公开(公告)号：US10378087B2

公开(公告)日：2019-08-13

申请号：US14963366

申请日：2015-12-09

Applicant: General Electric Company

Inventor： Laura Cerully Dial ,  Michael Francis Xavier Gigliotti, Jr.

IPC: C22F1/10 ,  C22C19/05 ,  B23K26/342 ,  B23K26/00 ,  C22C1/04 ,  B33Y80/00 ,  B22F3/105 ,  H01F1/147 ,  B33Y10/00 ,  B23K103/08

Abstract: Methods of forming an intermediate alloy and a Ni-base super alloy are disclosed along with the intermediate alloy and the Ni-base super alloy formed by the method. The method includes at least partially melting and solidifying a powder including about 5 to 15 wt. % of Co, 10 to 20 wt. % of Cr, 3 to 6 wt. % of Mo, 3 to 6 wt. % of W, 2 to 4 wt. % of Al, 4.2 to 4.7 wt. % of Ti, 0.01 to 0.05 wt. % of Zr, 0.015 to 0.060 wt. % of C, 0.001 to 0.030 wt. % of B and balance substantially Ni to form an intermediate alloy including a dendrite structure that includes columnar regions and intercolumnar regions and a primary dendrite arm spacing less than about 3 micrometers. The intermediate alloy is heat-treated to form the texture-free Ni-base super alloy.

公开(公告)号：US10180072B2

公开(公告)日：2019-01-15

申请号：US14887531

申请日：2015-10-20

Applicant: General Electric Company

Inventor： Herbert Chidsey Roberts ,  Richard William Albrecht, Jr. ,  Michael John McCarren ,  Peter Andrew Flynn ,  Michael Francis Xavier Gigliotti, Jr. ,  Eric Alan Estill

IPC: F01D5/30 ,  F01D5/06 ,  F01D5/32 ,  F01D5/34 ,  B22F7/06 ,  B22F3/105 ,  B22F5/00 ,  B33Y10/00 ,  B33Y80/00 ,  B22F5/04 ,  F01D5/02

Abstract: A bladed disk for a gas turbine engine is provided. The bladed disk includes a rotor disk, a plurality of rotor blades, and an interlocking transition zone. The rotor disk includes a plurality of fused layers of a first material formed via additive manufacturing and defines an outer rim. The plurality of rotor blades includes a plurality of fused layers of a second material formed via additive manufacturing. The interlocking transition zone includes a plurality of projections alternately extending from the outer rim of the rotor disk and the plurality of rotor blades, respectively, to undetachably couple the rotor disk and the plurality of rotor blades.

公开(公告)号：US10030298B2

公开(公告)日：2018-07-24

申请号：US14831930

申请日：2015-08-21

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Laura Cerully Dial ,  William Thomas Carter ,  Michael Francis Xavier Gigliotti, Jr.

IPC: C23C10/08 ,  C23C10/28 ,  C23C10/02 ,  C23C10/60 ,  C23F1/20 ,  C23F1/44 ,  C23F17/00 ,  C23C10/30 ,  C25D5/50 ,  C23C24/08 ,  C25D3/12

CPC classification number: C23C10/08 ,  C23C10/02 ,  C23C10/28 ,  C23C10/30 ,  C23C10/60 ,  C23C24/08 ,  C23F1/20 ,  C23F1/44 ,  C23F17/00 ,  C25D3/12 ,  C25D5/50 ,  F01D5/288 ,  F05D2260/202

Abstract: A surface of an article is modified by first disposing a nickel-enriched region at the surface of a substrate, then enriching the nickel-enriched region with aluminum to form an aluminized region, and finally removing at least a portion of the aluminized region to form a processed surface of the substrate. Upon removal of this material, the roughness of the surface is reduced from a comparatively high initial roughness value to a comparatively low processed roughness value. In some embodiments, the processed roughness is less than about 95% of the initial roughness. Moreover, the sequence of steps described herein may be iterated one or more times to achieve further reduction in substrate surface roughness.

公开(公告)号：US09914172B2

公开(公告)日：2018-03-13

申请号：US14887459

申请日：2015-10-20

Applicant: General Electric Company

Inventor： Herbert Chidsey Roberts ,  Richard William Albrecht, Jr. ,  Michael John McCarren ,  Peter Andrew Flynn ,  Michael Francis Xavier Gigliotti, Jr. ,  Eric Alan Estill

IPC: B29C67/00 ,  B22F7/06 ,  B28B1/00 ,  B22F3/105 ,  B29C64/106 ,  B33Y10/00 ,  B33Y80/00 ,  B29K63/00

CPC classification number: B22F7/06 ,  B22F3/1055 ,  B28B1/001 ,  B29C64/106 ,  B29K2063/00 ,  B33Y10/00 ,  B33Y80/00 ,  Y02P10/295

Abstract: A method of joining two components using additive manufacturing is provided. The method includes forming a first component made of a first material; forming an interlocking transition zone from the first material and a second material; and forming a second component made of the second material. The interlocking transition zone includes a plurality of projections alternately extending from the first component and the second component, respectively, to undetachably couple the first component and the second component.