherein the projections are 3D printed features protruding outwards from the front, back and/or rim surface; the projections are arranged forming a pattern so that a heat transfer capability is created at the front, back and/or rim surface; and the ratio of the distance between projections to the forged disc external radius is lower than 0.15. Furthermore, the present invention also provides a method for manufacturing a rotatable forged disc for a bladed rotor wheel.

A method for holding a part blank inside a holding assembly. The holding assembly includes a first holding portion. The first holding portion includes an inner cavity containing a fluid. The part blank and the first holding portion are at least partially manufactured by additive manufacturing. The holding method includes a heating of the holding assembly and the part blank to deform the first holding portion by fluid expansion in the inner cavity and to reduce a gap between the part blank and the holding assembly by expansion of the first holding portion in relation to the part blank.

A method for the layer-by-layer additive manufacturing of a composite material having the selective irradiation of a base material to produce a first, dense material phase and to produce a second, porous material phase, wherein the production of the first material phase and the production of the second material phase take place alternately. A correspondingly produced composite material and to a component has the composite material.