United Technologies Corporation

Ralph B Bogard

Robert W Baumgarten

John M Robertson

Bryant H Walker

Raymond M Walker

Brian T Dunn

Donald P Achor

A method is taught for joining a wrought alloy material to a cast alloy, so as to obtain a joint having superior structural integrity. A cast nickel-base superalloy part may be bonded to a wrought nickel-base superalloy part, for example, by positioning a suitable part or blank of said wrought superalloy adjacent to the cast superalloy part, applying a local bonding force to the interface while locally heating the interface to a temperature which causes localized softening, metal flow, and bonding, removing said bonding force, and subjecting the bonded assembly to a local or isothermal heat treatment so as to minimize distortion, optimize properties, and stress relieve the bonded assembly. This method may be used, for example, for the repair or replacement of vane assembly retaining lugs, whereby a replacement lug of a wrought alloy is solid state bonded to the vane assembly in place of the previous retaining lug.

Technique for direct bonding cast and wrought materials

A method is taught for the replacement of turbine disk airseal lands, whereby a replacement land ring is solid state bonded to the disk in place of a worn or damaged land.

Method for replacing worn airseal lands on engine compressor or turbine

Techniques for fabricating or repairing integrally bladed rotors are developed. A new or replacement blade is bonded to a projecting stub. The new blade has a collar through which bonding forces are transmitted. After bonding with heat and pressure, final machining and heat treatment operations are performed.

Fabrication or repair technique for integrally bladed rotor assembly

A forging apparatus has an upper die and lower die with the lower die being positioned on a die stack with the upper die being movable by a ram, said upper and lower dies having cylindrical portions extending towards each other where the rim of the formed disc is to be located. Blade dies are positioned around the radial opening presented between the two faces of the upper and lower die as they rest on a preformed blank, said cylindrical array of blade dies being held in position by two wires around their outer circumference and supported in the forging operation by a cylindrical back-up die; the cylindrical array of blade dies being slanted outwardly at its upper and lower edge from where they engage the cylindrical portions, forming an upper and lower annular cam surface. Ring members are positioned around both of said cylindrical sections for slidable movement thereon, said ring members being of wedge-shape cross-section so that as they are moved inwardly, when they contact said cam surfaces, they will cam said blade dies radially outward. Actuating pins extend from each of said ring members to a location above and below their respective upper and lower dies where they can be actuated by spider arms fixed to an actuating shaft which extends through their respective ram or die stack. Knockout pins are located in the upper and lower dies and are actuated by rods extending through each of the actuating shafts.

Growing community of inventors

North Palm Beach, FL, United States of America

Ralph B Bogard