Honeywell International Inc.

Paul Chipko

Derek Raybould

James Piascik

Matthew J Pohlman

Thomas E Strangman

Harry Lester Kington

Reza Oboodi

Bahram Jadidian

Martin Carlin Baker

Jimmy Wiggins

Leroy Allen Fizer

William E Fischer

Malak Fouad Malak

Chien-Wei Li

Bjoern Schenk

Bradley Reed Tucker

Lee Poandl

Methods are disclosed for fabricating heat exchangers and Heat Exchanger (HX) tubes, as are heat exchangers fabricated in accordance with such methods. In embodiments, the method includes fabricating an HX tube by at least partially forming the elongated tube body utilizing a cold spray process during which a metallic feedstock powder is deposited over a removable mandrel. The HX tube is separated from the removable mandrel at some juncture following cold spray deposition of the tube body.

Heat exchangers, heat exchanger tubes, and additive manufacturing cold spray processes for producing the same

Embodiments of laminated stator cores suitable for usage in high temperature applications are provided, as are embodiments of methods for manufacturing high temperature laminated stator core. In one embodiment, the method includes obtaining a plurality of coated laminates each comprising a laminate over which a coating precursor layer is formed. The coating precursor layer contain inorganic dielectric particles having a softening point. The plurality of coated laminates are arranged in a laminate stack, which is then fired at temperatures equal to or greater than the softening point of the inorganic dielectric particles. During firing, a compressive force is applied to the laminate stack sufficient to consolidate the inorganic dielectric particles into a plurality of coherent interlaminate dielectric layers electrically insulating and bonding together the plurality of coated laminates as the high temperature laminated stator core.

High temperature laminated stator cores and methods for the manufacture thereof

Methods are disclosed for fabricating heat exchangers and Heat Exchanger (HX) tubes, as are heat exchangers fabricated in accordance with such methods. In embodiments, the method includes the steps or processes of obtaining a Non-Equilibrium Alloy (NEA) feedstock powder comprised of an alloy matrix throughout which at least one minority constituent is dispersed. The first minority constituent precipitates from the alloy matrix when the NEA feedstock powder is exposed to temperatures exceeding a critical temperature threshold (T) for a predetermined time period. A cold spray process is carried-out to at least partially form the HX tubes from the NEA feedstock powder; and the HX tubes are subsequently installed in the heat exchanger. The HX tubes are exposed to a maximum temperature (T) during the cold spray process, which is maintained below Tto substantially preserve the non-equilibrium state of the NEA feedstock powder through cold spray deposition.

Methods for manufacturing high temperature laminated stator cores

A coated component is provided comprising a silicon-based substrate and a braze layer overlying the silicon-based substrate. The braze layer comprises silicon, tantalum, and a metal element having substantially the same melt temperature with silicon as tantalum has with silicon. The braze layer further comprises ceramic particles. Protective coatings are also provided.

Protective coatings and coated components comprising the protective coatings

Dispersion strengthened aluminum base alloys are shaped into metal parts by high strain rate forging compacts or extruded billets composed thereof. The number of process steps required to produce the forged part are decreased and strength and toughness of the parts are increased. The dispersion strengthened alloy may have the formula Al,Fe,SiX, wherein X is at least one element selected from Mn, V, Cr, Mo, W, Nb, and Ta, 'a' ranges from 2.0 to 7.5 weight-%, 'b' ranges from 0.5 to 3.0 weight-%, &#x201c;c&#x201d; ranges from 0.05 to 3.5 weight-%, and the balance is aluminum plus incidental impurities. Alternatively, the dispersion strengthened alloy may be described by the formula Al,Fe,SiVX, wherein X is at least one element selected from Mn, Mo, W, Cr, Ta, Zr, Ce, Er, Sc, Nd, Yb, and Y, &#x201c;a&#x201d; ranges from 2.0 to 7.5 weight-%, &#x201c;b&#x201d; ranges from 0.5 to 3.0 weight-%, &#x201c;d&#x201d; ranges from 0.05 to 3.5 weight-%, &#x201c;c&#x201d; ranges from 0.02 to 1.50 weight-%, and the balance is aluminum plus incidental impurities. In both cases, the ratio [Fe+X]:Si in the dispersion strengthened alloys is within the range of from about 2:1 to about 5:1.

High strain rate forming of dispersion strengthened aluminum alloys

A braze material and method of brazing titanium metals. The material may consist of Ti, Ni, Cu Zr, PM and M where PM is a precious metal and M may be Fe, V, Cr, Co, Mo, Nb, Mn, Si, Sn, Al, B, Gd, Ge or combinations thereof, with the (Cu+PM)/Ni ratio around 0.9. Optionally, a second brazing may be performed to rebraze any braze joint that did not braze successfully. The second brazing material has a lower braze temperature than the first and may consist of a mixture of Ti, Ni, Cu, Zr PM and M with from 1-20 wt % more Zr, PM, M or combinations thereof than the first braze. The braze material may be placed on a base material, in a vacuum furnace, and heated to form a braze joint between the braze and base material. The heating step may occur from about 800-975&#xb0; C. and over 3 to 15 minutes.

Low cost brazes for titanium

A turbine blade tip and shroud clearance control coating system comprising an abrasive blade tip coating and an abradable shroud coating are provided. The abrasive layer may comprise abrasive particles of cubic zirconia, cubic hafnia or mixtures thereof, and the abradable layer may be a nanolaminate thermal barrier coating that is softer than the abrasive layer. The invention further provides an alternate coating system comprising an abradable blade tip coating and an abrasive shroud coating.

Turbine blade tip and shroud clearance control coating system

A braze material and method of brazing titanium metals. The material may consist of Ti, Ni, Cu Zr, PM and M where PM is a precious metal and M may be Fe, V, Cr, Co, Mo, Nb, Mn, Si, Sn, Al, B, Gd, Ge or combinations thereof, with the (Cu+PM)/Ni ratio around 0.9. Optionally, a second brazing may be performed to rebraze any braze joint that did not braze successfully. The second brazing material has a lower braze temperature than the first and may consist of a mixture of Ti, Ni, Cu, Zr PM and M with from 1&#x2013;20 wt % more Zr, PM, M or combinations thereof than the first braze. The braze material may be placed on a base material, in a vacuum furnace, and heated to form a braze joint between the braze and base material. The heating step may occur from about 800&#x2013;975&#xb0; C. and over 3 to 15 minutes.

A protective barrier coating system including a diffusion barrier coating and an oxidation barrier coating and method for use in protecting silicon-based ceramic turbine engine components. A complete barrier coating system includes a thermal barrier coating of stabilized zirconia and an environmental barrier coating of an alloyed tantalum oxide. The oxidation barrier coating includes a layer of metallic silicates formed on a substrate of silicon nitride or silicon carbide to be protected. The oxidation barrier coating can include silicates of scandium, ytterbia or yttrium. The oxidation barrier coating may also include an inner layer of SiONbetween the diffusion barrier and the metallic silicate layer. The oxidation barrier coating can be applied to the substrate by spraying, slurry dipping and sintering, by a sol-gel process followed by sintering, by plasma spray, or by electron beam-physical vapor deposition. The diffusion layer of essentially pure SiNcan be applied to the substrate to prevent the migration of damaging cations from the protective layers to the substrate and is preferably formed by chemical vapor deposition. A method for protecting silicon based substrates can comprise a step of forming an oxidation barrier coating on a substrate, where a step of forming the oxidation barrier includes a step of sintering the oxidation barrier and substrate in a wet gas containing hydrogen.

Oxidation barrier coatings for silicon based ceramics

Oxidation protection of a titanium-based alloy is provided with improved fatigue properties by a titanium aluminide coating of between 2 to 12 microns by diffusing the Al into the Ti at a temperature below the melting point of the Al. The coating is gas deposited and protects the titanium-based alloys from oxidation at high temperature utilization.

Elevated temperature oxidation protection coatings for titanium alloys and methods of preparing the same

Oxidation protection of a titanium heat exchanger is provided by a titanium aluminide or solgel coating. The coating protects bare titanium and brazed surfaces of the heat exchanger.

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Blairstown, NJ, United States of America

Paul Chipko