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公开(公告)号：US10370975B2
公开(公告)日：2019-08-06
申请号：US14887509
申请日：2015-10-20
发明人： Herbert Chidsey Roberts , Richard William Albrecht, Jr. , Michael John McCarren , Peter Andrew Flynn , Michael Francis Xavier Gigliotti, Jr. , Eric Alan Estill
IPC分类号： F01D5/16 , B33Y80/00 , F01D5/18 , F01D25/06 , B22F5/04 , B22F3/105 , F01D5/14 , F01D5/28 , F01D5/22
摘要： A rotor blade formed via additive manufacturing is provided. The rotor blade includes an airfoil and a coupled component. The airfoil includes a plurality of fused layers of a first material formed via additive manufacturing and defines a leading edge and a tip at a distal end. The coupled component includes a plurality of fused layers of a second material formed via additive manufacturing. An interlocking transition zone includes a plurality of projections alternately extending from the airfoil and the coupled component, respectively, to undetachably couple the airfoil and the coupled component.
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公开(公告)号：US10239157B2
公开(公告)日：2019-03-26
申请号：US15091739
申请日：2016-04-06
IPC分类号： B23K26/342 , B23K26/06 , B23K26/08 , B22F3/105 , B22F5/00 , B22F5/04 , B29C64/153 , B29C64/241 , B29C64/282 , B29C64/205 , B23K101/00 , B33Y10/00 , B33Y30/00
摘要： An apparatus for manufacturing an axi-symmetric part. The apparatus includes a vessel configured to contain the powder. The vessel is also configured to receive a part such that at least a portion of the part contacts the powder contained within the vessel. A first energy source is configured to generate a first beam of energy. The first beam of energy is configured to melt the powder at a first predetermined location such that the melted powder fuses to the part.
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公开(公告)号：US20170106587A1
公开(公告)日：2017-04-20
申请号：US14887459
申请日：2015-10-20
发明人： Herbert Chidsey Roberts , Richard William Albrecht, JR. , Michael John McCarren , Peter Andrew Flynn , Michael Francis Xavier Gigliotti, Jr. , Eric Alan Estill
CPC分类号： B22F7/06 , B22F3/1055 , B28B1/001 , B29C64/106 , B29K2063/00 , B33Y10/00 , B33Y80/00 , Y02P10/295
摘要： 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.
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公开(公告)号：US09884393B2
公开(公告)日：2018-02-06
申请号：US14887481
申请日：2015-10-20
发明人： Herbert Chidsey Roberts , Richard William Albrecht, Jr. , Michael John McCarren , Peter Andrew Flynn , Michael Francis Xavier Gigliotti, Jr. , Eric Alan Estill
CPC分类号： B23P6/007 , B22F3/1055 , B22F5/009 , B22F5/04 , B22F2007/068 , B22F2999/00 , B33Y10/00 , B33Y80/00 , F01D5/005 , F01D5/147 , F01D5/288 , F05D2230/80 , F05D2230/90 , F05D2240/307 , F05D2250/241 , F05D2260/36 , F05D2300/10 , F05D2300/20 , Y02P10/295 , B22F2005/005
摘要： Methods for repairing surface of a metal substrate are provided, which can include preparing the surface of the metal substrate for repair; melt attaching a base layer onto the surface of the metal substrate; fusing a plurality of first layers of a first material via additive manufacturing to the base coating; forming an interlocking transition zone via additive manufacturing from the first material and a second material; and fusing a plurality of second layers of the second material via additive manufacturing on the interlocking transition zone. The interlocking transition zone can have a plurality of projections alternately extending from the plurality of first layers and the plurality of second layers, respectively, to undetachably couple the plurality of first layers to the plurality of second layers. A repaired metal substrate is also provided.
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公开(公告)号：US10184344B2
公开(公告)日：2019-01-22
申请号：US14887556
申请日：2015-10-20
发明人： Herbert Chidsey Roberts , Richard William Albrecht, Jr. , Michael John McCarren , Peter Andrew Flynn , Michael Francis Xavier Gigliotti, Jr. , Eric Alan Estill
摘要： Turbine nozzles are provided for gas turbine engines. The turbine nozzle includes an arcuate inner band; an arcuate outer band; and a nozzle vane disposed between the arcuate inner band and the arcuate outer band. The radially inner end of the nozzle vane is attached to the arcuate inner band through an interlocking transition zone including a plurality of projections alternately extending from the radially inner end of the nozzle vane and the arcuate inner band, respectively, to undetachably couple the nozzle vane and the arcuate inner band. Optionally, the radially outer end of each nozzle vane is also attached to the arcuate outer band through an interlocking transition zone.
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公开(公告)号：US20170291260A1
公开(公告)日：2017-10-12
申请号：US15091739
申请日：2016-04-06
IPC分类号： B23K26/342 , B23K26/06 , B23K26/08
CPC分类号： B23K26/342 , B22F3/1055 , B22F5/009 , B22F5/04 , B22F2003/1056 , B23K26/0604 , B23K26/0823 , B23K2101/001 , B29C64/153 , B29C64/205 , B29C64/241 , B29C64/282 , B33Y10/00 , B33Y30/00 , Y02P10/295
摘要： An apparatus for manufacturing an axi-symmetric part. The apparatus includes a vessel configured to contain the powder. The vessel is also configured to receive a part such that at least a portion of the part contacts the powder contained within the vessel. A first energy source is configured to generate a first beam of energy. The first beam of energy is configured to melt the powder at a first predetermined location such that the melted powder fuses to the part.
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公开(公告)号：US20170107836A1
公开(公告)日：2017-04-20
申请号：US14887556
申请日：2015-10-20
发明人： Herbert Chidsey Roberts , Richard William Albrecht, JR. , Michael John McCarren , Peter Andrew Flynn , Michael Francis Xavier Gigliotti, JR. , Eric Alan Estill
CPC分类号： F01D9/044 , F01D9/041 , F01D9/042 , F01D25/005 , F01D25/12 , F05D2220/32 , F05D2250/20 , F05D2250/32 , F05D2250/43 , F05D2250/70 , F05D2260/30 , F05D2300/17 , Y02T50/673
摘要： Turbine nozzles are provided for gas turbine engines. The turbine nozzle includes an arcuate inner band; an arcuate outer band; and a nozzle vane disposed between the arcuate inner band and the arcuate outer band. The radially inner end of the nozzle vane is attached to the arcuate inner band through an interlocking transition zone comprising a plurality of projections alternately extending from the radially inner end of the nozzle vane and the arcuate inner band, respectively, to undetachably couple the nozzle vane and the arcuate inner band. Optionally, the radially outer end of each nozzle vane is also attached to the arcuate outer band through an interlocking transition zone.
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公开(公告)号：US10180072B2
公开(公告)日：2019-01-15
申请号：US14887531
申请日：2015-10-20
发明人： Herbert Chidsey Roberts , Richard William Albrecht, Jr. , Michael John McCarren , Peter Andrew Flynn , Michael Francis Xavier Gigliotti, Jr. , Eric Alan Estill
IPC分类号： F01D5/30 , F01D5/06 , F01D5/32 , F01D5/34 , B22F7/06 , B22F3/105 , B22F5/00 , B33Y10/00 , B33Y80/00 , B22F5/04 , F01D5/02
摘要： 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.
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公开(公告)号：US09914172B2
公开(公告)日：2018-03-13
申请号：US14887459
申请日：2015-10-20
发明人： Herbert Chidsey Roberts , Richard William Albrecht, Jr. , Michael John McCarren , Peter Andrew Flynn , Michael Francis Xavier Gigliotti, Jr. , Eric Alan Estill
IPC分类号： B29C67/00 , B22F7/06 , B28B1/00 , B22F3/105 , B29C64/106 , B33Y10/00 , B33Y80/00 , B29K63/00
CPC分类号： B22F7/06 , B22F3/1055 , B28B1/001 , B29C64/106 , B29K2063/00 , B33Y10/00 , B33Y80/00 , Y02P10/295
摘要： 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.
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公开(公告)号：US20170107823A1
公开(公告)日：2017-04-20
申请号：US14887509
申请日：2015-10-20
发明人： Herbert Chidsey Roberts , Richard William Albrecht, JR. , Michael John McCarren , Peter Andrew Flynn , Michael Francis Xavier Gigliotti, JR. , Eric Alan Estill
CPC分类号： F01D5/147 , B22F3/1055 , B22F5/04 , B33Y80/00 , F01D5/16 , F01D5/187 , F01D5/22 , F01D5/288 , F01D25/06 , F05D2220/30 , F05D2230/31 , F05D2230/60 , F05D2230/90 , F05D2240/303 , F05D2240/307 , F05D2240/81 , F05D2260/231 , F05D2260/30 , Y02P10/295 , Y02T50/671 , Y02T50/673 , Y02T50/6765
摘要： A rotor blade formed via additive manufacturing is provided. The rotor blade includes an airfoil and a coupled component. The airfoil includes a plurality of fused layers of a first material formed via additive manufacturing and defines a leading edge and a tip at a distal end. The coupled component includes a plurality of fused layers of a second material formed via additive manufacturing. An interlocking transition zone includes a plurality of projections alternately extending from the airfoil and the coupled component, respectively, to undetachably couple the airfoil and the coupled component.
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