Abstract:
Provided are a component and an additive manufacturing method for fabricating a component. The additive manufacturing method for fabricating a component includes providing a first wire segment and a second wire segment, the first and second wire segments each having a cross-sectional stackable geometry; positioning the first wire segment into an alignment with the second wire segment to form a workpiece stack, the alignment aligning adjacent surfaces in a line of sight direction; and directing an energy beam toward the first wire segment and the second wire segment along the alignment to weld the first wire segment to the second wire segment to form a welded stack. The component includes a workpiece stack comprising a plurality of wire segments welded together along aligned adjacent surfaces.
Abstract:
The present disclosure generally relates to a sealed metal laminate structure comprising: a metal layer having a first surface and an opposite second surface; a first enamel layer laminated on the first surface of the metal layer, except at an exposed metal protrusion at a perimeter edge of the sealed metal laminate structure; a second enamel layer laminated on the second surface of the metal layer, except at the exposed metal protrusion at the perimeter edge of the sealed laminate structure; and a phosphate sealer deposited on the exposed metal protrusion of the sealed metal laminate structure. The present disclosure also relates to a metal laminate structure without a phosphate sealer. In addition, systems and methods for treating workpieces, including metal laminate structures, are discussed.
Abstract:
A seal assembly between a rotor and a stator is disclosed. In one embodiment, the seal assembly includes: a rotor; a stator positioned around the rotor; and a plurality of seal leaves positioned between the rotor and the stator, the plurality of seal leaves circumferentially stacked around the rotor to define a seal ring between the rotor and the stator, wherein gaps between adjacent seal leaves are partially filled, such that contact faces and residual gaps are between adjacent seal leaves, wherein the contact faces generate friction to dampen vibrations during operation. Such damping effects still allow the compliant motion of the seal leaves with minimal leaf vibration. Also, thicker and more resilient leaves may be applied with reduced leakage through the root gaps.
Abstract:
Disclosed are methods, apparatuses, and systems with regard to laminations. In an embodiment, an apparatus includes a lamination having a variable thickness and a spacer connected with the lamination at a location, wherein the location of the spacer is based on a determined thickness of the lamination.
Abstract:
Electrodes for and methods of electrical discharge machining are provided. For example, a method for forming a feature in a ceramic matrix composite (CMC) component comprises repeatedly advancing an electrode into and retracting the electrode from the CMC component until a desired depth is reached, where the electrode has a head end, a tip end, and a shaft extending from the head end to the tip end. The shaft has a first side and a second side each recessed inward such that the head end and the tip end are wider than the shaft. A method for forming a feature in a CMC component also may include feeding a dielectric fluid into the feature utilizing the recessed sides. In some embodiments, electrodes may include a shaft extending from a head end to a tip end and a central plane, where the shaft is recessed widthwise toward the central plane.
Abstract:
Electrodes for and methods of electrical discharge machining are provided. For example, a method for forming a feature in a ceramic matrix composite (CMC) component comprises repeatedly advancing an electrode into and retracting the electrode from the CMC component until a desired depth is reached, where the electrode has a head end, a tip end, and a shaft extending from the head end to the tip end. The shaft has a first side and a second side each recessed inward such that the head end and the tip end are wider than the shaft. A method for forming a feature in a CMC component also may include feeding a dielectric fluid into the feature utilizing the recessed sides. In some embodiments, electrodes may include a shaft extending from a head end to a tip end and a central plane, where the shaft is recessed widthwise toward the central plane.
Abstract:
An electrical discharge machining (EDM) system according to embodiments includes: a guide structure; a plurality of electrode devices positioned at least partially within the guide structure, the plurality of electrode devices aligned to provide a plurality of electrical discharges to a workpiece, each of the plurality of electrode devices including: an electrode for positioning proximate the workpiece; an electrode holder coupled to the electrode for holding the electrode proximate the workpiece; and a driver coupled to the electrode holder, the driver adapted to modify a position of the electrode holder and the electrode; and a control system operably connected with the driver, the control system configured to provide instructions to the driver of at least one of the plurality of electrode devices to modify a position of the at least one of the plurality of electrodes independently of at least one other one of the plurality of electrodes.
Abstract:
Systems and methods for controlled and precise EDM manufacturing of a component are disclosed. In one embodiment, a system includes: a tank for holding a fluid; a first electrode array in the tank, the first electrode array including a plurality of electrodes configured to shape a workpiece; a workpiece fixture for positioning the workpiece at least partially immersed in the fluid and proximate the first electrode array; a pulse generator for creating an electric discharge between the workpiece and the first electrode array to remove material from the workpiece; a gap sensing circuit communicatively connected to the workpiece and the first electrode array, the gap sensing circuit configured to monitor the electric discharge between the workpiece and the first electrode array; and a computing device communicatively connected to the gap sensing circuit and the workpiece fixture, the computing device manipulating a position of the workpiece in the tank relative the first electrode array based upon data obtained from the gap sensing circuit.
Abstract:
The present disclosure generally relates to a sealed metal laminate structure comprising: a metal layer having a first surface and an opposite second surface; a first enamel layer laminated on the first surface of the metal layer, except at an exposed metal protrusion at a perimeter edge of the sealed metal laminate structure; a second enamel layer laminated on the second surface of the metal layer, except at the exposed metal protrusion at the perimeter edge of the sealed laminate structure; and a phosphate sealer deposited on the exposed metal protrusion of the sealed metal laminate structure. The present disclosure also relates to a metal laminate structure without a phosphate sealer. In addition, systems and methods for treating workpieces, including metal laminate structures, are discussed.
Abstract:
Various embodiments include a sealed laminated metal structure. This laminated metal structure has a metal layer, where the metal layer has a first surface and an opposite second surface. A material is laminated on each of the first and second surfaces of the metal layer. In some cases, the laminated metal structure is removed from a larger laminated sheet of metal. The laminated metal structure is subjected to alternating current electrolytic deburring and cleaning to remove any burrs along the perimeter edge. After deburring and cleaning, a sealer, which is a phosphate compound, is deposited on the perimeter edge of the laminated metal structure where the metal is exposed using alternating current.