Mikro Systems, Inc.

Siemens Energy, Inc.

Other

United Technologies Corporation

Tecomet, Inc

Raytheon Technologies Corporation

Iain Fraser

Michael P Appleby

James E Atkinson

John R Paulus

Gary Brian Merrill

Allister William James

Andrew Jeremiah Burns

Benjamin E Heneveld

Jill Klinger

Scott Avery Watson

David C Appleby

An investment casting process for a hollow component such as a gas turbine blade utilizing a ceramic core () that is cast in a flexible mold () using a low pressure, vibration assisted casting process. The flexible mold is cast from a master tool () machined from soft metal using a relatively low precision machining process, with relatively higher precision surfaces being defined by a precision formed insert () incorporated into the master tool. A plurality of identical flexible molds may be formed from a single master tool in order to permit the production of ceramic cores at a desired rate with a desired degree of part-to-part precision.

Investment casting process for hollow components

Certain exemplary embodiments can provide a composition, system, machine, device, manufacture, circuit, and/or user interface adapted for, and/or a method and/or machine-readable medium comprising machine-implementable instructions for, activities that can comprise, after removing a cast device from a stack-lamination-derived mold, said cast device formed from a molding composition, applying a desired shape to said cast device to form a shaped cast device, said molding composition comprising: a ceramic composition comprising silica; an cycloaliphatic epoxy binder composition, said cycloaliphatic epoxy binder composition present in said molding composition in an amount up to 30% by weight of said molding composition; a silicone composition comprising a siloxane resin, said silicone composition present in said molding composition in an amount up to 30% by weight of said molding composition; and a solvent composition adapted to dissolve said cycloaliphatic epoxy binder composition and said silicone composition.

Systems, devices, and/or methods for manufacturing castings

In certain exemplary embodiments of the present invention, three-dimensional micro-mechanical devices and/or micro-structures can be made using a production casting process. As part of this process, an intermediate mold can be made from or derived from a precision stack lamination and used to fabricate the devices and/or structures. Further, the micro-devices and/or micro-structures can be fabricated on planar or nonplanar surfaces through use of a series of production casting processes and intermediate molds. The use of precision stack lamination can allow the fabrication of high aspect ratio structures. Moreover, via certain molding and/or casting materials, molds having cavities with protruding undercuts also can be fabricated.

Methods for manufacturing three-dimensional devices and devices created thereby

A component (A,B,C) has a core formed of a stack () of sheets () of material with cutouts (A) aligned to form passages () in the core. An outer casing () spans the stack axially (), brackets at least parts of opposed ends of the stack, and holds the sheets together in axial compression (). Respective cooperating elements () on the casing and the stack may register the casing with respect to the stack. Pins () in some sheets may engage holes () in adjacent sheets to register the sheets with each other. The casing may be segmented (A,B,C). A hoop () may be compressed around the segmented casing. A gas turbine fuel injector may be formed of a stack () with an inlet element () compressed () onto the stack by the casing ().

Product with internal passages made of stacked sheets with compressive casing

A hot gas path component () including: a metallic substrate () disposed beneath an outer surface () of the component () that is exposed to a hot gas present during operation of an internal combustion engine; a thermal barrier coating (TBC) () disposed on the metallic substrate () and defining a first portion () of the component outer surface (); and a powder metallurgy structure () bonded to the metallic substrate () and in contact with the TBC ().

Internal combustion engine hot gas path component with powder metallurgy structure

Certain exemplary embodiments can provide a system, machine, device, manufacture, circuit, and/or composition of matter adapted for and/or resulting from, and/or a method for activities that can comprise and/or relate to, a first form comprising: a plurality of surface artifacts that substantially spatially replicate a surface geometry of a stacked foil mold; and a prong that is adapted to form a hole in a cast product.

Systems, devices, and/or methods for producing holes

Fabricating a core of a component (A,B,C) from a stack () of sheets () of material with cutouts (A) in the sheets aligned to form passages () in the core. A casing preform () is then fitted over the core. The preform is processed to form a casing () that brackets at least parts of opposed ends of the stack. Shrinkage of the casing during processing compresses () the sheets together. The preform may slide () over the core, and may be segmented (A,B,C) to fit over the core. A hoop () may be fitted and compressed around the segmented casing (A,B,C).

Hybrid manufacturing process and product made using laminated sheets and compressive casing

In certain exemplary embodiments of the present invention, three-dimensional micro-mechanical devices and/or micro-structures can be made using a production casting process. As part of this process, an intermediate mold can be made from or derived from a precision stack lamination and used to fabricate the devices and/or structures. Further, the micro-devices and/or micro-structures can be fabricated on planar or nonplanar surfaces through use of a series of production casting processes and intermediate molds. The use of precision stack lamination can allow the fabrication of high aspect ratio structures. Moreover, via certain molding and/or casting materials, molds having cavities with protruding undercuts also can be fabricated. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. This abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

Growing community of inventors

Ruckersville, VA, United States of America

Iain Fraser