Rolls-royce Corporation

Charles Alan Bulgrin

Matthew T Kush

Carl R Russo

Bruce Edward Varney

Joseph Peter Henderkott

Brett J Barker

Brian J Shoemaker

Greg Lopshire

Jeffrey F Rhodes

Eric Koenig

Rusty M Garner

William Westphal

Mike Engle

Michael Tamaddoni

Bradley W Burkett

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.

Techniques and assemblies for joining components

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.

Virtual throat inspection

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.

Techniques and assemblies for joining components using solid retainer materials

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.

Methods for fabricating cast components with cooling channels

An airfoil cooling system may be provided. An airfoil may have a pressure side and a suction side that are separated by a leading edge. The leading edge may pass through a stagnation point of the airfoil. A spar may have an outer surface comprising standoffs. The standoffs may define a cooling channel that extends across the leading edge on the outer surface of the spar, from the pressure side to the suction side. The cooling channel may have a first portion and a second portion defined by the standoffs. The first portion may be located closer to a base or a tip of the airfoil than the second portion. The spar may further comprise an inlet on the pressure side or the suction side. The inlet may be configured to convey a cooling fluid from a passageway located inside of the spar to the cooling channel.

Airfoil leading edge cooling channels

Airfoil edge cooling channels

Methods of providing an undercut on a support member for a coversheet and coversheet support systems having undercuts are provided. A coversheet support system may include a spar. The spar may include a support member on an outer surface of the spar. The support member may extend outward from the outer surface of the spar. The support member may include an outer surface and an undercut. The undercut may be located in a portion of the support member between the outer surface of the spar and the outer surface of the support member. In addition, the coversheet support system may include a coversheet. The coversheet may be metallurgically bonded to the outer surface of the support member.

Undercut on airfoil coversheet support member

An engine including a turbine section with a number of vane assemblies attached to a support housing. The assemblies are secured to the support housing with fasteners and retaining clips for the fasteners.

Growing community of inventors

Plainfield, IN, United States of America

Charles Alan Bulgrin