Hamilton Sundstrand Corporation

United Technologies Corporation

Brent J Merritt

Craig M Beers

Darryl A Colson

Viktor Kilchyk

Christopher McAuliffe

John M Beck

Harold W Hipsky

Seth E Rosen

Eric Chrabascz

Ronald M Struziak

Victoria S Richardson

John Perella

Kenneth Crawford

Calvin R Parent

Lawrence A Binek

Mark Vignali

David Anderson, Jr

Danielle Mansfield-Marcoux

Paul J Dziorny

Alpesh Patel

Murtuza Lokhandwalla

Robert Telakowski

Clarence J Wytas

Roberto J Perez

Paul E Hamel

Pieter Van Lieu

John F Maher, Jr

Mark L Harris

Gary T Luedtke

Mark Mongillo

David Anderson

Christofer Mcauliffe

A ram air journal bearing shaft includes an additively manufactured body having a main body portion and a journal bearing portion. The main body portion and the journal bearing portion are coaxial along a first axis. At least a first set of heat exchanger fins extends from an outer diameter of the ram air journal bearing shaft to an inner diameter tie rod passage. Each heat exchanger fin in the first set of heat exchanger fins is additively manufactured as an integral structure to the additively manufactured body. A set of cooling air passages is disposed circumferentially about the first axis. Each cooling air passage is defined between adjacent heat exchanger fins of the first set of heat exchanger fins. The ram air journal bearing shaft is configured such that a cooling flowpath through the cooling air passages is established.

Ram air fan including additively manufactured heat exchanger insert

In one aspect, a seal plate for a rotary machine includes a hub centered on a central axis and a disk portion extending radially outward from the hub. The hub and the disk portion include a plastic substrate and metal plating disposed on at least apportion of an outer surface of the plastic substrate. The plastic substrate has a matrix material and fibers embedded in the matrix material. The fibers have a first coefficient of thermal expansion. The metal plating has a second coefficient of thermal expansion. The fibers are selected such that a bulk coefficient of thermal expansion of the plastic substrate at the outer surface of the plastic substrate substantially matches the second coefficient of thermal expansion of the metal plating.

Metal plated additively manufactured plastic seal plates and their method of manufacturing

A ram air journal bearing shaft includes an additively manufactured body having a main body portion and a journal bearing portion. The main body portion and the journal bearing portion are coaxial along a first axis. The additively manufactured body includes at least a first set of regions additively manufactured using a first material and a second set of regions additively manufactured using a second material. At least a first set of heat exchanger fins extends from an outer diameter of the ram air journal bearing shaft to an inner diameter tie rod passage. Each heat exchanger fin in the first set of heat exchanger fins is additively manufactured as an integral structure to the additively manufactured body. A set of cooling air passages are disposed circumferentially about the first axis. Each cooling air passage is defined between adjacent heat exchanger fins of the first set of heat exchanger fins and the ram air journal bearing shaft is configured such that a cooling flowpath through the cooling air passages is established.

Ram air fan including bimetalic additively manufactured heat exchanger insert

An additively manufactured component includes an outer shell, the outer shell enclosing a space therein. An inner lattice structure is in the space of the outer shell. Interspaces are formed in the inner lattice structure. A method of forming an additively manufactured component includes evacuating a chamber in which the additively manufactured component will be formed, and forming in the chamber layer by layer an outer shell enclosing a core. The core includes a lattice structure with interspaces formed in the lattice structure.

Additively manufactured turbomachinery components with designed atmosphere of an inner voided core for heat transfer control

A journal bearing shaft is provided and includes a single monolithic body. The single monolithic body includes a tie rod, an end cap integrally connected to and extending radially outwardly from an end of the tie rod and defining openings, a journal bearing interface portion integrally connected to and extending aft from a distal edge of the end cap and a bi-metal heat exchanger integrally connected to and extending aft from an aft edge of the journal bearing interface portion and including an exterior body formed of a first material and heat exchange fins formed of a second material differing from the first material and extending radially between the exterior body and the tie rod.

Addtively manufactured bi-metal integral shaft and motor rotor heat exchanger and tie rod for ram air fan

An airfoil having: a composition gradient defining a first coefficient of thermal expansion and a second coefficient of thermal expansion that differs from the first coefficient of thermal expansion; and a thermoelectric junction operationally coupled to the composition gradient, wherein the composition gradient is formed of either of a plurality of dissimilar metals or of plastic with fillings or fibers.

Airfoil formed of thermally adaptive materials and a thermoelectric junction

An air cycle machine includes a turbine section, a compressor section, and an axial flux magnetic gear system electromechanically coupling the turbine section to the compressor section. The axial flux magnetic gear system includes a stator, two rotors, a winding system, and a control module. The stator includes stator pole sections and is oriented about a stator axis. Each rotor includes magnets arranged radially about a rotational axis which is aligned with the stator axis. Each rotor interacts with the stator such that the rotor rotates at a rotational speed when the axial flux magnetic gear system is exposed to an electrical current. The winding system stabilizes the position of the rotors along their rotational axes. The control module is configured to supply the electrical current to at least one of the winding system, the stator, and the rotors to drive rotation of the rotors.

Axial flux motor powered air cycle machine

Geared air cycle machine

A rotor blade for a turbomachine includes a base, a tip opposite the base in a spanwise direction, a leading edge, and a trailing edge opposite the leading edge in a chordwise direction. A pressure surface extends from the leading edge to the trailing edge, and extends from the base to the tip. A suction surface extends from the leading edge to the trailing edge, and extends from the base to the tip. The tip includes a tip seal additively manufactured to the rotor blade. The tip seal includes a first portion with a first composition and a second portion with a second composition different from the first composition.

Additively manufactures multi-metallic adaptive or abradable rotor tip seals

A rotor assembly is provided and includes a two-piece rotor impeller and a rotor shaft. The two-piece rotor impeller includes a blade section and a forward section, which is connected to the blade section. The rotor shaft includes an aft section at which the rotor shaft terminates. The aft section is directly attached to the forward section of the rotor impeller. The blade section includes a converging blade configured to converge to a point with a minimized internal diameter (ID).

Radial impeller with maximized inducer area

A seal plate for a rotary machine includes a hub centered on a central axis of the rotary machine, a disk portion extending radially outwards from the hub, and a variable lattice structure in an interior of the seal plate. The variable lattice structure includes a first region of the seal plate having a first lattice structure, and a second region of the seal plate having a second lattice structure. The second lattice structure of the second region is denser than the first lattice structure of the first region. The second region is a deflection region, a stress region, or an energy containment region of the seal plate.

Turbomachinery seal plate with variable lattice densities

In one aspect, a rotor shroud for a rotary machine includes a disk portion extending along and oriented about a central axis of the rotary machine, a transition portion extending from the disk portion, and a flared portion extending axially from the transition portion. The disk portion, the transition portion, and the flared portion include a plastic substrate and metal plating disposed on at least apportion of an outer surface of the plastic substrate. The plastic substrate has a matrix material and fibers embedded in the matrix material. The fibers have a first coefficient of thermal expansion. The metal plating has a second coefficient of thermal expansion. The fibers are selected such that a bulk coefficient of thermal expansion of the plastic substrate at the outer surface of the plastic substrate substantially matches the second coefficient of thermal expansion of the metal plating.

Metal plated additively manufactured plastic rotor shrouds and their method of manufacturing

A component, having: a base having beads formed of with first and second thermoplastic polymers, respectively having first and second coefficients of thermal expansion (CTE), where each of the beads has an outer surface and an inner surface that abut each other; a lower support section formed on the base, having a mixture of a third thermoplastic polymer and a catalyst formed with metal; an upper support section on the component, formed on the lower support section via electrolysis deposition, a metallic coating, to thereby control thermal expansion and contraction of the component; and reinforcement fibers embedded the base, the lower support section and the upper support section.

Metal plated plastic ACM part with internal thermally adaptive structure

A variable diffuser includes a backing plate, a shroud, a diffuser body between the backing plate and the shroud, a plurality of passages through the diffuser body, and a valve adjacent to the shroud and the diffuser body. The valve movably occludes a portion of the plurality of passages.

Variable pipe diffuser

A rotating shaft for a rotary machine includes a first shaft portion centered on a central axis and a variable lattice structure in an interior of the rotating shaft. The variable lattice structure includes a first region of the rotating shaft having a first lattice structure and a second region of the rotating shaft having a second lattice structure. The second lattice structure of the second region is denser than the first lattice structure of the first region. The second region is a deflection region or a stress region of the rotating shaft.

Growing community of inventors

Southwick, MA, United States of America

Brent J Merritt