United Technologies Corporation

Rtx Corporation

Raytheon Technologies Corporation

John J Marcin

Steven J Bullied

Dilip M Shah

Alan David Cetel

Carl R Verner

Ryan C Breneman

James Thompson Beals

Kevin W Schlichting

William P Stillman

Stephen Douglas Murray

Michael A Disori

David J Hyland

Daniel A Bales

Mario P Bochiechio

David Ulrich Furrer

John E Holowczak

Dustin Wayne Davis

Dinesh K Gupta

Venkatarama K Seetharaman

Keith A Santeler

Sudhangshu Bose

Daniel F Paulonis

Joshua E Persky

Glenn A Cotnoir

Jacob A Snyder

Paul D Genereux

Reade R Clemens

John D Wiedemer

Bradford A Cowles

Michael K Turkington

Lea D Kennard

Keith Douglas Sheffler

Emily K Kreek

Robert Jacobi Henricks

Ingrid H Kerscht

Jacqueline B Wahl

Thomas W Prete

Russell A Beers

Venkat Seetharaman

Stephen D Murray

Keith Santeler

A cast part includes an outermost wall, at least one inner wall defining at least two internal passages and at least one cast cooling fin extending from an outer surface. The cast part including a cross-sectional circular area spanning at least a portion of each of four internal passages includes a ratio of interior empty space to inner wall space that improves heat transfer.

Cast plate heat exchanger and method of making using directional solidification

A method includes casting a metallic material () in a mold () containing a core, the core having a substrate () coated with a coating (). A removing of the metallic material from the mold and decoring leaves a casting having a layer formed by the coating. The coating has a ceramic having a porosity in a zone () near the substrate less than a porosity in a zone () away from the substrate.

Castings and manufacture methods

A cast part includes an outermost wall, at least one inner wall defining at least two internal passages and at least one cast cooling fin extending from an outer surface. The cooling fin includes a ratio of fin height to an average fin thickness that is greater than 2.0 and no more than 18.0. A method is also disclosed.

An apparatus for countergravity casting a metallic material, has: a crucible for holding melted metallic material; a casting chamber for containing a mold; a fill tube capable of extending into the crucible to communicate melted metallic material to the casting chamber; and a gas source coupled to a headspace of the melting vessel to allow the gas source to pressurize the headspace to establish a pressure differential to force the melted metallic material upwardly through the fill tube into the mold. Extraneous sulfur is prevented from entering the molten metal from the surrounding environment.

Countergravity casting apparatus and desulfurization methods

A casting mold () comprises a shell () extending from a lower end () to an upper end () and having: an interior space () for casting metal; and an opening () for receiving metal to be cast. A plurality of thermocouples () are vertically-spaced from each other on the shell.

Casting molds, manufacture and use methods

A method of removing a core of a cast component includes providing a casting that includes a silica based ceramic core in a temperature controlled closed volume; cycling temperature between a first temperature and a second temperature within the temperature controlled closed volume that repeatedly subjects the silica based ceramic core to a beta-to-alpha cristobalite transition that induces microfractures in the silica based ceramic core; and after the cycling temperature, chemically dissolving the silica based ceramic core from the casting.

Casting core removal through thermal cycling

An alloy part is cast in a mold () having a part-forming cavity (). The method comprises pouring a first alloy into the mold. The pouring causes: a surface () of the first alloy in the part-forming cavity to raise relative to the part-forming cavity; a branch flow of the poured first alloy to pass upwardly through a first portion () of a passageway; and the branch flow to pass downwardly through a second portion (), of the passageway; solidifying some of the first alloy in the passageway to block the passageway while at least some of the first alloy in the part-forming cavity remains molten. A second alloy is poured into the mold atop the first alloy and solidified.

Multi-shot casting

An alloy part is cast in a mold () having a part forming cavity (). The method comprises pouring a first alloy into the mold. The pouring causes: a surface () of the first alloy in the part forming cavity to raise relative to the part forming cavity; a branch flow of the poured first alloy to pass upwardly through a first portion () of a passageway; and the branch flow to pass downwardly through a second portion (), of the passageway; solidifying some of the first alloy in the passageway to block the passageway while at least some of the first alloy in the part forming cavity remains molten. A second alloy is poured into the mold atop the first alloy and solidified.

A refractory metal core for use in a casting system has a coating for providing oxidation resistance during shell fire and protection against reaction/dissolution during casting. In a first embodiment, the coating includes at least one oxide and a silicon containing material. In a second embodiment, the coating includes an oxide selected from the group of calcia, magnesia, alumina, zirconia, chromia, yttria, silica, hafnia, and mixtures thereof. In a third embodiment, the coating includes a nitride selected from the group of silicon nitride, sialon, titanium nitride, and mixtures thereof. Other coating embodiments are described in the disclosure.

Refractory metal core coatings

The invention is a process for removing ceramic thermal barrier layers from gas turbine engine hardware. A combination of chemical and mechanical steps are used to remove the thermal barrier coating from the substrate without removing the bond coat from the substrate. The process leaves the bond coat on the substrate in condition to receive a repair ceramic thermal barrier coating. The process includes a caustic solution treatment in an autoclave under controlled conditions followed by a mechanical abrasion process.

Thermal barrier removal process

A coated nickel base superalloy single crystal turbine airfoil blade (1), which is subject to gas turbine engine operation, can crack during refurbishment by a stress corrosion mechanism when exposed to certain corrosive media. The rapid thermal cycling that occurs during typical gas turbine engine operation results in high, non-uniform stresses across the airfoil, producing large localized residual strains in the article at ambient temperatures. Exposure to a corrosive environment, such as during coating removal or agressive cleaning, can produce chordwise cracks in a large number of the airfoils exposed. Such cracking is avoided by subjecting the articles to a preliminary stress relieving heat treatment which reduces the residual strains to a level below which cracking will not occur, prior to exposure to the corrosive media.

Stress relief of single crystal superalloy articles

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Marlborough, CT, United States of America

John J Marcin