Rolls-royce Corporation

Peter E Daum

Quinlan Yee Shuck

Scott Nelson

Martyn Anthony Jones

John P E Forsdike

Simon J Donovan

John Forsdike

Siddharth Ravichandran

Nathaniel Ashburn

Philip S Trickey

Scott Greene

Philip Trickey

In some examples, systems and techniques for repairing or otherwise forming a blade of a bladed disk. In one example, a method including positioning a shield member around a perimeter of a partial blade extending from a rotor disk of a bladed disk, the shield member being positioned adjacent to a build surface of the partial blade; and depositing, with the shield member around the perimeter of the partial blade, a material on the build surface using an additive manufacturing technique to form a repaired portion on the build surface of the partial blade.

Bladed disk repair process with shield

A method may include cold spraying a masking material on selected locations of a component to form a masking layer, wherein the masking material comprises a metal or alloy; additively manufacturing an additively manufactured portion of the component at locations at which the masking layer is not present; and removing the masking layer from the component. The masking layer may be configured to protect portions of the component by covering or otherwise providing a physical barrier that reduces or prevents material from adhering to unwanted portions of the component during a subsequent manufacturing and/or repair technique. Additionally, the masking layer may be reflective to infrared radiation and/or intimately contact the component and function as a heat sink or thermally conductive layer to transfer heat from the component.

Cold spray deposited masking layer

An abradable sealing element comprises a substrate and a sealing structure. The sealing structure comprises one or more wall structures extending from the substrate and defining at least one open cell which is filled with abradable material. The one or more wall structures are formed by additive-layer, powder-fed, laser-weld deposition onto the substrate. The one or more wall structures are formed from nickel-based superalloy and constitute from about 10% to about 50% of the total volume of the sealing structure.

Abradable sealing element

A material deposition head may include a ring configured to rotate about a first body portion and cause axial translation of the first body portion relative to a second body portion, where one or more nozzles are coupled to the first body portion. In some examples, at least one anti-rotation pin may substantially prevent rotation of the first body portion while the first body portion axially translates, and a seal may substantially prevent external contaminants from invading an interior portion of the material deposition head. In addition, a pointer tool attached to the head and an external translational measurement tool may permit measurement of an axial position of the one or more nozzles without requiring disassembly of the head or disruption of a substantially inert environment within which additive manufacturing may proceed. A method of axially translating the first body portion of the head also is disclosed.

Compact axially translational powder deposition head

A method of applying a laser metal formed build layer on a surface of an article. The surface of the article is melted locally using a light source to form a melt pool. Powdered metal is injected into the melt pool. The melt pool is solidified to form the build layer having a desired microstructure and geometry on the surface of the article.

Laser deposition using a protrusion technique

A method is provided of replacing a damaged blade of an integrally bladed rotor assembly including a disc and a plurality of blades extending outwardly from a rim of the disc. The method includes the steps of: removing the damaged blade to leave a blade repair stub projecting from the rim; locating sacrificial supports at the underside of the rim beneath the repair stub, the supports projecting axially beyond the trailing and leading edges of the rim; depositing metal around the trailing and leading edges of the repair stub, the deposited metal, supported by the sacrificial supports, projecting axially beyond the trailing and leading edges of the rim; attaching a replacement blade to the repair stub by linear friction welding; and removing excess deposited metal, upset metal from the linear friction welding, and the sacrificial supports.

Growing community of inventors

Fishers, IN, United States of America

Peter E Daum