Abstract:
A vacuum arc remelt apparatus comprising a crucible having a wall, said wall having an interior and an exterior opposite said interior; an electrode within the crucible proximate the interior; an ingot within the crucible and below the electrode, wherein said ingot includes a crown and shelf; and a vibration source at the exterior of the crucible proximate the crown and shelf.
Abstract:
A build plate for an additive manufacturing system is disclosed. The build plate includes a support structure, a sub-plate, and one or more transducers. The support structure is configured to support a stack of sintered layers of a pulverant material. Further, the support structure extends orthogonally to a build direction. The sub-plate is arranged along the support structure, and defines a transducer cavity. One or more transducers are arranged in the transducer cavities. The one or more transducers are operable to cause vibration of the support structure and the stack parallel to the build direction. Such vibration relieves internal stresses caused by sintering of the stack.
Abstract:
An additive manufacturing system utilizing an epitaxy process, and method of manufacture, utilizes a heating source and a cooling source to control thermal gradients and a solidification rate of each slice of a workpiece manufactured from a seed having a directional grain microstructure. An energy gun is utilized to melt selected regions of each successive layer of a plurality layers of a powder in a powder bed to successively form each solidified slice of the workpiece.
Abstract:
A workpiece manufactured from an additive manufacturing system (AMS) having a particle separator and a method of operating includes modeling the workpiece into layers and modeling the layers into a plurality of regions. The AMS then deposits one of a plurality of particle types into a respective one of the plurality of regions. In this way, the surface finishes of the component may be controlled and material densities from one region to the next and from one layer to the next are also controlled.
Abstract:
A hybrid airfoil according to an exemplary aspect of the present disclosure includes, among other things, a leading edge portion made of a first material, a trailing edge portion made of a second material, and an intermediate portion between the leading edge portion and the trailing edge portion made of a non-metallic material. A rib is disposed between the leading edge portion and the intermediate portion. A protrusion of one of the rib and the intermediate portion is received within a pocket of the other of the rib and the intermediate portion.
Abstract:
A system and method for prognostic health monitoring of thermal barrier coatings is provided. The system may comprise monitoring a thermal barrier coated gas turbine engine component, and measuring the infrared radiation emitting from the component. The measured thermal radiation data may be analyzed and compared to known material thermal radiation data in order to determine the health of the thermal barrier coating. The compiled comparison results may be compared against a historical statistical study to then determine the overall health of the thermal barrier coating. The system may comprise generating a health monitoring alert in response to the health of the thermal barrier coating indicating an imminent failure.
Abstract:
A component for use in a gas turbine engine includes a first section, a second section, and a functionally graded section. The first section is made of a metal material. The second section is made of a ceramic material and/or a ceramic matrix composite material. The functionally graded section is disposed between the first section and the second section.
Abstract:
An additive manufacturing system and method of operation includes a build table for supporting a powder bed that is packed through the use of a vibration inducing device proximate to the build table. Through this packing, voids of the bed produced by larger particles of a mixed powder are filled with smaller particles. After or during such packing of particles, the powder bed is leveled utilizing a leveling arm, then selected regions of the bed are melted utilizing an energy gun.
Abstract:
An additive manufacturing system utilizing an epitaxy process, and method of manufacture, utilizes a heating source and a cooling source to control thermal gradients and a solidification rate of each slice of a workpiece manufactured from a seed having a directional grain microstructure. An energy gun is utilized to melt selected regions of each successive layer of a plurality layers of a powder in a powder bed to successively form each solidified slice of the workpiece.
Abstract:
A workpiece manufactured from an additive manufacturing system (AMS) having a particle separator and a method of operating includes modeling the workpiece into layers and modeling the layers into a plurality of regions. The AMS then deposits one of a plurality of particle types into a respective one of the plurality of regions. In this way, the surface finishes of the component may be controlled and material densities from one region to the next and from one layer to the next are also controlled.