United Technologies Corporation

John F Blondin

Steven J Bullied

David A Litton

Mark F Bartholomew

John Joseph Marcin

Mario P Bochiechio

Carl R Verner

Ryan B Noraas

Ryan C Breneman

Raymond P Ristau

Kevin W Chittenden

Gary M Tamiso

Robert E LeBrun

Paul R Zamjohn

Charles A Roohr

Roy A Garrison

Robert C Renaud

Dennis M Kraemer

Brian T Hazel

Kevin W Schlichting

Benjamin Joseph Zimmerman

Kerry Kozaczuk

William F Werkheiser

John H Hyde

Donald G Broadhurst

A method to manufacture reticulated metal foam via a dual investment solid mold, includes pre-investing a precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor; and investing the encapsulated precursor with a ceramic plaster within an mold of a varied cross-section. A varied cross-section mold includes a mold thickness adjacent to an outer periphery of a pattern at a top of the varied cross-section mold is between 200-500% a thickness between the outer periphery of the pattern at a base of the varied cross-section mold. A varied cross-section mold includes a trapezoidal prism shape with a pour cone in a top, the top larger than the base.

Variable diameter investment casting mold for casting of reticulated metal foams

A method of manufacturing a component in a die casting cell that includes a die casting system according to an exemplary aspect of the present disclosure includes, among other things, isolating a first chamber from a second chamber of the die casting system, melting a charge of material in the first chamber, sealing the second chamber relative to the first chamber, and simultaneously injecting the charge of material within the second chamber to cast the component and melting a second charge of material within the first chamber.

Die casting system and cell

A method to manufacture reticulated metal foam includes coating a precursor in a molten wax to increase ligament thickness; and investment coating the molten wax coated precursor with a ceramic plaster.

Investment technique for solid mold casting of reticulated metal foams

A method to manufacture reticulated metal foam via a dual investment solid mold includes pouring molten metal material into a mold while the mold is located on a chill plate. A method to manufacture reticulated metal foam includes pouring molten metal material into a mold while the mold is located on a chill plate, the chill plate configured to apply an externally driven temperature gradient in the mold so that solidification progresses from the chilled end to the non-chilled end.

Chill plate for equiax casting solidification control for solid mold casting of reticulated metal foams

A suspension plasma spray feeder apparatus for delivering a suspension from a suspension source to a plasma spray gun. The feeder apparatus comprises a suspension line and a vibrator mounted to vibrate the suspension line.

Suspension plasma spray apparatus and use methods

A die casting system includes a die, a shot tube, a melting system and a vacuum system. The die includes a plurality of die components that define a die cavity. The shot tube is in fluid communication with the die cavity and is operable to deliver a charge of material to the die cavity. The melting system is positioned adjacent to the die and includes an alloy loader, a melting unit and a crucible. The vacuum system defines a first chamber and a second chamber separated from the first chamber by an isolation valve. The melting system is disposed within the first chamber, and the die is disposed within the second chamber.

A method for controlling a temperature of a portion of a die casting system having a shot tube plunger, according to an exemplary aspect of the present disclosure includes, among other things, communicating a fluid through a fluid inlet of a fluid passageway of a thermal control scheme of the shot tube plunger. The fluid circulates through the fluid passageway of the thermal control scheme to selectively adjust a temperature of the shot tube plunger. The fluid is discharged through a fluid outlet of the fluid passageway.

Shot tube plunger for a die casting system

A shot tube plunger of a die casting system includes a tip portion and a thermal control scheme at least partially disposed within the shot tube plunger. The thermal control scheme includes a fluid passageway having at least one coiled portion that receives a fluid to adjust a temperature of the shot tube plunger.

Systems and methods for forming components with thermal barrier coatings are provided. In this regard, a representative method includes: providing a component having a first side and an opposing second side; and using a preformed mask to obstruct vapors from being deposited on the second side of the component while moving the component relative to the vapors such that the vapors form a thermal barrier coating on the first side of the component.

Systems and methods for forming components with thermal barrier coatings

A method of forming a cast component includes at least partially surrounding an investment mold in a heat-insulating packing material, feeding a molten alloy into the investment mold to provide a filled investment mold, and agitating the filled investment mold while solidifying the molten alloy.

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South Windsor, CT, United States of America

John F Blondin