Honeywell International Inc.

Charles J Gasdaska

William Lee Giesler

James Vincent Guiheen

Steven E Sund

Vikram Ramesh Jamalabad

Robert H Feest

Milton Ortiz

Jeffrey A Chard

M Rifat Ullah

Lennox Bruce

Methods for improving the manufacture of objects made by layered manufacturing techniques through improved tool path generation. A vertex improvement aspect improves tool paths used to form vertices. Outer perimeter vertices can be improved by automatically creating an outer boundary reflecting the design intent to have material extending to the perimeter vertex. The outer boundary can be used as a contour tool path or as a limit to travel by raster tool paths. Boundary vertices within parts can be improved by extending more internal boundary vertices outward toward enclosing vertices, thereby eliminating some internal voids. Contour boundaries near outer perimeter corners can be better defined by extending outward a contour tool path toward the corners. Narrow regions between combinations of outer and/or inner perimeters can be filled through improved tool paths. Layer regions near inner voids can receive consistent filling through an improved raster tool path method. Sub-perimeter voids between raster bead pair turn-arounds and contour beads can be eliminated by automatically adjusting the raster tool path vertices toward the adjacent raster bead pair and/or contour bead.

Tool path planning process for component by layered manufacture

A ceramic ball bearing assembly has raceway components generally held in residual compression by accompanying metal attachments. In a ceramic ball bearing assembly, an outer raceway is formed that is held in compression by a circumscribing steel ring. The components may be fitted together with the ceramic raceway subject to thermal contraction while the steel ring is subject to thermal expansion. Upon mating, the ceramic raceway slightly expands while the steel ring slightly contracts to impose residual compression upon the ceramic raceway. The residual compression preserves the ceramic raceway despite thermal or other stresses of operating environment. An inner ceramic raceway is constructed by employing one of several of the herein described methods, and the ceramic ball bearing assembly of the present invention may use balls, needles, cylinders, or other rolling elements in order to achieve smooth angular translation between the inner and outer ceramic raceways.

Ceramic ball bearings and assembly

Methods for improving layered manufacturing techniques to improve an objects' surface properties and shorten manufacturing time for support structures. One aspect of the invention forms surfaces having reduced or no concavities between layers having improved crack resistance. One method deposits alternate, surface improvement material on each layer near the future location of the main material surface, followed by deposition of the main material, the edges of which conform to the previously deposited and solidified alternate material. In this method, the center of the main material layers can be concave rather than the interlayer regions. Another aspect of the invention provides removable structures to support the deposition of main material. The support structures provide support over main material cavities for depositing the material to form the cavity ceilings, while minimizing the time and material required to build the support structures. Minimized support structures include structures formed as columns supported by the cavity floor and angle braces to supported by the cavity walls. Some supports are supported by the side wall but not the floor, and other by the floor and not the side walls.

Procedures for rapid build and improved surface characteristics in layered manufacture

A composite face seal having an annular seal rotor with a metal base portion and a radially extending flange. The flange having first and second axially facing surfaces. A first ceramic ring is mounted to the first surface of the flange by a first braze joint and a second ceramic ring is mounted to the second surface of the flange by a second braze joint. The composite face seal assembly further includes an annular stator having an axially facing surface that sealingly engages an axially facing surface of one of the ceramic rings. Each of the braze joints may comprise a molybdenum ring disposed between two braze rings or, for thicker seal assemblies, molybdenum and nickel rings disposed between braze rings.

Face seal assembly with composite rotor

A ceramic ball bearing assembly ( ) has raceway components generally held in residual compression by accompanying metal attachments. In a ceramic ball bearing assembly ( ), an outer raceway ( ) is formed that is held in compression by a circumscribing steel ring. The components may be fitted together with the ceramic raceway subject to thermal contraction while the steel ring is subject to thermal expansion. Upon mating, the ceramic raceway ( ) slightly expands while the steel ring slightly contracts to impose residual compression upon the ceramic raceway. The residual compression preserves the ceramic raceway despite thermal or other stresses of operating environment. An inner ceramic raceway ( ) is constructed by employing one of several of the herein described methods, and the ceramic ball bearing assembly of the present invention may use balls ( ), needles, cylinders, or other rolling elements in order to achieve smooth angular translation between the inner and outer ceramic raceways.

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Sparta, NJ, United States of America

Charles J Gasdaska