United Technologies Corporation

Hamilton Sundstrand Corporation

Raytheon Technologies Corporation

Rtx Corporation

Matthew E Lynch

Wayde R Schmidt

Tahany Ibrahim El-Wardany

Lawrence A Binek

Evan J Butcher

Daniel V Viens

Wendell V Twelves

Thomas P Filburn

Peter J Walsh

Wenping Zhao

Andrzej Ernest Kuczek

Ellen Y Sun

Joseph V Mantese

John P Wesson

William A Veronesi

Jagadeesh Kumar Tangudu

John E Holowczak

Joe Ott

Paul F Croteau

Om Parkash Sharma

Thomas J Martin

Vijay Narayan Jagdale

Kathleen E Sinnamon

Lexia Kironn

Malcolm P MacDonald

Catalin G Fotache

Michael Paul Humbert

Raja Kountanya

Lyutsia Dautova

Christopher W Robak

Brian A Fisher

Robert A Grelotti

Ranadip Acharya

Dustin Frame

Michael D Werkheiser

Masoud Anahid

Jagadeessh Tangudu

Vijay Jagdal

Lyustia Dautova

A process for uncertainty quantification for a predictive defect model for multi-laser additive manufacturing of a part including executing computational fluid dynamics modeling of a gas flow in an additive manufacturing machine manufacturing chamber; assigning a spatter particle size, velocity and direction relative to a melt pool on a powder bed disposed on a build plate within the manufacturing chamber; executing computational fluid dynamics post processing for spatter particle tracking; predicting a spatter particle landing pattern; feeding the spatter particle landing pattern prediction into a defect model; producing a layer thickness map, the layer thickness map configured to demonstrate a location of locally thicker layers on the part; and predicting defect location and density to accumulate lack-of-fusion risk as a function of part placement, orientation, and scan strategy.

Uncertainty quantification or predictive defect model for multi-laser powder bed fusion additive manufacturing

A heat exchanger core includes a first hollow cylinder extending circumferentially around a center axis and extending axially along the center axis. The first hollow cylinder includes a first passage disposed radially within the first hollow cylinder and extending axially through the first hollow cylinder. A second hollow cylinder extends circumferentially around the center axis and extends axially along the center axis. The first hollow cylinder is disposed radially within the second hollow cylinder. The second hollow cylinder includes a second passage disposed radially between the first hollow cylinder and the second hollow cylinder and extending axially between the first hollow cylinder and the second hollow cylinder. The first hollow cylinder fluidically separates the first passage from the second passage. The first and second hollow cylinders and the first and second passages are spaced from one another in a sinusoidal relationship.

Multi-scale unitary radial heat exchanger core

A metal lattice for a carbon dioxide scrubber includes a metal lattice body defining a plurality of intersecting ligaments, wherein nodes are formed at intersections of the plurality of intersecting ligaments, wherein a node density of the metal lattice body varies.

Additively manufactured carbon dioxide scrubber

An assembly is provided for a turbine engine. This turbine engine assembly includes a case structure and an air conduit. The case structure extends circumferentially about and axially along an axis. The air conduit has a conduit centerline, a conduit first end and a conduit second end. The air conduit extends longitudinally along the conduit centerline between the conduit first end and the conduit second end. The conduit first end is connected to the case structure at a first location. The conduit second end is connected to the case structure at a second location. The air conduit is displaced from the case structure longitudinally between the conduit first end and the conduit second end. At least a majority of the conduit centerline follows a non-straight trajectory.

Turbine engine with soaring air conduit

A method of constructing an additive manufactured article with erodible support. The method includes computing a length of an overhanging geometry that extends from an inner surface of an additively manufactured article; determining points along the overhanging geometry determining an outside point and an inside point from the multiple of overhanging geometry points; determining an anchor point by moving from the inside point I antiparallel to the build direction by a distance sufficient to form an angle greater than a critical angle of the additive process; connecting the anchor point to the overhanging geometry points to form ligament segments; thickening the ligament segments to form a solid ligament to form the erodible support; and additively manufacturing the overhanging geometry from the inner surface of the additively manufactured article via the erodible support, the erodible support erodible during operation of the additively manufactured article.

Erodible support structure for additively manufactured article and process therefor

A heat exchanger core includes a first side, a second side, a third side, and a fourth side. A first layer includes a first width extending in a first direction, a first length extending in a second direction, a first height extending in a third direction, and a first plurality of passages, which extend from an inlet to an outlet. A second layer includes a second width extending in the first direction, a second length extending in the second direction, a second height extending in the third direction, and a second plurality of passages extending from the first side to the second side. The first and second plurality of passages are adjacent to one another. The first and second plurality of passages include a sinusoidal profile in the third direction and a sinusoidal profile in the first direction.

Multi-scale heat exchanger core

A metal lattice for a carbon dioxide scrubber may comprise a metal lattice body defining a plurality of intersecting ligaments, wherein nodes are formed at said intersections. In various embodiments, the metal lattice may be manufactured using an additive manufacturing process. A node density of the metal lattice may vary. A ligament thickness of the metal lattice may vary. The metal lattice may comprise liner defining a channel extending through the metal lattice.

A metal lattice for a carbon dioxide scrubber may comprise a metal lattice body defining a plurality of intersecting ligaments, wherein nodes are formed at said intersections. In various embodiments, the metal lattice may be manufactured using an additive manufacturing process. A node density of the metal lattice may vary. A ligament thickness of the metal lattice may vary. In various embodiments, the metal lattice may be unstructured. In various embodiments, the metal lattice may comprise high aspect ratio ligaments for directing an air flow.

A ceramic component retention system includes a metallic component, a ceramic component, and at least one spring element arranged between the metallic component and the ceramic component. The metallic component has a first coefficient of thermal expansion, and the ceramic component has a second coefficient of thermal expansion. The at least one spring element is configured to mechanically couple the ceramic component to the metallic component.

High temperature compliant metallic elements for low contact stress ceramic support

An embodiment of a fan blade includes an interior region between a metallic pressure sidewall and a metallic suction sidewall. Each sidewall extends in span from a base to a tip, and extends in chord from a leading edge to a trailing edge. The interior region of the fan blade includes a first fully dense metallic portion and a first porous metallic portion. The first fully dense metallic portion has a volume occupying at least 10% of a total volume of the interior region, and substantially no porosity. The first porous metallic portion is integrally joined to the fully dense metallic portion, and is selected from a structured lattice, an unstructured foam, and combinations thereof.

Gas turbine engine fan blade, design, and fabrication

A method of fabricating a functionally graded turbine engine component is disclosed and includes the step of depositing layers of powder onto a base and solidifying/fusing each layer with a first directed energy beam to define a component. The method further includes varying a process parameter between deposited layers to define different material properties within the component. The method also proposes surface enhancement approach that can be used after depositing each layer to locally customize the material properties. The method also proposes machining the different internal surfaces to achieve the proper surface finishing required.

Turbine disk fabrication with in situ material property variation

An electrochemical machining system comprises a component having a passage, the passage has an opening and an internal surface formed along the passage, a conductive wire has insulation covering portions of the conductive wire forming gaps having exposed wire; the conductive wire is inserted in the passage; a power source is coupled to the component and the conductive wire forms an electrical circuit, wherein the component comprises an anode and the conductive wire comprises a cathode; and an electrolyte within the passage contacting the internal surface and the exposed wire, wherein the electrolyte comprises a charge-carrying liquid configured to complete the electrical circuit between the cathode and anode.

Method for electrochemical machining of complex internal additively manufactured surfaces

An impingement manifold includes a fluid inlet passage and a pressurized chamber. The pressurized chamber includes at least one lobe. The at least one lobe includes a flow improving feature configured to minimize vorticity of a flow field within the pressurized chamber, and at least one flow outlet.

Impingement manifold

A method of generating a smooth optimized part design for a workpiece is presented. Topology optimization is performed based on design objectives, to generate surface data describing an optimized but unfinished surface of the workpiece. The surface data is used to generate volumetric data describing the workpiece structure. A three dimensional smoothing filter is applied to the volumetric data. A manufacturing design is generated from the resulting smoothed volumetric data.

Generating smooth optimized parts

An illustrative example container includes a plurality of internal support members having a surface contour that at least approximates a minimum surface. The plurality of internal support members collectively provide structural support for carrying loads on the container. The plurality of internal support members collectively establish a plurality of cavities for at least temporarily containing fluid. An outer shell is connected with at least some of the internal support members. The outer shell includes a plurality of curved surfaces. The outer shell encloses the cavities.

Growing community of inventors

Canton, CT, United States of America

Matthew E Lynch