Honeywell International Inc.

Brian Hann

Mark C Morris

Donald G Godfrey

Harry Lester Kington

Derek Anthony Rice

Andy Szuromi

Christopher David Gatto

James J Cobb

Daira Legzdina

Andrew F Hieber

Michael G Volas

Daniel Greving

Aaron Moreth

Alex Holmes

Robert J Dawson

Andrew Szuromi

A method for hot isostatic pressing includes the steps of providing or obtaining an article of manufacture, which optionally includes a copper or nickel alloy, disposing the article of manufacture in a shroud, the shroud defining an enclosed volume wherein the article of manufacture is disposed, the shroud being configured as a multi-piece joined structure to retard gaseous mass transport from outside the shroud to inside the enclosed volume, disposing the shroud in a containment vessel of a hot isostatic pressing apparatus and disposing a getter material in the shroud and/or in the containment vessel, and introducing an inert gas at an elevated temperature and pressure into the containment vessel for hot isostatic pressing.

Hot isostatic pressing apparatus and hot isostatic pressing methods for reducing surface-area chemical degradation on an article of manufacture

Methods are provided for producing alloy forms from alloys containing one or more extremely reactive elements and for fabricating a component therefrom. The fabricating method comprises substantially removing a reactive gas from the fabrication environment. An alloy form of the alloy is formed. The alloy form is formed by melting the alloy or by melting one or more base elements of the alloy to produce a molten liquid and introducing the one or more extremely reactive elements into the molten liquid. The molten alloy is shaped into the alloy form. The component is formed from the alloy form. If the one or more extremely reactive elements are introduced into the molten liquid, such introduction occurs just prior to the shaping step.

Methods for producing alloy forms from alloys containing one or more extremely reactive elements and for fabricating a component therefrom

Embodiments of a gas turbine engine rotor including stress relief features are provided, as are embodiments of method for producing a gas turbine engine rotor. In one embodiment, the method includes producing a hub preform in which a plurality of elongated sacrificial cores are embedded. Blades are attached to an outer circumference of the hub preform by, for example, bonding a blade ring to the outer circumference of the preform. The blades are spaced about the rotational axis of the gas turbine engine rotor and circumferentially interspersed with the plurality of elongated sacrificial cores. The plurality of elongated sacrificial cores are then removed from the hub preform to yield a plurality of stress distribution tunnels extending in the hub preform.

Gas turbine engine rotors including intra-hub stress relief features and methods for the manufacture thereof

In accordance with an exemplary embodiment, a method of forming a oxide dispersion-strengthened alloy metal includes the steps of providing, in a powdered form, an oxide dispersion-strengthened alloy composition that is capable of achieving a dispersion-strengthened microstructure, directing a low energy density energy beam at a portion of the alloy composition, withdrawing the energy beam from the portion of the powdered alloy composition, and cooling the portion of the powdered alloy composition at a rate greater than or equal to about 10&#xb0; F. per second, thereby forming the oxide dispersion-strengthened alloy metal.

Methods for forming oxide dispersion-strengthened alloys

In accordance with an exemplary embodiment, a method of forming a ceramic reinforced titanium alloy includes the steps of providing, in a pre-alloy powdered form, a ceramic reinforced titanium alloy composition that is capable of achieving a dispersion-strengthened microstructure, directing a low energy density energy beam at a portion of the alloy composition, and forming a ceramic reinforced titanium alloy metal having ceramic particulates of less than 10 &#x3bc;m on a weight-average basis. The step of forming includes the sub-steps of withdrawing the energy beam from the portion of the powdered alloy composition and cooling the portion of the powdered alloy composition at a rate greater than or equal to about 10&#xb0; F. per second, thereby forming the ceramic reinforced titanium alloy metal.

Methods for forming ceramic reinforced titanium alloys

Methods of forming dual microstructure components include consolidating a powder material comprising an alloy to form a billet, the billet having a first grain structure, inductively heating the billet at an inductive heat treat temperature above a gamma prime solvus temperature of the alloy and subjecting the billet to a subsolvus heat treat temperature that is below the gamma prime solvus temperature of the alloy, waiting a period of time for the first grain structure in an outer portion of the billet to transform into a second grain structure that is coarser than the first grain structure, after the steps of inductively heating and subjecting the billet to the subsolvus heat treat temperature. The methods also include dividing the billet into at least two sections, and machining a final shape into one or more of the at least two sections to form the dual microstructure component.

Methods of forming dual microstructure components

A rotor component assembly including at least one void space formed therein that provides for reduction in weight of the component and/or cooling of the component during operation. The rotor component is formed by positioning a coated mild steel insert within a mold having an internal cross-section substantially the same in dimensions as the final rotor component. The mold is filled with a superalloy metal powder and undergoes hot-isostatic pressing to consolidate the powder about the coated core insert and form a superalloy structure. The mold is removed from about the superalloy structure and the core insert is removed from within the superalloy structure, thereby defining the at least one internal void within the rotor component.

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Avondale, AZ, United States of America

Brian Hann