公开(公告)号：US20190275617A1

公开(公告)日：2019-09-12

申请号：US16294415

申请日：2019-03-06

Applicant: Rolls-Royce Corporation

Inventor： Charles Alan Bulgrin ,  Carl R. Russo ,  Joseph Peter Henderkott ,  Matthew T. Kush ,  Greg Lopshire

IPC: B23K35/22 ,  B23K1/008 ,  B23K1/20

Abstract: The disclosure describes example techniques and assemblies for joining a first component and a second component. The techniques may include positioning the first and second component adjacent to each other to define a joint region between adjacent portions of the first component and the second component, the joint region being coated with an adhesion resistant coating. The techniques may also include positioning a braze material in the joint region, heating the braze material to form an at least softened material, and cooling the at least softened material to form a mechanical interlock including the braze material in the joint region joining the first and second components. The braze material does not metallurgically bond to the joint surface.

公开(公告)号：US20170326635A1

公开(公告)日：2017-11-16

申请号：US15595028

申请日：2017-05-15

Applicant: Rolls-Royce Corporation

Inventor： Charles Alan Bulgrin ,  Carl R. Russo ,  Matthew T. Kush

IPC: B22D25/02 ,  B22C7/00 ,  B22C9/10 ,  B22D29/00 ,  B22C1/00 ,  B22D21/00 ,  B22D27/04 ,  B22C9/24 ,  F01D25/12 ,  F01D9/02

CPC classification number: B22D25/02 ,  B22C1/00 ,  B22C7/00 ,  B22C9/106 ,  B22C9/108 ,  B22C9/24 ,  B22D21/005 ,  B22D27/04 ,  B22D27/045 ,  B22D29/002 ,  F01D9/02 ,  F01D25/12 ,  F05D2230/211 ,  F05D2300/10

Abstract: A method for fabricating a cast component with a cooling channel is provided. The method includes forming a shell mold over a pattern-ceramic matrix composite (CMC) elongated core arrangement to define a cavity in the shell mold. The pattern-CMC elongated core arrangement includes a pattern-forming material with a CMC elongated core disposed therein. The pattern-forming material in the cavity is replaced with metal via a casting process to form the cast component with the CMC elongated core disposed therein defining the cooling channel. The CMC elongated core is removed from the cast component to open the cooling channel for fluid communication.

公开(公告)号：US12036627B2

公开(公告)日：2024-07-16

申请号：US17664528

申请日：2022-05-23

Applicant: Rolls-Royce Corporation

Inventor： Charles Alan Bulgrin ,  Carl R. Russo ,  Joseph Peter Henderkott ,  Matthew T. Kush ,  Greg Lopshire

IPC: B23K35/22 ,  B23K1/00 ,  B23K1/008 ,  B23K1/19 ,  B23K1/20 ,  B23K20/18 ,  B23K101/00 ,  B23K103/08 ,  F01D5/00

CPC classification number: B23K35/224 ,  B23K1/0018 ,  B23K1/008 ,  B23K1/19 ,  B23K1/20 ,  B23K20/18 ,  B23K2101/001 ,  B23K2103/08 ,  F01D5/00

Abstract: The disclosure describes example techniques and assemblies for joining a first component and a second component. The techniques may include positioning the first and second component adjacent to each other to define a joint region between adjacent portions of the first component and the second component, the joint region being coated with an adhesion resistant coating. The techniques may also include positioning a braze material in the joint region, heating the braze material to form an at least softened material, and cooling the at least softened material to form a mechanical interlock including the braze material in the joint region joining the first and second components. The braze material does not metallurgically bond to the joint surface.

公开(公告)号：US10933466B2

公开(公告)日：2021-03-02

申请号：US15595028

申请日：2017-05-15

Applicant: Rolls-Royce Corporation

Inventor： Charles Alan Bulgrin ,  Carl R. Russo ,  Matthew T. Kush

IPC: B22D25/02 ,  B22D27/04 ,  B22C9/10 ,  B22C1/00 ,  B22C7/00 ,  B22C9/24 ,  B22D21/00 ,  B22D29/00 ,  F01D9/02 ,  F01D25/12

Abstract: A method for fabricating a cast component with a cooling channel is provided. The method includes forming a shell mold over a pattern-ceramic matrix composite (CMC) elongated core arrangement to define a cavity in the shell mold. The pattern-CMC elongated core arrangement includes a pattern-forming material with a CMC elongated core disposed therein. The pattern-forming material in the cavity is replaced with metal via a casting process to form the cast component with the CMC elongated core disposed therein defining the cooling channel. The CMC elongated core is removed from the cast component to open the cooling channel for fluid communication.

公开(公告)号：US20230033578A1

公开(公告)日：2023-02-02

申请号：US17664528

申请日：2022-05-23

Applicant: Rolls-Royce Corporation

Inventor： Charles Alan Bulgrin ,  Carl R. Russo ,  Joseph Peter Henderkott ,  Matthew T. Kush ,  Greg Lopshire

IPC: B23K35/22 ,  B23K1/008 ,  B23K1/20 ,  B23K1/00 ,  B23K1/19

Abstract: The disclosure describes example techniques and assemblies for joining a first component and a second component. The techniques may include positioning the first and second component adjacent to each other to define a joint region between adjacent portions of the first component and the second component, the joint region being coated with an adhesion resistant coating. The techniques may also include positioning a braze material in the joint region, heating the braze material to form an at least softened material, and cooling the at least softened material to form a mechanical interlock including the braze material in the joint region joining the first and second components. The braze material does not metallurgically bond to the joint surface.

公开(公告)号：US20210146485A1

公开(公告)日：2021-05-20

申请号：US16685265

申请日：2019-11-15

Applicant: Rolls-Royce Corporation

Inventor： Charles Alan Bulgrin ,  Matthew T. Kush ,  Rusty M. Garner ,  Carl R. Russo

IPC: B23K35/02 ,  B23K1/00

Abstract: The disclosure describes example techniques and assemblies for joining a first component and a second component. The techniques may include positioning the first and second component adjacent to each other to define a joint region between adjacent portions of the first component and the second component. The techniques may also include inserting a solid retainer material into the joint region through an aperture in one of the first component or the second component to form a mechanical interlock between the first component and the second component and sealing the aperture to retain the solid retainer material within the joint region. The solid retainer material includes at least one of a metal, a metal alloy, or a ceramic.

公开(公告)号：US11861270B2

公开(公告)日：2024-01-02

申请号：US16860368

申请日：2020-04-28

Applicant: Rolls-Royce Corporation

Inventor： Charles Alan Bulgrin ,  Bradley W. Burkett

IPC: G06F30/15 ,  G06T19/20 ,  G06F30/20

CPC classification number: G06F30/15 ,  G06F30/20 ,  G06T19/20

Abstract: An improved manufacturing method includes virtually aligning scanned virtual vane components that are virtual electronic counterparts of separately manufactured and three-dimensionally scanned physical vane components used in gas turbine engines. The improved method performs virtual alignments for any of various possible virtual combinations of the virtual vane components to predict how their physical counterparts would likely behave in combination with each other before those physical counterparts are inseparably combined. One or more optimal virtual combinations are identified, in turn indicating optimal physical combinations to select to form physical vanes incorporated into one or more gas turbine engines, in turn improving the quality of the vanes and ultimately engine performance.

公开(公告)号：US11565352B2

公开(公告)日：2023-01-31

申请号：US16685265

申请日：2019-11-15

Applicant: Rolls-Royce Corporation

Inventor： Charles Alan Bulgrin ,  Matthew T. Kush ,  Rusty M. Garner ,  Carl R. Russo

IPC: B23K1/00 ,  B23K35/02 ,  B23K35/30 ,  B23K103/00 ,  B23K101/00

Abstract: The disclosure describes example techniques and assemblies for joining a first component and a second component. The techniques may include positioning the first and second component adjacent to each other to define a joint region between adjacent portions of the first component and the second component. The techniques may also include inserting a solid retainer material into the joint region through an aperture in one of the first component or the second component to form a mechanical interlock between the first component and the second component and sealing the aperture to retain the solid retainer material within the joint region. The solid retainer material includes at least one of a metal, a metal alloy, or a ceramic.

公开(公告)号：US11338396B2

公开(公告)日：2022-05-24

申请号：US16294415

申请日：2019-03-06

Applicant: Rolls-Royce Corporation

Inventor： Charles Alan Bulgrin ,  Carl R. Russo ,  Joseph Peter Henderkott ,  Matthew T. Kush ,  Greg Lopshire

IPC: B23K35/22 ,  B23K1/20 ,  B23K1/008 ,  B23K1/00 ,  B23K1/19 ,  B23K103/08 ,  B23K20/18 ,  B23K101/00 ,  F01D5/00

Abstract: The disclosure describes example techniques and assemblies for joining a first component and a second component. The techniques may include positioning the first and second component adjacent to each other to define a joint region between adjacent portions of the first component and the second component, the joint region being coated with an adhesion resistant coating. The techniques may also include positioning a braze material in the joint region, heating the braze material to form an at least softened material, and cooling the at least softened material to form a mechanical interlock including the braze material in the joint region joining the first and second components. The braze material does not metallurgically bond to the joint surface.

公开(公告)号：US20210334427A1

公开(公告)日：2021-10-28

申请号：US16860368

申请日：2020-04-28

Applicant: Rolls-Royce Corporation

Inventor： Charles Alan Bulgrin ,  Bradley W. Burkett

IPC: G06F30/15 ,  G06T19/20

Abstract: An improved manufacturing method includes virtually aligning scanned virtual vane components that are virtual electronic counterparts of separately manufactured and three-dimensionally scanned physical vane components used in gas turbine engines. The improved method performs virtual alignments for any of various possible virtual combinations of the virtual vane components to predict how their physical counterparts would likely behave in combination with each other before those physical counterparts are inseparably combined. One or more optimal virtual combinations are identified, in turn indicating optimal physical combinations to select to form physical vanes incorporated into one or more gas turbine engines, in turn improving the quality of the vanes and ultimately engine performance.