公开(公告)号：US11980938B2

公开(公告)日：2024-05-14

申请号：US17534111

申请日：2021-11-23

Applicant: Rolls-Royce Corporation ,  Rolls-Royce plc

Inventor： Scott Nelson ,  Martyn Anthony Jones ,  Quinlan Yee Shuck ,  Peter E. Daum ,  Nathaniel Ashburn

IPC: B22F10/25 ,  B22F10/50 ,  B23K26/342 ,  B23K26/70 ,  B23P6/00 ,  B28B1/00 ,  B33Y10/00 ,  B33Y80/00 ,  F28F1/12 ,  B23K101/00

CPC classification number: B22F10/25 ,  B22F10/50 ,  B23K26/342 ,  B23K26/703 ,  B23K26/706 ,  B23P6/007 ,  B28B1/001 ,  B33Y10/00 ,  B33Y80/00 ,  F28F1/12 ,  B23K2101/001

Abstract: In some examples, systems and techniques for repairing or otherwise forming a blade of a bladed disk. In one example, a method including positioning a shield member around a perimeter of a partial blade extending from a rotor disk of a bladed disk, the shield member being positioned adjacent to a build surface of the partial blade; and depositing, with the shield member around the perimeter of the partial blade, a material on the build surface using an additive manufacturing technique to form a repaired portion on the build surface of the partial blade.

公开(公告)号：US11692446B2

公开(公告)日：2023-07-04

申请号：US17448661

申请日：2021-09-23

Applicant: Rolls-Royce North American Technologies, Inc. ,  Rolls-Royce Corporation

Inventor： Matthew T. Kush ,  Michael Wood ,  Scott Nelson ,  Joseph Peter Henderkott

IPC: B22F5/04 ,  F01D5/18 ,  B23K1/00 ,  B22F10/22 ,  B33Y80/00 ,  B22F5/00 ,  B22F7/00 ,  B23K101/00

CPC classification number: F01D5/187 ,  B22F5/00 ,  B22F5/04 ,  B22F7/00 ,  B22F10/22 ,  B23K1/0018 ,  B33Y80/00 ,  B23K2101/001 ,  F05D2230/22 ,  F05D2230/237 ,  F05D2230/31 ,  Y10T29/49337

Abstract: A method for forming a component for a gas turbine engine may include forming a first portion of the component that includes a cast metal or metal alloy, forming a second portion of the component that includes presintered preform defining at least one support structure, positioning the second portion on the first portion to define an assembly such that the first portion and the second portion define at least one cooling channel therebetween, and heating the assembly to join the first portion and the second portion and form the component.

公开(公告)号：US20230091046A1

公开(公告)日：2023-03-23

申请号：US17934410

申请日：2022-09-22

Applicant: Rolls-Royce Corporation

Inventor： Scott Nelson ,  Brandon David Ribic

IPC: B22F10/85 ,  B33Y30/00 ,  B33Y50/02 ,  B22F12/90 ,  B23K26/34

Abstract: An additive manufacturing system may include an energy delivery device configured to deliver energy to a build surface of a component to form a melt pool in the build surface of the component; a powder delivery device configured to direct a powder stream toward the melt pool; a plurality of mass sensors, each mass sensor associated with a portion of the additive manufacturing system; a plurality of heat sensors; and one or more computing devices. The computing device(s) are configured to receive data from the plurality of mass sensors; determine an overall mass flux based on the data from the mass sensors; control the powder delivery device based on the overall mass flux; receive data from the plurality of heat sensors; determine an overall heat flux based on the data from the heat sensors; and control the energy delivery device based on the overall heat flux.

公开(公告)号：US11577333B2

公开(公告)日：2023-02-14

申请号：US16744345

申请日：2020-01-16

Applicant: Rolls-Royce Corporation ,  Trustees of the Colorado School of Mines

Inventor： Scott Nelson ,  Raymond Xu ,  Stephen Liu ,  Juan Carlos Madeni ,  Brian Paul Rodgers

IPC: B23K1/005 ,  B23K35/32 ,  B23K35/30 ,  B23K1/00 ,  C04B35/80 ,  B23K26/324 ,  B23K35/02 ,  B23K103/00

Abstract: A method of connecting two CMC substrates that includes providing two substrates; placing one substrate approximate to the other substrate, such that at least a portion of the two substrates overlap and define a brazing area; placing a brazing material approximate the brazing area; defining a primary raster pattern that encompasses the brazing area and a portion of the two substrates outside the brazing area; defining a secondary raster pattern that encompasses the brazing area; allowing a laser to scan the primary raster pattern to preheat the brazing area to a temperature below the brazing material's melting point; allowing the laser to scan the secondary raster pattern to heat the brazing area to a temperature that is above the brazing material's melting point; melting and allowing the brazing material to flow within the brazing area; and cooling the brazing area to form a brazed joint connecting the two substrates.

公开(公告)号：US20220241881A1

公开(公告)日：2022-08-04

申请号：US17659397

申请日：2022-04-15

Applicant: Rolls-Royce Corporation

Inventor： Raymond Ruiwen Xu ,  Scott Nelson ,  Joseph Peter Henderkott

IPC: B23K1/00 ,  F01D5/00 ,  F01D25/00

Abstract: A method may include removing a portion of a base component adjacent to a damaged portion of the base component to define a repair portion of the base component. The base component may include a cobalt- or nickel-based superalloy, and the repair portion of the base component may include a through-hole extending from a first surface of the base component to a second surface of the base component. The method also may include forming a braze sintered preform to substantially reproduce a shape of the through-hole. The braze sintered preform may include a Ni- or Co-based alloy. The method additionally may include placing the braze sintered preform in the through-hole and heating at least the braze sintered preform to cause the braze sintered preform to join to the repair portion of the base component and change a microstructure of the braze sintered preform to a brazed and diffused microstructure.

公开(公告)号：US11351696B2

公开(公告)日：2022-06-07

申请号：US16278265

申请日：2019-02-18

Applicant: Rolls-Royce Corporation ,  Rolls-Royce High Temperature Composites Inc.

Inventor： Scott Nelson ,  Quinlan Shuck ,  Sean Landwehr ,  Sungbo Shim

IPC: B28B1/00 ,  B33Y10/00 ,  B29C64/165 ,  B33Y40/00 ,  C04B35/622 ,  C04B35/628 ,  C04B35/657 ,  C04B35/571 ,  C04B35/573 ,  C04B35/58 ,  C04B35/591 ,  C04B35/80

Abstract: A system and method for forming a porous ceramic preform is provided. The method may include forming a stacked powder structure including a binder layer and a powder layer on the binder layer. The binder layer may be formed by depositing a binder with a spray nozzle on a substrate. The powder layer may be formed by depositing a powder on the binder layer. The porous ceramic preform may be formed by heating the stacked powder structure to pyrolyze the binder. The porous ceramic preform is configured to be infiltrated by a molten material. The substrate may comprise a ceramic fiber preform. After melt infiltration of the porous ceramic preform and the ceramic fiber preform, a densified ceramic feature having a predetermined geometry may be formed on a ceramic matrix composite (CMC) component.

公开(公告)号：US20210387257A1

公开(公告)日：2021-12-16

申请号：US17348360

申请日：2021-06-15

Applicant: Rolls-Royce Corporation

Inventor： Quinlan Yee Shuck ,  Scott Nelson ,  Raymond Ruiwen Xu

IPC: B22F7/06 ,  B33Y80/00 ,  B28B11/24

Abstract: A method for connecting or joining a first substrate and a second substrate across an interface between the first substrate and the second substrate. The method includes disposing a fastener precursor in the bore and sintering the fastener precursor in the bore. The fastener precursor densifies and shrinks in at least one dimension to mechanically interlock with a contour in the bore and form a mechanical fastener in the bore, and the mechanical fastener forms an interlock between the first substrate and the second substrate.

公开(公告)号：US20210370399A1

公开(公告)日：2021-12-02

申请号：US17097924

申请日：2020-11-13

Applicant: Rolls-Royce Corporation ,  Rolls-Royce North American Technologies, Inc.

Inventor： Quinlan Yee Shuck ,  Scott Nelson ,  Raymond Ruiwen Xu ,  Brandon David Ribic ,  Matthew R. Gold

IPC: B22F10/18 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y70/10 ,  B33Y80/00 ,  B22F3/10 ,  B33Y40/20 ,  B64G1/58

Abstract: In some examples, an additive manufacturing technique including forming an as-deposited coating on a substrate by depositing a filament via a filament delivery device, wherein the filament includes a sacrificial binder and a powder; removing substantially all the binder from the as-deposited coating; and sintering the as-deposited coating to form a thermal coating; wherein the thermal coating is configured to ablate in response to absorption of energy from an external environment, and wherein the ablation of the thermal coating reduces the energy transferred to the substrate.

公开(公告)号：US20210146602A1

公开(公告)日：2021-05-20

申请号：US17095226

申请日：2020-11-11

Applicant: Rolls-Royce Corporation ,  Rolls-Royce North American Technologies, Inc.

Inventor： Quinlan Yee Shuck ,  Scott Nelson ,  Raymond Ruiwen Xu ,  Brandon David Ribic ,  Matthew R. Gold

IPC: B29C64/118 ,  B29C64/245 ,  B29C64/295 ,  B29C64/205 ,  B33Y70/00

Abstract: An additive manufacturing technique includes depositing, via a filament delivery device, a filament onto a surface of a substrate. The filament includes a binder and a high entropy alloy powder. The technique also includes sacrificing the binder to form a preform and sintering the preform to form a component.

公开(公告)号：US20210146434A1

公开(公告)日：2021-05-20

申请号：US17098010

申请日：2020-11-13

Applicant: Rolls-Royce Corporation ,  Rolls-Royce North American Technologies, Inc.

Inventor： Quinlan Yee Shuck ,  Scott Nelson ,  Raymond Ruiwen Xu ,  Brandon David Ribic ,  Matthew R. Gold

IPC: B22F3/04 ,  B30B11/00 ,  B22F3/15

Abstract: A method may include cold isostatic pressing a fused filament fabricated component comprising a plurality of roads and channels between at least some roads of the plurality of roads. The plurality of roads may include a sacrificial binder and a powder including a metal or alloy. The cold isostatic pressing reduces a presence of the channels between the at least some roads to form a compacted fused filament fabricated component. The method also may include removing substantially all the sacrificial binder from the compacted fused filament fabricated component and leave a powder component; and sintering the powder component to form a sintered component.