Precision Castparts Corp.

Laxmappa Hosamani

James Raphord Barrett

Jedidiah David Rust

Jason Joseph Schmertman

Terry M Nelson

Michael Charles Watt

Roger A Swanson

Method for forming a unitary component from a plurality of powder metallurgy compacts. The method in some embodiments includes fluidizing first and second surfaces, wherein a first powder metallurgy compact defines the first surface and a second powder metallurgy compact defines the second surface. The method also includes joining the fluidizing first and second surfaces to form a bonded structure and thermally treating the bonded structure to fuse the first and second compacts into a unitary component.

Method for bonding powder metallurgical parts

A metal article, at least a portion of which has a honeycomb structure, is described. The article was produced by an investment casting process. The metal casting comprises a base and plural walls which form a honeycomb structure that project outwardly in a first direction from at least a portion of the base. The base typically has a thickness of about 5 mm or less. The honeycomb structure may be defined by plural cells having geometric shapes. For instance, plural interconnected regular polygons, such as plural interconnected pentagons or hexagons, plural irregular interconnected polygons, or plural regular and irregular interconnected polygons may be used. The maximum distance between any two points on the periphery of the cell and passing through the interior space defined by the geometric shape is about 40 mm. The walls of the casting may have a wall thickness of from about 0.3 mm to about 3.2 mm thick. The method for forming the metal casting comprises first forming a pattern having a base, preferably with a thickness of 5 mm or less, and plural walls that extend upwardly from the base and define a honeycomb structure. A mold is formed around the pattern by surrounding the pattern with a refractory material. The pattern is then removed to form a void within the mold in the shape of the pattern. The void is then filled with a molten metal composition. The metal composition is allowed to solidify in the shape of the desired article, and the mold is then removed.

Honeycomb casting

A method for casting long thin metal articles is described. A particular embodiment is directed to the casting of seals that are used in the low pressure turbine section of a gas turbine engine. The method first involves forming a mold, and then preheating the mold so that the temperature towards the upper portion of the mold is close to the liquidus temperature of the metal composition being cast. The temperature of the bottom portion of the mold is below the solidus temperature of the metal alloy composition. After the metal is poured into the mold cavity, the mold heating system preferably is moved at a selected rate so that the portion of the mold being heated by the furnace is slowly decreased. Withdrawal rates slower than about 30 inches per hour produce satisfactory casting results.

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Beaverton, OR, United States of America

Laxmappa Hosamani