Rtx Corporation

United Technologies Corporation

Raytheon Technologies Corporation

United States of America As Represented by the Administrator of Nasa

John D Riehl

Robin H Fernandez

Larry Foster

Xiaomei Fang

Dmitri Novikov

Charles R Watson

Gajawalli V Srinivasan

John Harner

Zhigang Wang

Rajiv A Naik

Gary A Wigell

Sergei F Burlatsky

William Bogue

David Ulrich Furrer

James Olaf Hansen

Kathryn S Read

Christopher J Hertel

George Alan Salisbury

Brandon A Gates

Jesse C Meyer

Michael A Morden

Vadim V Atrazhev

Raymond P Martina

Hillary Anne Huttenhower

Vadim I Sultanov

Joseph Jalowka

Dmitry Dmitriev

Gabriel L Suciu

James Thompson Beals

John W Connell

David A Litton

Brian T Hazel

Xia Tang

Andrzej Ernest Kuczek

Ioannis Alvanos

Paul F Croteau

William J Brindley

Douglas Michael Berczik

Henry H Thayer

Alan C Barron

Kevin L Rugg

Frank L Palmieri

John W Hopkins

Aaron R Tomich

Anthony G Ruglio

Thomas M Morin

Steven R Clarke

Dorel M Moisei

Bradley L Paquin

Zachary Paul Konopaske

Kevin M Bell

Bruce R Saxton

Allen R Frost

Donald H Spencer

James Masloski

Molly Kole

Jeffrey Ian Phillips

Sergei Fedorovich Burlatsky

Vadim Iosifovich Sultanov

Dmitry Vladimirovich Dmitriev

Vadim Vladimirovich Atrazhev

Dmitri Leonidovich Novikov

A tooling assembly for use in forming z-channels in a fibrous ceramic preform includes a mandrel having a first plurality of holes extending into a mandrel body, a first subset of the plurality of holes being through-holes extending completely through the mandrel, and a second subset of the holes comprising blind pockets, and a plurality of channels extending longitudinally along the mandrel in a direction orthogonal to the first plurality of holes. The tooling assembly further includes an outer fixture at least partially enclosing the mandrel, the outer fixture including at least one piece comprising a second plurality of holes extending completely through the at least one piece, the second plurality of holes being aligned with respective corresponding ones of the first plurality of holes such that a needle can be inserted through each of the second plurality of holes in the at least one piece and into the respective ones of the first plurality of holes in the mandrel.

Internal tooling configuration for the creation of z-channels in woven ceramic matrix composite preforms

A method is provided for machining a workpiece. During this machining method, an aperture is formed in the workpiece using a machining system. The machining system includes an ultrasonic machining device, a slurry delivery device and a controller. The forming of the aperture includes delivering a slurry to an interface between the ultrasonic machining device and the workpiece using the slurry delivery device, and transmitting ultrasonic vibrations into the slurry using the ultrasonic machining device. A feedback parameter is monitored during the forming of the aperture using the controller. A slurry delivery parameter for the slurry delivery device is adjusted during the forming of the aperture based on the feedback parameter using the controller.

Ultrasonic machining an aperture in a workpiece

An adaptive surface texturing method is provided for use with a part formed of ceramic matrix composites (CMCs) to be coated with an environmental barrier coating (EBC). The method includes coating a CMC surface of the part with an initial coating, determining a contour and an undulation pattern of the CMC surface and designing a texturing pattern to follow the contour and the undulation pattern and to be formed in the initial coating based on a thickness of the initial coating and an average particle size of a slurry of the EBC.

Adaptive surface texturing for ceramic matrix composites

A method of machining includes removing material from a target region of a ceramic component to form a blind opening in the ceramic component via removing a bulk of the material by a laser machining operation and then removing a remainder of the material by a mechanical machining operation.

Multi-step method for machining blind opening in ceramic component

The present disclosure provides methods and systems for composite-to-metal hybrid bonded structures compromising the laser surface treatment on titanium alloys to promote adhesive bond performance. For example, a computer may be programmed to set a laser path corresponding to a predetermined geometric pattern. A laser may be coupled to the computer and apply a pulsed laser beam to a contact surface of the titanium alloy along the predefined geometric pattern. The laser may generate an open pore oxide layer on the contact surface of the substrate with a thickness of 100 and 500 nm. The open pore oxide layer may have a topography corresponding to the predefined geometric pattern. The topography may contain high degree of open pore structure and promote adhesive bond performance. Adhesive, primer or composite resin matrix may fully infiltrate into the open pore structures. Adhesive and composite laminate may co-cure to form composite-to-titanium hybrid bonded structures.

Adhesive bonded composite-to-metal hybrid vanes and method of manufacture

A method of machining includes mounting a component in a drilling machine. The component has a target region where the hole is to be drilled. The component and a jet head are situated relative to each other in a drilling arrangement in which the target region is at a first position that is vertically equal to or vertically above a second position at which the jet head is located. A liquid stream is jetted from the jet head and contains either abrasive particles or a laser beam. The stream impinges the target region, and the abrasive particles or the laser beam cause removal of material from the component to form the hole. The liquid stream rebounds off of the component as back-splash. The drilling arrangement causes gravitational draining of the back-splash from the target region to reduce interference between the back-splash and the liquid stream.

Method and system for drilling ceramic

Methods and systems for the laser surface treatment on stainless steel alloys and nickel alloys may include a computer may be programmed to set a laser path corresponding to a predetermined geometric pattern. A laser may be coupled to the computer and apply a pulsed laser beam to a contact surface of the substrate along the predefined geometric pattern. The pulsed laser beam may have a laser power between 0.1 W and 100 W, single pulse fluence 1 mJ/mmand 1025 mJ/mmand a laser speed between 25.4 cm/s and 127 cm/s. The laser may generate an open pore oxide layer on the contact surface of the substrate with a thickness of 0.1-1 μm, an open pore distance of 0.05-1 μm. The open pore oxide layer may have a topography corresponding to the predefined geometric pattern. The topography may contain open pore structures and promote adhesive bond performance.

Laser surface treatment on stainless steel and nickel alloys for adhesive bonding

A drench system includes a rotating mount to rotate a workpiece, a showerhead to dispense a fluid onto the workpiece; and a tray to collect the fluid and recirculate the fluid to the shower. A method of repairing or remanufacturing a coating includes abrading a surface to at least partially remove a portion of a coating to leave an abraded surface; applying a sol-gel over the abraded surface; applying a corrosion resistant primer onto the sol-gel; and applying an erosion coating onto the corrosion resistant primer.

Processes and tooling associated with coating application

A method of forming a ceramic matrix composite includes applying a tackifier of ethanol and 3% to 12% polyvinyl butyral to a ceramic material, removing the ethanol from the ceramic material, and removing the polyvinyl butyral. The step of applying the tackifier includes one of a spraying, pipetting, painting, and immersing technique.

Localized PVB based tackifier application for CMC

A tackified ceramic fabric sheet includes a pre-preg layer having a fabric of woven ceramic tows and a tackifier compound surrounding the tows and comprising 15% to 60% polyvinyl butyral with ethanol. The sheet further includes a removable first backing film layer on a first side of the pre-preg layer.

PVB-based sacrificial tackifier for CMC

Disclosed herein is a ceramic matrix composite airfoil comprising a triple bifurcated ply that defines a suction side, an outer platform, a pressure side and an inner platform of the airfoil, wherein the triple bifurcated ply comprises at least one ply that comprises a consolidated region, wherein the consolidated region is split into two bifurcated regions in three locations in three different directions.

Bifurcated fabric architecture for airfoils, methods of manufacture thereof and airfoils comprising the same

A method for treating a surface of a contoured titanium substrate used for adhesively bonded engine components. The method including applying energy from a fiber laser system to a contoured surface of a titanium substrate, the laser energy is distributed to the contoured titanium surface by at least one of direct light of sight, reflection, or scattering of one or more laser beam.

Method for adhesive bonding of titanium components using a fiber laser system

An airfoil for a gas turbine engine according to an example of the present disclosure includes, among other things, an airfoil section extending between a leading edge and a trailing edge in a chordwise direction and extending between a tip and a root section in a spanwise direction. A composite core defines the root section and a portion of the airfoil section. First and second skins extend along opposed sides of the composite core.. A method of forming a composite airfoil is also disclosed.

Composite airfoil for gas turbine

A method of repairing an erosion coating coupled to a substrate, wherein the coating comprises an anodization layer on the substrate, a bond primer layer on the anodization layer, a corrosion-resistant primer on the bond primer, and an erosion coating on the corrosion-resistant primer. The method comprises abrading an erosion coating; abrading a corrosion-resistant primer; creating an abraded surface comprising a bond primer over an anodization layer coupled to the substrate, applying a sol-gel adhesion promoter layer to said abraded surface; applying a corrosion-resistant layer over the sol-gel adhesion promoter layer; and applying an erosion coating layer over the corrosion-resistant layer.

Method to strip and recoat erosion coatings applied to fan blades and structural guide vanes

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Hebron, CT, United States of America

John D Riehl