An improved stator assembly for use in a gas-turbine engine is disclosed. The stator assembly may comprise a vane, an inner diameter (ID) ring, an outer diameter (OD) ring, a vane disposed between the ID ring and the OD ring, a potting component coupling the vane to at least one of the OD ring or the ID ring, and a potting embedded component disposed within the potting component. The potting embedded component may prevent disbond of the potting component during operation of the gas-turbine engine.

Composite components, such as gas turbine engine airfoils, and methods of forming composite components are provided. For example, a composite component of a gas turbine engine comprises a plurality of continuous fiber layers, each continuous fiber layer formed from a plurality of continuous fibers disposed in a matrix material, and a chopped fiber layer comprising a plurality of chopped fibers formed as a filmed sheet. The chopped fiber layer is laid up with the plurality of continuous fiber layers to form the composite component. A method for forming a composite component comprises laying up a plurality of continuous fiber layers, each continuous fiber layer comprising continuous fibers disposed in a matrix material; laying up a chopped fiber layer with the plurality of continuous fiber layers, the layup of the plurality of continuous fiber layers and the chopped fiber layer forming a reinforced layup; and curing the reinforced layup.

A turbocharger includes a turbine housing that is a cast component, a turbine scroll passage, a discharge port, and a discharge port defining member. The turbine scroll passage surrounds the circumference of a turbine chamber defined in the turbine housing and the circumference of the turbine chamber. Exhaust gas that has passed through the turbine chamber is conducted to the discharge port. The discharge port defining member constitutes a wall surface of the discharge port. The discharge port defining member includes a tubular main body wall and an outer circumferential edge. The main body wall constitutes a wall surface of the discharge port. The outer circumferential edge extends from the distal end of the main body wall and outward in the radial direction of the impeller shaft. The outer circumferential edge is fixed between the turbine housing and a downstream exhaust pipe, which is connected to the discharge port.

An improved stator assembly for use in a gas-turbine engine is disclosed. The stator assembly may comprise a vane, an inner diameter (ID) ring, an outer diameter (OD) ring, a vane disposed between the ID ring and the OD ring, a potting component coupling the vane to at least one of the OD ring or the ID ring, and a potting embedded component disposed within the potting component. The potting embedded component may prevent disbond of the potting component during operation of the gas-turbine engine.

Aspects of the disclosure are directed to a brush seal comprising: a first plate, a wire mesh adjacent the first plate, a bristle pack adjacent the wire mesh, and a second plate adjacent the bristle pack. Aspects of the disclosure are directed to a method comprising: positioning a wire mesh adjacent to a first plate, positioning a bristle pack adjacent to the wire mesh, positioning a second plate adjacent to the bristle pack, applying a toolset to hold the first plate, the wire mesh, the bristle pack, and the second plate in a stack-up, and performing an operation to form a brush seal from the stack-up of the first plate, the wire mesh, the bristle pack, and the second plate.

A heat insulating sheet member capable of enhancing a heat insulating performance of an exhaust gas introduction path by an easy operation, including such a path in a turbocharger. The heat insulating sheet member is a bendable member formed from an inorganic flexible material. The heat insulating sheet member includes a first region corresponding to an inlet of a bottom wall portion, a second region corresponding to at least a terminating end portion of the scroll portion, a third region provided between the first region and the second region and corresponding to a coupling wall portion, and a fourth region corresponding to an outer peripheral wall portion. The first region and the third region, the third region and the second region, and the first region and the fourth region are coupled to each other with the inorganic flexible material in a continuous state.

In general, techniques are described for fused filament fabrication of abradable coatings. An additive manufacturing system comprising a substrate defining a major surface, a filament delivery device, and a computing device may be configured to perform various aspects of the techniques. The computing device may be configured to control the filament delivery device to deposit a filament on the substrate, the filament including a powder and a binder, wherein the binder is configured to be substantially removed from the filament and the powder includes a metal or alloy configured to be sintered to form an abradable layer.

A bearing includes a thrust gas bearing attached to a journal bearing and two or more converging-diverging orifices defined in a surface of at least one of the thrust gas bearing and the journal bearing. The converging-diverging orifices supply at least one pressurized gas to an interior of the bearing. Hydrodynamic lifting grooves are provided on the faces of the thrust gas bearing and the journal bearing and provide improved load capacity and sealing capabilities. Control over the ratios of the pressurized gases provides for additional sealing capabilities and reduced leakage. A metal mesh damper provides increased damping of the gas bearing.

An improved stator assembly for use in a gas-turbine engine is disclosed. The stator assembly may comprise a vane, an inner diameter (ID) ring, an outer diameter (OD) ring, a vane disposed between the ID ring and the OD ring, a potting component coupling the vane to at least one of the OD ring or the ID ring, and a potting embedded component disposed within the potting component. The potting embedded component may prevent disbond of the potting component during operation of the gas-turbine engine.

A secondary air system for an aircraft engine comprises an air flow path communicating between a source of pressurized cooling air and an air consuming component. A filter is disposed in the air flow path upstream from the air consuming component. The filter has at least one of: openings of a size selected for capturing suspended particles; and a filter surface material for binding with chemical contaminants.