Rolls-royce Corporation

Rolls-royce North American Technologies Inc.

Rolls-royce High Temperature Composites Inc.

Quinlan Yee Shuck

Scott Nelson

Raymond Ruiwen Xu

Brandon David Ribic

Matthew R Gold

Jacque Sue Bader

Pavlo Earle

Sungbo Shim

Timothy Fuesting

Kong Ma

Robert F Proctor

Peter E Daum

Martyn Anthony Jones

Evan Raeker

Ted Joseph Freeman

Sean E Landwehr

Joseph Peter Henderkott

Carl R Russo

Gavin J Baxter

John Grubbs

Greg Lopshire

Brian Drier

Johnny D Grubbs

Amanda Dawn Graham

Jonathan McCrory

Nathaniel Ashburn

Martin Lee McCormick

Brandon David Ricbi

In general, techniques are described for a patterned filament for fused filament fabrication. An additive manufacturing system may include a substrate defining a major surface, a filament delivery device, and a computing device. The computing device may be configured to control the filament delivery device to deposit a filament on the substrate, the filament including a primary material and a first binder, where the primary material distributed in a pattern having a first cross sectional geometry that differs from a second cross sectional geometry of the filament, and the binder is configured to be substantially removed from the filament.

Patterned filament for fused filament fabrication

A system may include one or more computing devices configured to receive image data representing illuminated powder of a powder stream between a powder delivery device of an additive manufacturing system and a build surface of a component; determine at least one metric associated with the powder stream based on the received image data; determine whether the at least one metric indicates an abnormal state of the at least one metric; and cause the additive manufacturing system to perform at least one action in response to determining that the at least one metric indicates the abnormal state.

Powder flow measurement in additive manufacturing systems

In some examples, a technique including positioning supports such that the supports are between a first metallic substrate and a second metallic substrate, wherein an undulating member is located between the first metallic substrate and the second metallic substrate, the undulating member defining a plurality of first peaks adjacent to a first surface of the first metallic substrate and a plurality of second peaks adjacent to a second surface of the second metallic substrate, wherein a first support of the supports is positioned such that the first support extends between a first peak of the plurality of first peaks and the second surface of the second metallic substrate; welding the first peak to the first surface of the first metallic substrate in an area of the first support; and removing the first support by at least one of a thermal removal process or a chemical removal process.

Techniques for forming composite sandwich structures

A system may include a powder source; a powder delivery device; an energy delivery device; and a computing device. The computing device may be configured to: control the powder source to deliver metal powder to the powder delivery device; control the powder delivery device to deliver the metal powder to a surface of an abrasive coating; and control the energy delivery device to deliver energy to at least one of the abrasive coating or the metal powder to cause the metal powder to be joined to the abrasive coating.

Abrasive coating including metal matrix and ceramic particles

An additive manufacturing system may include an energy source, an optical system to modify and direct an energy beam from the energy source toward a component to form a melt pool, and a material delivery device to deliver material to the melt pool. The optical system may form an annular energy beam, direct the annular energy beam toward the component, receive at least a portion of thermal emissions produced by the annular energy beam and the melt pool, and direct the portion of the thermal emissions toward an imaging device, which may be used to control the energy source.

Melt pool monitor

An additive manufacturing technique may include depositing, via a filament delivery device, a filament onto a surface of a substrate. The filament includes a binder and a powder including at least one metal or alloy and at least one braze alloy. The technique also includes sacrificing the binder to form a preform. The technique also includes sintering the preform to form a component including the at least one metal or alloy and the at least one braze alloy.

Fused filament fabrication of braze alloys

A system may include a current source; a first metal or alloy component with a first major surface electrically coupled to the current source; a second metal or alloy component with a second major surface electrically coupled in series to the first component and the current source via an external electrical conductor, where the first and second major surfaces are positioned adjacent to each other to define a joint region; a metal or alloy powder disposed in at least a portion of the joint region; and a controller. The controller may be configured to cause the current source to output an alternating current that conducts through the first component and the second component to induce magnetic eddy currents, magnetic hysteresis, or both within at least a portion of the metal or alloy powder disposed in at least the first portion of the joint region.

Joining metal or alloy components using electric current

A method may include depositing, from a slurry, suspension, or tape, on a surface of an additively manufactured component comprising a metal or alloy, powder comprising at least one of a metal, an alloy, or a ceramic; sintering the powder to form a surface layer on the additively manufactured component; and hot isostatic pressing the additively manufactured component and the surface layer.

Surface treatment of additively manufactured components

An additive manufacturing system includes an energy source and a material delivery device. The energy source is configured to direct an energy beam toward a component to form a melt pool. The material delivery device is configured to feed a wire toward the melt pool to deposit material on the component. In some examples, the material delivery device is configured to discharge a current to the wire to disengage the wire from the melt pool. In some examples, the material delivery device is configured to measure an arc voltage between the wire and the component.

Wire feedstock control during additive manufacturing

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

In general, techniques are described for fused filament fabrication of abradable coatings. An additive manufacturing system comprising a substrate defining a major surface, a filament delivery device, and a computing device may be configured to perform various aspects of the techniques. The computing device may be configured to control the filament delivery device to deposit a filament on the substrate, the filament including a powder and a binder, wherein the binder is configured to be substantially removed from the filament and the powder includes a metal or alloy configured to be sintered to form an abradable layer.

Fused filament fabrication of abradable coatings

A method for connecting or joining a first substrate and a second substrate across an interface between the first substrate and the second substrate. The method includes disposing a fastener precursor in the bore and sintering the fastener precursor in the bore. The fastener precursor densifies and shrinks in at least one dimension to mechanically interlock with a contour in the bore and form a mechanical fastener in the bore, and the mechanical fastener forms an interlock between the first substrate and the second substrate.

Semi-compliant fasteners for mechanical locking

A heat shield assembly adapted for use with gas turbine engines, airframes, and aircraft includes a carrier and a heat-shield tile. The carrier is adapted to couple to the gas turbine engine, airframe, or aircraft. The heat-shield tile includes material different than the carrier and is arranged to cover the carrier to protect the carrier from high-temperature gases surrounding the heat shield assembly.

High temperature heat shield assemblies

A method of forming a ferrous metal case-hardened layer using additive manufacturing. The method includes delivering, by a material delivery device, a filler material to a surface of a substrate. The substrate includes a first ferrous metal. The filler material includes a second ferrous metal and a carbon-based material. The method also includes directing, by an energy delivery device, an energy toward a volume of the filler material to join at least some of the filler material to the substrate to form a component.

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Indianapolis, IN, United States of America

Quinlan Yee Shuck