A process for manufacturing a preformed sheet having geometric surface features for a geometrically segmented abradable ceramic thermal barrier coating on a turbine engine component, the process comprising the steps of providing a preformed sheet material. The process includes forming a partially of geometric surface features in the sheet material. The process includes joining the sheet material to a substrate of the turbine engine component. The process includes disposing a thermally insulating topcoat over the geometric surface features and forming segmented portions that are separated by faults extending through the thermally insulating topcoat from the geometric surface features.

A method for producing a turbomachine impeller, which has a radially inner hub body, a radially outer shroud body and blades extending between the hub body and the shroud body. The blades, the hub body and the shroud body are designed as an integral, monolithic assembly includes providing a blank; milling the blank to form a basic contour of the hub body, the shroud body, and the blades; performing build-up welding or additive manufacturing at least once on the main contour that is formed and subsequently performing milling at least once on portions that are formed by the build-up welding.

The invention relates to a method of producing a low-pressure compressor stator for an axial turbine engine. The stator comprises an external shroud with stubs and an annular row of stator blades extending radially towards the inside from the stubs. The method comprises the following stages: supply or production of a starting bar; bending of the bar so that it makes a circle, in order to form an unwrought external shroud; turning to form an axial annular wall delimited by annular fixing flanges; orbital friction-welding of a row of blades onto the stubs of the external shroud. The stubs are realized during a milling stage of the bar or of the external shroud, the milling being carried out before or after the bending stage. The shroud and the blades can be produced in titanium or in a thermoplastic polymer.

A method of repairing a diaphragm of a rotary machine includes removing an initial steam path from the diaphragm. The initial steam path includes a plurality of initial partitions. Each initial partition is associated with an original trailing edge profile and an original axial length. The method also includes coupling a replacement steam path to the diaphragm. The replacement steam path includes a plurality of replacement partitions. Each replacement partition has a replacement axial length that is greater than the original axial length.

A tool system for stress relieving a turbocharger turbine wheel longitudinally welded to a hardened rotor shaft. The shaft has a journal bearing region and a turbine-end body forming an A datum surface for receiving an axial bearing. The tool system includes an induction coil and an electronic oscillator, and a tool. The tool forms an opening configured to receive the rotor shaft such that the journal bearing region of the shaft extends into the tool housing while the A datum surface adjoins an end of the tool housing. The induction coil is positioned around the turbine-end body. The housing forms an annular cooling chamber surrounding the journal bearing region of the shaft. The housing forms an inlet passage to provide cooling fluid to the annular chamber, and an outlet passage to remove cooling fluid from the annular chamber.

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.

A turbomachine rotor having a radially inner hub element, a radially outer cover element, and rotor blades which extend between the hub element and the cover element and have rotor blade airfoils. The rotor blades are an integral component of the hub element and are bonded to the cover element according to a first alternative or are an integral component of the cover element and are bonded to the hub element according to a second alternative. The rotor blades have an integral socket adjacently to the cover element according to the first alternative or adjacently to the hub element according to the second alternative, and the rotor blades are bonded to the cover element according to the first alternative or to the hub element according to the second alternative via the socket.

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.

A method for manufacturing a turbine wheel comprising casting the turbine wheel from an austenitic nickel-chromium-based superalloy, subjecting the cast turbine wheel to hot isostatic pressing and then subjecting a surface of the hot isostatically pressed turbine wheel to plastic deformation, wherein said hot isostatic pressing is effected at a pressure of 98 to 200 MPa and a temperature of 1160 to 1220 C. for a time period of 225 to 300 minutes. There is further described a hot isostatically pressed cast turbine wheel manufactured from an austenitic nickel-chromium-based superalloy, the turbine wheel having a plastically deformed surface; and a turbocharger incorporating such a turbine wheel.

A hybrid additive manufacturing process is utilized for creating a shrouded rotor with the shrouded rotor having a hub at a radial center, a shroud at a radial outer side, and vanes extending therebetween. The hybrid additive manufacturing process includes forming the shrouded rotor in stages, with a first stage being formed by depositing material in an axial direction through a first stage of the hub, machining an outer surface of the first stage of the hub to smooth the outer surface, depositing material on the first stage of the hub in a radial direction through a first stage of the vanes and the shroud, and machining all surfaces of the first stage of the vanes and an inner surface of the first stage of the shroud to smooth the surfaces. Subsequent stages of the shrouded rotor are formed similarly to the first stage.