Rolls-royce Corporation

Rolls-royce North American Technologies Inc.

Joseph Peter Henderkott

Raymond Ruiwen Xu

Timothy Fuesting

Kong Ma

Scott Nelson

Matthew T Kush

Robert F Proctor

Jeffrey F Rhodes

Charles Alan Bulgrin

Carl R Russo

Michael D Wood

Greg Lopshire

Quinlan Yee Shuck

John Alan Weaver

Michael George Glavicic

Larry Allen Junod

Andrew J Ritchey

Corina Moga

Pramod Khandelwal

Danny Ray Carr

Ronald J Snyder

John F Click

Michael Wood

John Weaver

Timothy Paul Fuesting

The disclosure describes assemblies, systems, and techniques for reinforcing complex geometries of pressure vessels using a pre-sintered preform (PSP) braze material that includes a low-melt powder and a high-melt powder. An example component includes a substrate comprising at least a portion of a pressure vessel. The substrate defines a contoured exterior surface of the pressure vessel. The component includes a pre-sintered preform (PSP) reinforcement formed on the surface of the substrate by brazing, wherein the PSP reinforcement comprises a low-melt powder and a high-melt powder.

Pre-sintered preform braze reinforcement of pressure vessels

An assembly for a dual-walled component of a gas turbine engine and methods of forming and repairing a dual-walled component. The assembly includes a cold section part having an outer surface that defines a plurality of impingement apertures, a hot section part including a pre-sintered preform, the hot section part positioned over the outer surface of the cold section part, and a plurality of support structures including the pre-sintered preform, the plurality of support structures positioned between the hot section part and the cold section part, the plurality of support structures separating the hot section part from the cold section part to define at least one cooling channel therebetween.

Dual-walled components for a gas turbine engine

A dual walled component includes a spar comprising a plurality of pedestals; a coversheet attached to a first set of pedestals from the plurality of pedestals; and a repaired coversheet portion attached to a second set of pedestals from the plurality of pedestals and to the coversheet, where the repaired coversheet portion includes a braze material.

Repair of dual walled metallic components using braze material

The disclosure describes example techniques and assemblies for joining a first component and a second component. The techniques may include positioning the first and second component adjacent to each other to define a joint region between adjacent portions of the first component and the second component, the joint region being coated with an adhesion resistant coating. The techniques may also include positioning a braze material in the joint region, heating the braze material to form an at least softened material, and cooling the at least softened material to form a mechanical interlock including the braze material in the joint region joining the first and second components. The braze material does not metallurgically bond to the joint surface.

Techniques and assemblies for joining components

The disclosure describes assemblies, systems, and techniques for reinforcing complex geometries of pressure vessels using a pre-sintered preform (PSP) braze material that includes a low-melt powder and a high-melt powder. An example technique includes positioning a PSP reinforcement on a surface of a substrate. The technique includes heating the PSP reinforcement to soften or melt at least one constituent metal or alloy of the low-melt powder. During heating, the PSP reinforcement is configured to conform to a contour of the surface of the substrate. The technique also includes cooling the PSP reinforcement to define a reinforced component.

A system is for bonding a cover sheet to a core to form or repair a dual wall structure. The system includes a cover sheet probe and an inner pedestal probe. A three dimensional contoured tip of the cover sheet probe abuts against a three dimensional contoured outer surface of the cover sheet opposite a pedestal of the core. The pedestal abuts the inner surface of the cover sheet. The inner pedestal probe may be coupled to the core to create a conductive electrical path from the cover sheet probe through at least part of the structure. A flow of electric power is controlled and supplied to the cover sheet probe to heat a junction between the area of the cover sheet abutting the pedestal and the pedestal. A heated area is created in the junction and fixedly couples the coversheet and the pedestal.

Bonding system for dual walled turbine components

A method may include removing a portion of a base component adjacent to a damaged portion of the base component to define a repair portion of the base component. The base component may include a cobalt- or nickel-based superalloy, and the repair portion of the base component may include a through-hole extending from a first surface of the base component to a second surface of the base component. The method also may include forming a braze sintered preform to substantially reproduce a shape of the through-hole. The braze sintered preform may include a Ni- or Co-based alloy. The method additionally may include placing the braze sintered preform in the through-hole and heating at least the braze sintered preform to cause the braze sintered preform to join to the repair portion of the base component and change a microstructure of the braze sintered preform to a brazed and diffused microstructure.

Repair of through-hole damage using braze sintered preform

A bonding probe is used for bonding a cover sheet to a core to form or repair a dual wall structure. The bonding probe includes a body, an attachment end at a distal end of the body, a head at an opposite end of the body, a tip extending from the head, and a cooling passageway. The attachment end couples the body to a resistance welder. The tip extends to form a proximate end of the body. The tip includes a contacting area having a predetermined three dimensional contoured surface. The contacting area aligns with a predetermined area of a three dimensional outer surface of a cover sheet of a dual walled structure. The cooling passageway provides a passageway for a flow of cooling fluid. The cooling passageway extends through the head, and into the tip.

Bonding probe for bonded dual walled turbine components

A method for forming a component for a gas turbine engine may include forming a first portion of the component that includes a cast metal or metal alloy, forming a second portion of the component that includes presintered preform defining at least one support structure, positioning the second portion on the first portion to define an assembly such that the first portion and the second portion define at least one cooling channel therebetween, and heating the assembly to join the first portion and the second portion and form the component.

Airfoil with sintered powder components

A gas turbine engine component may include an airfoil extending radially from a base to a blade tip, the airfoil including a pressure sidewall and a suction sidewall each extending between a leading edge and a trailing edge opposite the leading edge, an internal cooling circuit extending from the base to the blade tip; and a squealer tip. The squealer tip may include a first and a second squealer tip rail adjacent to the first squealer tip rail, and a squealer tip cap extending between the first and second squealer tip rails. The blade tip, the first and second squealer tip rails, and the squealer tip cap may define an internal squealer tip cooling channel. The blade tip may define a supply aperture that fluidly connect the internal cooling circuit and the internal squealer tip cooling channel.

Turbine blade squealer tip including internal squealer tip cooling channel

A method of diffusion bonding utilizing vapor deposition comprises depositing a coating from a vapor comprising a temperature suppressant element onto a surface of a first component comprising a metal alloy, thereby forming a vapor deposited coating comprising the temperature suppressant element; assembling the first component with a second component comprising a mating surface to form an assembly, the vapor deposited coating contacting the mating surface; and exposing the assembly to a bonding temperature and a compressive force, thereby diffusion bonding the first component to the second component and forming a monolithic third component.

Method of diffusion bonding utilizing vapor deposition

A bonding system is used for bonding a cover sheet to a core to form or repair a dual wall structure. The bonding system includes a plurality of bonding probes and controller circuitry. The bonding probes include a three dimensional (3D) contoured tip configured to align with a predetermined area of a 3D contoured cover sheet of a dual wall structure. The controller circuitry comprises processor circuitry and sensor circuitry. The sensor circuitry provides a location of an area of the 3D contoured cover sheet for bonding. The processor circuitry identifies a bonding probe having a contacting area that aligns with the 3D contour of the cover sheet in the location provided by the sensor circuitry.

Growing community of inventors

Westfield, IN, United States of America

Joseph Peter Henderkott