Raytheon Company

Michael L Andersen

Travis L Mayberry

James A Pruett

Gregory P Schaefer

John S Moore

Todd Lovell

Thomas J Stephens

A manifold structure and method of forming a manifold structure includes using an ultrasonic additive manufacturing (UAM) process to build up a solid structure, machining the solid structure to form a cavity and free-standing support pillars within the cavity, and using a UAM process to build up a finstock layer over the cavity. The support pillars formed by machining have yield strengths high enough to support UAM of the finstock layer over the cavity. A plurality of finstock layers are built up within the cavity to segment the cavity into a plurality of cavities. UAM of the finstock layers enables the finstock layers to be stacked in a direction normal to a direction of flow through the cavity for efficiently transferring heat through the manifold structure.

Internal cavity support methodology for ultrasonic additive manufacturing

A manifold structure and method of forming a structure having at least one enclosed cavity includes using an ultrasonic additive manufacturing (UAM) process to build up a solid component, forming a cavity in the solid component, filling the cavity with a sacrificial material, using a UAM process to build up a finstock layer over the cavity filled with the powder material to enclose the cavity and form the enclosed cavity, and removing the sacrificial material from the enclosed cavity after the finstock layer is ultrasonically welded to the solid component. The sacrificial material has an adequate density to support the UAM process of forming the finstock layer over the cavity and the material may be removed from the enclosed cavity, resulting in an enclosed cavity having smooth surfaces with an optimal fluid flow area therethrough.

Powdered metal as a sacrificial material for ultrasonic additive manufacturing

A wearable retina/iris authentication system includes: a frame; a retina/iris scanner mounted to the frame for capturing images of a retina and/or an iris of a user; a mobile computing device, the mobile computing device including a memory for storing information about the user; a position determining device coupled to the mobile computing device for continuously determining a location of the user and providing the location to the mobile computing device; a display mounted to the frame and coupled to the mobile computing device for displaying information received from the mobile computing device; a database for storing information about one or more of a plurality of retina images and a plurality of iris images for matching with the captured images of one or more of the retina and the iris of the user; and a communication interface for comminuting with external systems remote to the wearable system.

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Denver, CO, United States of America

Michael L Andersen