Raytheon Technologies Corporation

United Technologies Corporation

Rtx Corporation

Alan C Barron

John P Rizzo, Jr

James Tilsley Auxier

Norman W Cofalka

Tracy A Propheter-Hinckley

Brian T Hazel

Joel H Wagner

Gordon Miller Reed

Dewight R Cassells

Mary Catherine Gurak

Michael G McCaffrey

Steven Wayne Burd

Eric A Hudson

Robin Mihekun Miller

John D Riehl

Edwin Otero

Henry H Thayer

Anton G Banks

Mary Colby

Bartolomeo Palmieri

Edris Raji

Kaitlin M Tomeo

Christopher J Millea

Richard L Smith

Tracy A Propheter-hinckley

Michael J Schober

Kendall J Schneider

James Masloski

A process for coating a component includes applying a bond coat on a substrate of a component; applying a thermal barrier material to the bond coat; and applying a conforming reflective layer to the thermal barrier material, the conforming reflective layer conforming to porous microstructure of the ceramic coating.

Reflective coating and coating process therefor

A method of forming an aerodynamic component for use in a gas turbine engine using ceramic matrix composites (CMCs) is provided. The method includes executing a full densification of the CMCs once a final shape of the aerodynamic component is achieved, identifying first and second sectors of an exterior surfaces of the aerodynamic component which have a surface roughness of less than a first roughness level and identifying second sectors of the exterior surface of the component which have a surface roughness of greater than a second roughness level, machining the first sectors to increase the surface roughness to greater than the first roughness level and machining the second sectors to decrease the surface roughness to less than the second roughness level.

Machining of ceramic matrix composite during preforming and partial densification

A refractory metal core (RMC) finishing method according to an exemplary aspect of the present disclosure includes, among other things, performing a plurality of finishing operations on a plurality of RMC samples, analyzing one or more properties of at least a portion of the plurality of RMC samples and selecting a combination of finishing operations for generating an RMC having desirable properties for manufacturing a part free from defects.

Refractory metal core finishing technique

An airfoil for a gas turbine engine includes a substrate portion extending from an airfoil leading edge to an airfoil trailing edge portion. The airfoil trailing edge portion includes a flared portion wherein a substrate portion thickness increases along a camber line of the airfoil, and a trailing edge defined as a full constant radius extending from a pressure side of the airfoil to a suction side of the airfoil. A coating portion includes a coating applied over at least a portion of the substrate portion.

Airfoil with trailing edge rounding

A system for automated adaptive manufacturing of airfoil castings is disclosed. The system may receive a three dimensional scan of a work piece. The system may compare the three dimensional scan to a digital model of the work piece. The system may identify an area of dimensional abnormality on the work piece based on the comparison. The system may alter the area of dimensional abnormality on the work piece.

Systems and methods for automated adaptive manufacturing of airfoil castings

A method of manufacturing a casting is provided and includes establishing desired dimensions of a nominal casting, executing a casting process to produce multiple actual castings with each of the multiple actual castings having respective dimensions that differ from each other and from the desired dimensions of the nominal casting and engaging one or more tools to adaptively machine, without rigidly-programmed toolpaths, each of the multiple actual castings to reduce the respective differences between the actual dimensions of each of the multiple actual castings and the desired dimensions.

Manufacturing thin-walled castings utilizing adaptive machining

A method of coating a component having a multiple of cooling holes includes removing at least a portion of a prior coating; directing a gas through at least one of the multiple of cooling holes; and applying a coat layer while directing the gas through at least one of the

Coating process for gas turbine engine component with cooling holes

A method of removing features from a cast workpiece includes generating a nominal toolpath for machining the cast workpiece. The cast workpiece is mounted onto a platform of a computer numeric control machine. The cast workpiece is inspected with a probe to generate probe data. Features to be removed are identified based upon the probe data generated during the inspection. Any expected features of the cast workpiece that are missing from the cast workpiece are identified. A transformation matrix is applied to the nominal toolpath with a controller of the computer numeric control machine, wherein the transformation matrix is based upon the probe data. Alignment of the cast workpiece is adjusted relative to the computer numeric control machine based on the transformation matrix with the computer numeric control machine. Features are removed from the cast workpiece that were identified during inspection.

Method of manufacture using autonomous adaptive machining

A method of manufacturing an airfoil. The method includes fixing the airfoil in a workpiece space, detecting a position of the airfoil in the workpiece space using a force-sensing element, and removing material from the airfoil to reduce a dimension of the airfoil. In various embodiments, detecting the position of the airfoil includes moving the force-sensing element across a surface of the airfoil. For example, the surface of the airfoil may be a first surface, wherein removing material from the airfoil to reduce the dimension of the airfoil comprises removing material from a second surface of the airfoil opposite the first surface. Removing material from the second surface of the airfoil may be performed without moving the force-sensing element across the second surface of the airfoil.

Airfoil aerodynamics

A finishing apparatus including a central control machine having a computerized controller, at least one articulating device controlled by the central control machine and operable to move the machining tool, and at least one of a touch sensor apparatus and a visual sensor apparatus mounted to said machining tool and communicatively coupled to the computerized controller. The computerized controller configured to cause the finishing apparatus to position a machining element in contact with an exterior surface of a film cooled article, move the machining element along the exterior surface while maintaining contact between the machining element and the surface, identify an actual position of a film opening based on sensory feedback while maintaining contact between the machining element and the surface, and remove material from the exterior surface at the film opening using said machining element.

Apparatus for creating a film cooled article for a gas turbine engine

A blade outer air seal for a turbomachine includes a base portion configured to attach to a turbomachine housing, a thermal coating disposed on the base portion, and at least one groove defined in an external surface of the thermal coating. The groove can be machined. A method of manufacturing a blade outer air seal includes disposing a thermal coating on a base portion, and machining at least one groove into the thermal coating. The method can also include using an automated force sensing and vision sensing equipped robotic system.

Grooved blade outer air seals

A method of polishing an outer surface of a ceramic coated gas turbine engine component includes applying a rotating diamond brush to the outer surface. The brush is configured to achieve a uniform finish of 150 microinches Ror less over the surface. The brush contains diamond impregnated bristles, and is affixed to a rotary head of a robotic arm. A force sensing controller limits brush forces against the component. The component disclosed is a hot section turbine vane designed for directional control of high temperature, high-pressure combustion gases, but the method may be applied to other components contained within such aerospace applications. The polished coating provides an improved thermal barrier for maintaining structural integrity of the component in environments having temperatures ranging up to 2,000 degrees Celsius. The method limits abrasive removal of ceramic material to only 0.0005 to 0.00075 inch, and saves time and expense over past practices.

Ceramic coating polishing method

A method for finishing a film cooled article includes providing a film cooled article including at least one inner cooling plenum and at least one opening connecting the inner cooling plenum to an exterior surface of the film cooled article, positioning a machining element in contact with the exterior surface of the film cooled article, automatically moving the machining element along the exterior surface while maintaining contact between the machining tool and the surface, identifying an actual position of at least one film opening based on sensory feedback from the machining element using a controller, removing material from the exterior surface at the at least one film opening using the machining element, thereby creating a depression at the at least one film opening.

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Jupiter, FL, United States of America

Alan C Barron