United Technologies Corporation

Raytheon Technologies Corporation

Hamilton Sundstrand Corporation

Raytheon Technoiogies Corporation

Rtx Corporation

John Joseph Marcin

Steven J Bullied

Mario P Bochiechio

Carl R Verner

Dilip M Shah

Alan David Cetel

David Ulrich Furrer

Joseph V Mantese

James Tilsley Auxier

Ryan C Breneman

Dustin Wayne Davis

Andrew Joseph Boyne

Thomas Anthony Rebbecchi

Mark F Bartholomew

John F Blondin

Kevin W Chittenden

Paul D Genereux

Kevin W Schlichting

Joel H Wagner

Venkatarama K Seetharaman

Stephen Douglas Murray

Marc R Sauerhoefer

Reade R Clemens

Raymond P Ristau

Lea D Kennard

Gary M Tamiso

Justin Andreas Neutra

David Henry Abbott

Dorothea Nadette Carraway

James Peter Aduskevich

Raymond Paul Langevin

Richard Alan Stone

Robert C Renaud

Dennis M Kraemer

Robert E LeBrun

Paul R Zamjohn

Charles A Roohr

Kerry Kozaczuk

Roy A Garrison

Gabriel L Suciu

Mark F Zelesky

James Thompson Beals

Russell Albert Beers

Herbert A Chin

Theodore W Hall

David A Krause

Paul L Reynolds

Bradford A Cowles

Michael K Turkington

Delwyn E Norton

Maria Arceo Herring

Kirk C Newton

Carl E Kelly

Emily K Kreek

Donald D Schofield

Richard L Ritchie

Thomas W Prete

Tracy A Propheter-Hinckley

Thomas N Slavens

Joseph Parkos, Jr

James Olaf Hansen

John R Farris

Thomas J Watson

Wangen Lin

Lee Drozdenko

William P Stillman

Scot Adams Webb

Ryan B Noraas

Lea Kennard Castle

Michael A Kmetz

Michael A Disori

Brandon A Gates

Michael A Morden

Jesse C Meyer

Albert Rabinovich

David J Hyland

Dorothea C Wong

Ben S Reinert

Dilip N Shah

Santosh Ranganath

Weiduo Yu

Ryan Tonk

Christopher Heinze

Darrell J Holding

Robert M Shemenski

Mario P Bochiecchio

Andrew Boyne

A hybrid casting process for structural components uses a re-usable metallic mold rather than a sand mold to produce more consistent cast components. The hybrid casting process uses a metallic mold coupled to a core mold to produce the near net shape of the cast component. Machining operations are performed on the near net shape cast component to produce a final component that meets tolerances and other specifications of the structural component.

Hybrid casting process for structural castings

An apparatus for countergravity casting a metallic 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 said headspace to establish a pressure differential to force the melted metallic material upwardly through said fill tube into the mold. Added sulfur-gettering particles subsequently filtered or sulfur-gettering material removes sulfur from the melted metallic material.

Countergravity casting apparatus and desulfurization methods

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 method of making an airfoil includes making a refractory metal core that defines an interior of the airfoil by a tomo-lithographic process, making a mold that defines an exterior of the airfoil, inserting the refractory metal core into the mold, and pouring an airfoil material between the refractory metal core and the mold to cast the airfoil.

Method of making airfoils

A method of making a composite core includes forming first and second cores of refractory metal and ceramic material. Each of the first and second cores is formed with two layers of a material. The layers are bonded together to form a laminate master pattern, and a flexible mold is formed around the pattern. The pattern is removed from the flexible mold, and slurry material, either pulverulent refractory metal material or ceramic material, is poured into the flexible mold. The slurry material is sintered to form each core. The first core is used as an insert while making the second core to create a final composite core.

Method of making complex internal passages in turbine airfoils

A blade (-) comprises an airfoil () and an attachment root (). The blade has a tipward zone (--) and a rootward zone (-). The rootward zone has a single crystal structure. The tipward zone has a single crystal structure. The crystalline orientations of the rootward zone and tipward zone are at least 15&#xb0; out of registry with each other.

Turbine blades and manufacture methods

A method of manufacturing a heat shield panel assembly is provided. The method including: injecting melted wax into a negative cavity of a heat shield panel, the heat shield panel including one or more orifices; allowing the wax to solidify to form a positive pattern of the heat shield panel; removing the positive pattern from the negative cavity; coating the positive pattern with a ceramic; melting the positive pattern away from the ceramic, the ceramic having a cavity forming a second negative cavity of the heat shield panel; pouring melted metal into the cavity; allowing metal in the cavity to solidify to form the heat shield panel; removing the ceramic from the heat shield panel; and forming each of one or more threaded studs separately from the heat shield panel, each of the one or more threaded studs including a stud portion and a thread portion simultaneously formed.

Method to produce jet engine combustor heat shield panels assembly

A method of manufacturing a heat shield panel assembly is provided. The method including: forming a heat shield panel, wherein the heat shield panel includes one or more orifices; and forming each of one or more threaded studs through operations including: injecting melted wax into a negative cavity of a threaded stud; allowing the wax to solidify to form a positive pattern of the threaded stud; removing the positive pattern of the threaded stud from the negative cavity of the threaded stud; coating the positive pattern of the threaded stud with a ceramic; melting the positive pattern of the threaded stud away from the ceramic, the ceramic having a second cavity forming a second negative cavity of the threaded stud; pouring melted metal into the second cavity; allowing metal in the second cavity to solidify to form the threaded stud; and removing the ceramic from the threaded stud.

A method comprises: providing a spiral metallic workpiece having a cast structure associated with such spiral; and at least partially flattening the workpiece.

Cast components and manufacture and use methods

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

High modulus turbine shafts and high modulus cylindrical articles are described as are the process parameters for producing these shafts and cylindrical articles. The shafts/articles have a high Young's modulus as a result of having high modulus &#x3c;111&#x3e; crystal texture along the longitudinal axis of the shaft/article. The shafts are produced from directionally solidified seeded &#x3c;111&#x3e; single crystal cylinders that are axisymmetrically hot worked before a limited recrystallization process is carried out at a temperature below the recrystallization temperature of the alloy. The disclosed process produces an intense singular &#x3c;111&#x3e; texture and results in shaft or cylindrical article with a Young's modulus that is at least 40% greater than that of conventional nickel or iron alloys or conventional steels.

High elastic modulus shafts and method of manufacture

A method of fabricating a casting is provided. The method includes creating a mixture of ceramic powder and a binder, pouring the mixture around sacrificial patterns, executing a first thermal treatment to set the mixture into a solid mold without damaging the sacrificial patterns, executing a second thermal treatment to remove the sacrificial patterns without removing any of the binder from the solid mold, executing at least one of a third thermal treatment and a chemical treatment to remove a quantity of the binder to transform the solid mold into a solid breakaway mold and pouring molten metallic material into the solid breakaway mold.

Production of multi-passage hollow casting

Growing community of inventors

Marlborough, CT, United States of America

John Joseph Marcin