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公开(公告)号：US09334741B2
公开(公告)日：2016-05-10
申请号：US12765004
申请日：2010-04-22
CPC分类号： F01D5/182 , B33Y80/00 , F01D5/183 , F01D5/184 , F05D2230/22 , F05D2230/90 , F05D2250/18 , F05D2250/185 , F05D2250/28 , F05D2250/30 , F05D2260/203 , F05D2260/221 , Y10T428/24273
摘要： A wall structure (32, 42, 68, 70, 80) with layers (A, B, C, D, E) of non-random voids (26A, 26B, 28B, 30B) that interconnect to form discretely defined tortuous passages between an interior (21) and an exterior surface (23) of the wall for transpiration cooling of the wall. A coolant flow (38) through the wall may be metered by restrictions in coolant outlets (31) and/or within the passages to minimize the coolant requirement. Pockets (44) may be formed on the exterior surface of the wall for thermal Insulation (46). The layers may be formed by lamination, additive manufacturing, or casting. Layer geometries include alternating layers (A, B, C) with different overlapping void patterns (42), 3-D lattice structures (70), and offset waffle structures (80).
摘要翻译： 具有非随机空隙（26A，26B，28B，30B）的层（A，B，C，D，E）的壁结构（32,42,68,70,80），其互连以在 所述壁的内部（21）和外表面（23）用于所述壁的蒸发冷却。 通过壁的冷却剂流（38）可以通过冷却剂出口（31）和/或通道内的限制来计量，以使冷却剂需求最小化。 口袋（44）可以形成在隔热壁的外表面上（46）。 层可以通过层压，添加剂制造或铸造形成。 层几何形状包括具有不同重叠空白图案（42），3-D网格结构（70）和偏置华夫饼结构（80）的交替层（A，B，C）。
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公开(公告)号：US09056354B2
公开(公告)日：2015-06-16
申请号：US13221077
申请日：2011-08-30
CPC分类号： B22F3/105 , B22F7/02 , B32B15/16 , B82Y30/00 , C04B2235/5454 , C04B2235/666 , C04B2235/95 , C04B2235/9607 , C04B2235/9615
摘要： A method of forming a ceramic layer on a metal substrate. A substrate (40) is formed (54) from a powder (24) of the metal, and may optionally be partially sintered (56). A layer (43) of powdered ceramic is formed (58) on or applied against the substrate (45). The ceramic powder may include a proportion of nano-sized particles effective to reduce the ceramic sintering temperature and to increase the sintering shrinkage of the ceramic layer to more closely match that of the metal substrate. The substrate and layer are then co-sintered (21, 60) at a temperature and for a duration that densifies and bonds them, producing a metal/ceramic layered material system with low interface stress that is durable to temperature variations in a gas turbine. Spark plasma sintering (32, 34, 36) may be used to sinter and/or co-sinter substrate and layer materials that normally cannot be sintered.
摘要翻译： 在金属基板上形成陶瓷层的方法。 从金属的粉末（24）形成基底（54）（54），并且可任选地部分地烧结（56）。 在基板（45）上形成（58）粉末状陶瓷层（58）。 陶瓷粉末可以包括一定比例的有效降低陶瓷烧结温度的纳米尺寸颗粒，并且增加陶瓷层的烧结收缩率以更接近于金属基材的烧结收缩。 然后将基材和层在温度和持续时间内共烧结（21,60），使其致密化并粘合，产生具有低界面应力的金属/陶瓷层状材料体系，这对于燃气轮机的温度变化是耐久的。 可以使用火花等离子体烧结（32,34,36）来烧结和/或共烧烧通常不能烧结的衬底和层材料。
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3.发明授权Method of forming a thermal barrier coating system with engineered surface roughness 有权形成具有工程表面粗糙度的热障涂层系统的方法公开(公告)号：US08999226B2
公开(公告)日：2015-04-07
申请号：US13268101
申请日：2011-10-07
申请人： Andrew J. Burns , Gary B. Merrill , John R. Paulus
发明人： Andrew J. Burns , Gary B. Merrill , John R. Paulus
CPC分类号： F01D25/007 , B22F3/22 , B22F5/04 , B22F7/02 , B22F7/06 , B22F2005/005 , C04B35/62222 , C23C24/08 , F01D25/005 , Y10T428/12472 , Y10T428/239 , Y10T428/24355 , Y10T428/24529 , Y10T428/24545
摘要： A method of manufacturing a substrate (16) with a ceramic thermal barrier coating (28, 32). The interface between layers of the coating contains an engineered surface roughness (12, 24) to enhance the mechanical integrity of the bond there between. The surface roughness is formed in a surface of a mold (10,20) and is infused by a subsequently cast layer of material (16, 28). The substrate may be partially sintered (76) prior to application of the coating layer(s) and the coated substrate and coating layer(s) may be co-sintered to form a fully coherent strain-free interlayer.
摘要翻译： 一种用陶瓷热障涂层（28,32）制造衬底（16）的方法。 涂层之间的界面包含工程表面粗糙度（12,24），以增强其间的结合的机械完整性。 表面粗糙度形成在模具（10,20）的表面中，并且被随后浇铸的材料层（16,28）输注。 在施加涂层之前，基材可以部分烧结（76），并且涂覆的基材和涂层可以被共烧结以形成完全相干的无应变中间层。
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公开(公告)号：US08936068B2
公开(公告)日：2015-01-20
申请号：US13087428
申请日：2011-04-15
申请人： Ching-Pang Lee , Gary B. Merrill , Andrew J. Burns
发明人： Ching-Pang Lee , Gary B. Merrill , Andrew J. Burns
CPC分类号： B22C9/043 , B22C7/02 , B22C7/026 , B22C9/04 , B22C9/22 , B22D17/00 , B22D29/00 , Y10T428/12361
摘要： A method of casting a component (42) having convoluted interior passageways (44). A desired three dimensional structure corresponding to a later-formed metal alloy component is formed by stacking a plurality of sheets (18, 20) of a fugitive material. The sheets contain void areas (22) corresponding to a desired interior passageway in the metal alloy component. A ceramic slurry material is cast into the three dimensional structure to form either a ceramic core (34) or a complete ceramic casting vessel (38). If just a ceramic core is formed, a wax pattern is formed around the ceramic core and an exterior ceramic shell (38) is formed around the wax pattern by a dipping process prior to the removal of the fugitive material and wax. An alloy component having the desired interior passageway is cast into the casting vessel after the fugitive material is removed.
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公开(公告)号：US08500411B2
公开(公告)日：2013-08-06
申请号：US12794972
申请日：2010-06-07
CPC分类号： B23P15/02 , B22C9/04 , B22C9/10 , F01D5/147 , F01D21/003 , Y10T29/49336
摘要： A turbine airfoil usable in a turbine engine and including a depth indicator for determining outer wall blade thickness. The airfoil may include an outer wall having a plurality of grooves in the outer surface of the outer wall. The grooves may have a depth that represents a desired outer surface and wall thickness of the outer wall. The material forming an outer surface of the outer wall may be removed to be flush with an innermost point in each groove, thereby reducing the wall thickness and increasing efficiency. The plurality of grooves may be positioned in a radially outer region of the airfoil proximate to the tip.
摘要翻译： 一种可用于涡轮发动机并且包括用于确定外壁叶片厚度的深度指示器的涡轮机翼型。 翼型件可以包括在外壁的外表面中具有多个凹槽的外壁。 凹槽可以具有表示外壁的期望外表面和壁厚的深度。 形成外壁的外表面的材料可以被去除以与每个凹槽中的最内点齐平，从而减小壁厚并提高效率。 多个凹槽可以定位在靠近尖端的翼型件的径向外部区域中。
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6.发明申请METHOD OF FORMING A THERMAL BARRIER COATING SYSTEM WITH ENGINEERED SURFACE ROUGHNESS 有权形成具有工程表面粗糙度的热障涂层系统的方法公开(公告)号：US20130052415A1
公开(公告)日：2013-02-28
申请号：US13268101
申请日：2011-10-07
申请人： Andrew J. Burns , Gary B. Merrill , John R. Paulus
发明人： Andrew J. Burns , Gary B. Merrill , John R. Paulus
CPC分类号： F01D25/007 , B22F3/22 , B22F5/04 , B22F7/02 , B22F7/06 , B22F2005/005 , C04B35/62222 , C23C24/08 , F01D25/005 , Y10T428/12472 , Y10T428/239 , Y10T428/24355 , Y10T428/24529 , Y10T428/24545
摘要： A method of manufacturing a substrate (16) with a ceramic thermal barrier coating (28, 32). The interface between layers of the coating contains an engineered surface roughness (12, 24) to enhance the mechanical integrity of the bond there between. The surface roughness is formed in a surface of a mold (10,20) and is infused by a subsequently cast layer of material (16, 28). The substrate may be partially sintered (76) prior to application of the coating layer(s) and the coated substrate and coating layer(s) may be co-sintered to form a fully coherent strain-free interlayer.
摘要翻译： 一种用陶瓷热障涂层（28,32）制造衬底（16）的方法。 涂层之间的界面包含工程表面粗糙度（12,24），以增强其间的结合的机械完整性。 表面粗糙度形成在模具（10,20）的表面中，并且被随后浇铸的材料层（16,28）输注。 在施加涂层之前，基材可以部分烧结（76），并且涂覆的基材和涂层可以被共烧结以形成完全相干的无应变中间层。
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公开(公告)号：US08137611B2
公开(公告)日：2012-03-20
申请号：US11082415
申请日：2005-03-17
CPC分类号： B28B1/008 , B28B19/00 , B32B1/00 , B32B1/08 , B32B3/04 , B32B9/005 , B32B2264/101 , B32B2264/102 , C04B35/50 , C04B35/80 , C04B38/067 , C04B2235/3229 , Y10T428/24479
摘要： A method of processing solid core ceramic matrix composite articles. The method improves the physical characteristics of the article by forming the airfoil using a co-processing method wherein a refractory ceramic is cast against a preformed ceramic matrix composite (CMC) shell. In one aspect, the shell is continuous to help prevent delaminations. In another aspect, the shell is open. In one embodiment, the article includes a split line. The split line helps the article to be less susceptible to damage caused from internal strain.
摘要翻译： 固体陶瓷基复合材料的加工方法。 该方法通过使用协同处理方法形成翼型来改善制品的物理特性，其中耐火陶瓷与预制的陶瓷基复合材料（CMC）壳体相对铸造。 在一个方面，壳是连续的以帮助防止分层。 另一方面，壳体是敞开的。 在一个实施例中，物品包括分割线。 分割线帮助物品不易受内部应变造成的损坏。
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公开(公告)号：US20110299990A1
公开(公告)日：2011-12-08
申请号：US12794972
申请日：2010-06-07
CPC分类号： B23P15/02 , B22C9/04 , B22C9/10 , F01D5/147 , F01D21/003 , Y10T29/49336
摘要： A turbine airfoil usable in a turbine engine and including a depth indicator for determining outer wall blade thickness. The airfoil may include an outer wall having a plurality of grooves in the outer surface of the outer wall. The grooves may have a depth that represents a desired outer surface and wall thickness of the outer wall. The material forming an outer surface of the outer wall may be removed to be flush with an innermost point in each groove, thereby reducing the wall thickness and increasing efficiency. The plurality of grooves may be positioned in a radially outer region of the airfoil proximate to the tip.
摘要翻译： 一种可用于涡轮发动机并且包括用于确定外壁叶片厚度的深度指示器的涡轮机翼型。 翼型件可以包括在外壁的外表面中具有多个凹槽的外壁。 凹槽可以具有表示外壁的期望外表面和壁厚的深度。 形成外壁的外表面的材料可以被去除以与每个凹槽中的最内点齐平，从而减小壁厚并提高效率。 多个槽可以定位在靠近尖端的翼型件的径向外部区域中。
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公开(公告)号：US20110143162A1
公开(公告)日：2011-06-16
申请号：US12637030
申请日：2009-12-14
申请人： Gary B. Merrill , Andrew J. Burns
发明人： Gary B. Merrill , Andrew J. Burns
CPC分类号： B23K20/021 , B23P15/04 , B23P15/246 , B23P2700/12 , B33Y80/00 , F01D5/147 , F05D2230/30 , Y10T156/10 , Y10T156/1052 , Y10T428/1241 , Y10T428/12493
摘要： A method of manufacturing a component, including providing a three-dimensional computer model of the component to be produced; deconstructing the three-dimensional computer model by defining a plurality of model slices; forming a plurality of metallic foils, where each foil corresponds to a specific model slice; assembling the plurality of formed foils in a tool to form a three-dimensional component stack; and bonding the three-dimensional component stack to form the component. Characteristics of the foils may differ in various portions of the stack, such as being a different material, having a different thickness, or having a different grain orientation. The control of dimensional tolerances of internal structures, such as cooling passages, in three dimensions is devolved into two separate steps of 1) selecting a thickness of each slice/foil, and 2) controlling in two dimensions a material removal process applied to the respective foil.
摘要翻译： 一种制造部件的方法，包括提供要生产的部件的三维计算机模型; 通过定义多个模型切片来解构三维计算机模型; 形成多个金属箔，其中每个箔对应于特定的模型切片; 将多个形成的箔组装在工具中以形成三维组件堆叠; 并结合三维组件堆叠以形成组件。 箔的特征可能在堆叠的各个部分不同，例如具有不同厚度的不同材料，或具有不同的晶粒取向。 三维内部结构（如冷却通道）的尺寸公差的控制被分解为两个单独的步骤：1）选择每个切片/箔的厚度，以及2）在二维中控制施加到相应的材料的材料去除过程 挫败。
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10.发明申请Subsurface Inclusions of Objects for Increasing Interlaminar Shear Strength of a Ceramic Matrix Composite Structure 有权用于增加陶瓷基复合结构的层间剪切强度的物体的表面包含公开(公告)号：US20100291349A1
公开(公告)日：2010-11-18
申请号：US12464512
申请日：2009-05-12
申请人： Gary B. Merrill , Jay A. Morrison
发明人： Gary B. Merrill , Jay A. Morrison
IPC分类号： B32B3/00
CPC分类号： C04B35/80 , B32B18/00 , C04B2237/38 , C04B2237/64 , Y10T428/24479 , Y10T428/24562 , Y10T428/24612 , Y10T428/249928
摘要： A ceramic matrix composite (CMC) structure 12 includes a plurality of layers (e.g., 16, 18, 20) of ceramic fibers. The CMC structure 12 further includes a plurality of spaced apart objects 22 on at least some of the plurality of layers along a thickness of the composite structure. The inclusion of the objects introduces an out-of-plane fiber displacement arranged to increase an interlaminar shear strength of the structure.
摘要翻译： 陶瓷基复合材料（CMC）结构12包括陶瓷纤维的多个层（例如16,18,20）。 CMC结构12还沿着复合结构的厚度在多个层中的至少一些层上包括多个间隔开的物体22。 包含物体引入布置成增加结构的层间剪切强度的面外光纤位移。
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