United Technologies Corporation

Raytheon Technologies Corporation

Raytheon Technoiogies Corporation

Rtx Corporation

James Tilsley Auxier

Thomas N Slavens

Joseph V Mantese

John Joseph Marcin

David Ulrich Furrer

Ryan C Breneman

Bret M Teller

Dustin Wayne Davis

Andrew Joseph Boyne

Thomas Anthony Rebbecchi

Parth Jariwala

Tracy A Propheter-Hinckley

Mark F Zelesky

Matthew S Gleiner

Brooks E Snyder

Alan C Barron

Lea Kennard Castle

Norman W Cofalka

JinQuan Xu

Eric A Hudson

Dominic J Mongillo, Jr

Steven D Porter

Mario P Bochiechio

Nicholas M LoRicco

Yafet Girma

Steven Bruce Gautschi

Joel H Wagner

Jeffrey T Morton

Allan N Arisi

David Richard Griffin

Charles Thistle

Alex J Schneider

Shiela R Woodard

Rodney H Warner

Jeremy Styborski

Roger Gates

Brandon S Donnell

Christine F McGinnis

Karl A Mentz

Jason L O'Hearn

Tracy A Propheter-hinckley

Megan J Kwolek

Andrew Boyne

Nicholas M Loricco

A gas turbine engine component has a component body configured to be positioned within a flow path of a gas turbine engine having an external pressure, and wherein the component body includes at least one internal cavity having an internal pressure. At least one inlet opening is formed in an outer surface of the component body to direct hot exhaust gas flow into the at least one internal cavity, and there is at least one outlet from the internal cavity. The internal pressure is less than an inlet external pressure at the inlet opening and the internal pressure is greater than an outlet external pressure at the outlet opening to controllably ingest hot exhaust gas via the inlet opening and expel the hot exhaust gas via the outlet opening to maintain a laminar boundary layer along the outer surface of the component body.

Method and apparatus to enhance laminar flow for gas turbine engine components

A system for automated adaptive manufacturing of airfoil castings is disclosed. The system may receive a three dimensional scan of a work piece. The system may compare the three dimensional scan to a digital model of the work piece. The system may identify an area of dimensional abnormality on the work piece based on the comparison. The system may alter the area of dimensional abnormality on the work piece.

Systems and methods for automated adaptive manufacturing of airfoil castings

A method of manufacturing a casting is provided and includes establishing desired dimensions of a nominal casting, executing a casting process to produce multiple actual castings with each of the multiple actual castings having respective dimensions that differ from each other and from the desired dimensions of the nominal casting and engaging one or more tools to adaptively machine, without rigidly-programmed toolpaths, each of the multiple actual castings to reduce the respective differences between the actual dimensions of each of the multiple actual castings and the desired dimensions.

Manufacturing thin-walled castings utilizing adaptive machining

A gas turbine engine according to an example of the present disclosure includes, among other things, a rotor and a vane spaced axially from the rotor, and a blade outer air seal spaced radially from the rotor. At least one of the rotor and the vane includes an airfoil section extending from a platform. At least one of the airfoil section, the platform and the blade outer air seal includes a first cavity extending in a first direction, the first cavity defining a reference plane along a parting line formed by a casting die, and a plurality of trip strips including a first set of trip strips distributed in the first direction along a surface of the first cavity and on a first side of the reference plane, each of the plurality of trip strips defining a respective groove axis extending longitudinally between a first end and an opposed, second end of a respective one the plurality of trip strips, and the groove axes being oriented with respect to a pull direction of the casting die. A casting core and method for fabricating a gas turbine engine component is also disclosed.

Core arrangement for turbine engine component

A core for use in casting an internal cooling circuit within a gas turbine engine component includes a base core portion and an additive core portion additively manufactured to the base core portion. A method of manufacturing a core for use in casting an internal cooling circuit within a gas turbine engine component including additively manufacturing an additive core portion to a base core portion.

Additively manufactured core for use in casting an internal cooling circuit of a gas turbine engine component

A core assembly for a casting system according to an exemplary aspect of the present disclosure includes, among other things, a core that includes a body and at least one hole formed through the body and a spacer that extends through the at least one hole. The spacer includes a stud portion and a chaplet portion configured to abut a surface of the body that circumscribes the at least one hole.

Core assembly including studded spacer

A turbine airfoil includes an airfoil outer wall that defines leading and trailing ends and first and second sides that join the leading and trailing ends. At least one cooling passage is embedded in the airfoil outer wall and has a radially-elongated entrance manifold, a radially-elongated diffuser orifice that opens to an exterior surface of the airfoil outer wall, and a bank of sub-passages fluidly connecting the radially-elongated entrance manifold with the radially-elongated diffuser orifice. The radially-elongated diffuser orifice is sloped relative to the radially-elongated entrance manifold.

Turbine airfoil with minicore passage having sloped diffuser orifice

A mold for manufacturing a casted workpiece is, at least in-part, manufactured utilizing an additive manufacturing process. The mold may have a core having non-line-of-sight features that are additively manufactured and in contact with an outer shell of a wax mold and/or an outer shell of a casting mold of the mold. The outer shell of either the wax or casting molds may also be additively manufactured, and the shell of the casting mold may be additively manufactured as one unitary piece to the core.

Additive manufactured mold, a method of manufacturing the mold, and a workpiece casted from the mold

A method of removing features from a cast workpiece includes generating a nominal toolpath for machining the cast workpiece. The cast workpiece is mounted onto a platform of a computer numeric control machine. The cast workpiece is inspected with a probe to generate probe data. Features to be removed are identified based upon the probe data generated during the inspection. Any expected features of the cast workpiece that are missing from the cast workpiece are identified. A transformation matrix is applied to the nominal toolpath with a controller of the computer numeric control machine, wherein the transformation matrix is based upon the probe data. Alignment of the cast workpiece is adjusted relative to the computer numeric control machine based on the transformation matrix with the computer numeric control machine. Features are removed from the cast workpiece that were identified during inspection.

Method of manufacture using autonomous adaptive machining

A blade outer air seal includes a seal body that has a channel on a radially inner side that defines a first height portion outside of the channel and a second height portion within the channel. A first cavity is in the first height portion and a second cavity is in the second height portion. An abradable coating is over the radially inner side and fills the first and second cavities.

Abradable coating for grooved BOAS

A process for directional solidification of a cast part comprises energizing a primary inductive coil coupled to a chamber having a mold containing a material; energizing a primary inductive coil within the chamber to heat the mold via radiation from a susceptor, wherein the resultant electromagnetic field partially leaks through the susceptor coupled to the chamber between the primary inductive coil and the mold; determining a magnetic flux profile of the electromagnetic field; sensing a magnetic flux leakage past the susceptor within the chamber; generating a control field from a secondary compensation coil coupled to the chamber, wherein the control field controls the magnetic flux experienced by the cast part; and casting the material within the mold under the controlled degree of flux leakage.

Method for magnetic flux compensation in a directional solidification furnace utilizing a stationary secondary coil

A process for directional solidification of a cast part comprises energizing a primary inductive coil coupled to a chamber having a mold containing a material; generating an electromagnetic field with the primary inductive coil within the chamber, wherein said electromagnetic field is partially attenuated by a susceptor coupled to said chamber between said primary inductive coil and said mold; determining a magnetic flux profile of the electromagnetic field after it passes through the susceptor; sensing a component of the magnetic flux in the interior of the susceptor proximate the mold; positioning a mobile secondary compensation coil within the chamber; generating a control field from a secondary compensation coil, wherein said control field controls said magnetic flux; and casting the material within the mold.

Method for magnetic flux compensation in a directional solidification furnace utilizing an actuated secondary coil

An induction furnace assembly comprising a chamber having a mold; a primary inductive coil coupled to the chamber; a layered susceptor comprising at least two layers of magnetic field attenuating material surrounding the chamber between the primary inductive coil and the mold to nullify the electromagnetic field in the hot zone of the furnace chamber.

Multi-layer susceptor design for magnetic flux shielding in directional solidification furnaces

A casting core may comprise a tip flag material having a forward cavity and a first spear cavity disposed aft of the forward cavity. A trailing edge discharge material may be separated from the tip flag material and include a first row of cavities. The first row of cavities may comprise a first racetrack cavity. A second row of cavities may be disposed aft of the first row of cavities and include a second racetrack cavity. A third row of cavities may be disposed aft of the second row of cavities and include a circular cavity. A fourth row of cavities may be disposed aft of the third row of cavities and include a second spear cavity.

Internally cooled airfoil

A refractory metal core laminate assembly, comprising: a first refractory metal core layer having exterior surfaces and a first side and a second side opposite the first side; a second refractory metal core layer having exterior surfaces and a first side and a second side opposite the first side, the second refractory metal core layer being arranged above the first refractory metal core layer with the second refractory metal core layer first side facing the first refractory metal core layer second side; a layer of a powder bed material between the first refractory metal core layer second side and the second refractory metal core layer first side; and a coating of the powder bed material coupled to the first refractory metal core layer exterior surfaces and the second refractory metal core layer exterior surfaces.

Construction of multi-layered refractory metal core for investment casting

Growing community of inventors

Bloomfield, CT, United States of America

James Tilsley Auxier