Pratt-Whitney Canada Corp

Marc Lorenzo Campomanes

Orlando Scalzo

Alain Bouthillier

Guillaume Poitras

Vincent Savaria

Bruno Chatelois

Melissa Despres

Charles Becze

Jean Fournier

Mathieu Fagnan

Eric Hosking

Thomas Georges

Bastien Ste-Marie

Bastien Ste Marie

Marianne Coutu

Charles Edward Becze

Methods of manufacturing a turbine shroud segment for a gas turbine engine are disclosed. One method involves receiving a turbine shroud segment green part, machining an axial cooling flow passageway in the turbine shroud segment green part, and after the machining of the axial cooling flow passageway, debinding and sintering the machined turbine shroud segment green part. Another method involves receiving a turbine shroud segment green part, machining a textured surface on the radially outer surface of the body to obtain a machined turbine shroud segment green part, and after the machining of the textured surface, debinding and sintering the machined turbine shroud segment green part. Another method involves injecting powder injection molding material into a mold having cavities defining negatives of features forming a textured surface on the radially outer surface of the body, and debinding and sintering the molded turbine shroud segment green part.

Method of manufacturing a turbine shroud segment

A method of manufacturing a shroud segment for gas turbine engine includes providing an insert having a plurality of pins that extend into a platform cavity portion of a mold cavity. A powder injection molding feedstock is injected. When the green part is disengaged from the mold, each elongated feature is slid out of the green part to define a respective elongated cooling passage in the platform. The method may include, after debinding and sintering, projecting a coating material while defining an obstruction between source of coating material and the open end of each elongated feature with a shoulder of the element to prevent the coating material from reaching the open end, followed by machining to remove at least a part of the shoulder.

Method of manufacturing gas turbine engine element having at least one elongated opening

A method of forming a component from a part in the green state, including selecting at least one first portion of the part to undergo a different local volume reduction from at least one second portion to obtain the component. The green part is provided with the first portion(s) having a first solid loading and the second portion(s) having a second solid loading different from the first solid loading, then debound and sintered to obtain the component. The different first and second solid loadings produce the different local volume reduction in the first portion(s). The first portion(s) can be selected by determining a resulting final shape obtained from debinding and sintering a green part having a uniform first volumetric proportion of binder, and selecting the first portion(s) requiring a different local deformation than that producing the resulting final shape to obtain a desired final shape.

Method of forming a component from a green part

There is provided a method of treating a nickel base super alloy (NiSa) article. First, the NiSa article having fine grains is obtained. The NiSa article has a uniform distribution of the fine grains and substantially uniform mechanical properties throughout. One or more regions within the NiSa article are mechanically deformed. Then, the NiSa article is heat treated to obtain coarse grains in the one or more regions, the coarse grains having a size that is larger than that of the fine grains of the NiSa article outside of the one or more regions.

Method of manufacturing nickel based super alloy parts

A process for joining two or more powder injection molded parts by preparing at least two green parts from a feedstock including a binder and an injection powder. Placing the two or more green part into intimate contact, and maintaining the two green parts in intimate contact at a position with a linkage between the at least two green parts to produce an interconnected green assembly. Placing the assembly under shape retaining conditions, melting the binder of the interconnected green assembly under shape retaining conditions to produce a seamless body.

Process for joining powder injection molded parts

A method of manufacturing a gas turbine engine element, for example a shroud segment. An insert has at least one elongated feature received in a mold cavity. A powder injection molding feedstock is injected. When the green part is disengaged from the mold, each elongated feature is slid out of the green part to define a respective elongated passage. The cross-sectional dimension of the elongated feature may be 0.020 inches or less, and/or a ratio between the length and cross-sectional dimension of the elongated feature may be at least 25. The method may include, after debinding and sintering, projecting a coating material while defining an obstruction between source of coating material and the open end of each elongated feature with a shoulder of the element to prevent the coating material from reaching the open end, followed by machining to remove at least a part of the shoulder.

A method of sizing a cavity in a part and a part made from such method. The method includes forming the part having the cavity, including forming a plurality of protrusions extending within the cavity from at least one internal surface of the cavity, the protrusions having distal ends bordering an unobstructed portion of the cavity, the unobstructed portion having an initial dimension at least partially defined by a position of the distal ends, pressing a deforming element against the distal ends of the protrusions to plastically deform the protrusions toward the at least one internal surface of the cavity and increase the initial dimension to a final dimension, and disengaging the deforming element from the distal ends.

Method of sizing a cavity in a part

A method of manufacturing a part, including providing a green body made of powder injection molding material and connected to a solid support member partially contained in the green body. The support member is engaged with a retaining fixture of a machine tool. While supporting the green body through the engagement between the support member and the retaining fixture, the green body is machined to obtain a machined green part. The machined green part is debound and sintered. A method of forming a powder injection molding part in a green state including machining a molded body using a machine tool while supporting the blank with a retaining fixture, and a machining blank having a green body and a solid support member including one locating feature of a pair of complementary locating features snuggly engageable with one another are also discussed.

Method of forming green part and manufacturing method using same

A method of manufacturing a shroud segment, including separately molding at least first and second parts by powder injection molding. The first part has an inner surface and at least one fluid passage in communication with the inner surface. The second part has an outer surface complementary to the inner surface of the first part. At least one of the inner and outer surfaces is formed to define a plurality of grooves. A plurality of cooling passages in fluid communication with the at least one fluid passage are defined with the plurality of grooves by interconnecting the inner and outer surfaces while the first and second parts remain in a green state. The interconnected parts are debound and sintered to fuse the parts to define at least a portion of the shroud segment including the cooling passages.

Shroud segment and method of manufacturing

A component including a porous portion which may be permeable or impermeable to air, and a method for making. In one example, the component is a cooled wall segment for a gas turbine engine, including a body defining a contact surface configured to be in contact with circulating hot gas and an outer surface configured to be in contact with cooling air. The body includes a first portion with at least one retention element, and a porous second portion made of a porous material permeable to air, containing a plurality of interconnected pores, and having a porosity greater than that of the first portion. The second portion is engaged to the first portion, defines at least part of the contact surface, and defines at least part of a fluid communication between the outer surface and the contact surface through the interconnected pores. The wall segment may be for example a heat shield or shroud segment. Methods of forming components are also discussed.

Aircraft components with porous portion and methods of making

A method of supporting a part with particulate shape retaining media, the method including placing the part on a bed of the particulate shape retaining media, fluidizing the particulate shape retaining media until the part penetrates therein, and vibrating the bed of particulate shape retaining media to compact the particulate shape retaining media around the part. The part may be a green part to be debound in a powder injection molding process. Fluidization may be performed through vibrations at a different frequency than the compaction.

Method of supporting a part

A mold assembly includes a first mold part having guide passages defined therein. Protruding members are each movably received in a first portion of a respective guide passage to extend selectively in and out of the mold cavity. At least some of the protruding members are movable along different directions from one another. Cables are each connected to one of the protruding members and extend through a linear second portion of the respective guide passage and out of the first mold part. An actuator is connected to the cables and movable relative to the first mold part between an extended position and a retracted position. In the extended position, each protruding member protrudes into the mold cavity. In the retracted position, each of protruding member is retracted out of the mold cavity and contained within the respective guide passage. A guide element and a method of molding are also discussed.

Mold assembly and guide element thereof

A method of machining a turbine shroud segment including inserting an annular flange of a grinding wheel through a first gap defined between the shroud retention elements and into a second gap defined between the shroud platform and an axially extending, radially inwardly facing arcuate inner surface of one of the retention elements. The wheel flange is inserted with its supporting leg and the wheel body remaining out of contact with the shroud segment and with the wheel flange remaining out of contact with the platform. The inner surface is ground through contact with an annular outer grinding surface of the wheel flange. The wheel leg and body remain out of contact with the shroud segment and the wheel flange remains out of contact with the platform during grinding.

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Longueuil, Canada

Marc Lorenzo Campomanes