Hamilton Sundstrand Corporation

Raytheon Technologies Corporation

United Technologies Corporation

Ranadip Acharya

Tahany Ibrahim El-Wardany

Colette Opsahl Fennessy

Vijay Narayan Jagdale

Alexander Staroselsky

John A Sharon

William K Tredway

Yanzhi Chen

Sergey Mironets

Sergei F Burlatsky

Matthew Pess

Qingqing Zhang

Paul Sheedy

Wendell V Twelves

David Ulrich Furrer

Joseph J Sangiovanni

Michael A Klecka

Joseph Kenneth Coldwate

Daniel V Viens

John M Milton-Benoit

Diana Giulietti

Gajawalli V Srinivasan

Jeffrey Michael Mendoza

Kiley James Versluys

Changle Li

Abhijit Chakraborty

A method of providing a protective titanium layer to an outer surface of an aluminum component includes providing an aluminum component and forming a first layer of titanium-based bulk metallic glass on the component, wherein formation of the bulk metallic glass layer comprises depositing a titanium alloy powder using pulsed directed energy deposition.

Pulsed directed energy deposition based fabrication of hybrid titanium/aluminum material for enhanced corrosion resistance and strength

An additive manufacturing system configured to additively build an article can include an energy applicator, a build platform, and a powder nozzle configured to eject powder toward the build platform to be acted on by the energy applicator. The system can include a control module configured to control the energy applicator to create an amorphous structure forming at least a portion of the article.

Additively manufacturing of amorphous structures

An electrical machine stator can include a stator core having a stator core shape and made of a core material, a plurality of windings disposed in the stator core and made of a conductive material, and an insulative material surrounding the plurality of windings and configured to electrically insulate each winding from each other adjacent winding, and/or to insulate one or more of the windings from the stator core. The insulative material can be an amorphous metal.

Electrical machines, laminations, and methods of making the same

A process for additive manufacturing of a metal alloy material is provided that includes: a) providing a feedstock powder comprising base powder particles with nanoparticles attached to surfaces of the base powder particles; b) providing an additive manufacturing system with a laser power source relatively movable at a scan speed; c) wherein the additive manufacturing system has a process window for the feedstock powder; and d) exposing the feedstock powder to a predetermined power input from the laser power source at a predetermined scan speed to produce the metal alloy material. The concentration by volume of nanoparticles within the feedstock powder is such that independent first and second microstructures may be produced within the metal alloy material.

Method for additive manufacturing with modified powder

A method of additively manufacturing includes generating a thermal model driven scan map that identifies an equiaxed cap region, a single crystal (SX) region, and a columnar to equiaxed transition (CET) region; and forming an active melt pool with respect to the thermal model driven scan map such that a depth of the active melt pool is greater than a thickness of the equiaxed transition (CET) region.

Additive manufacturing based multi-layer fabrication/repair

An additive manufacturing (AM) system includes a process distortion compensation computing system and an AM peripheral device. The process distortion compensation computing system determines a digital nominal model that represents a physical target object excluding a distortion, and a digital distortion model that represents the physical target object including at least one distortion. The AM peripheral device forms a three-dimensional (3D) physical object based on a digital compensation model. The process distortion compensation computing system also determines a digital skeletal model indicating a predicted change in at least one of the shape and volume of the nominal model, and generates the digital compensation model based on the skeletal model that compensates for the at least one distortion.

Additive manufacturing including compensation modeling methodology with shape transformation

A spatial difference measurement method, can include generating first key features of a first skeleton of a nominal 3D model of an object and extrapolating the first key features onto the nominal 3D model. The method can include creating an actual 3D model of the object during or after a construction process (real or simulated). The method can include generating second key features of a second skeleton of the actual 3D model of the object and extrapolating the second key features onto the actual 3D model of the object. The method can include comparing the first key features extrapolated on the nominal 3D model to the second key features extrapolated on the actual 3D model to determine one or more distances between the first and second key features to measure a spatial difference between the nominal 3D model and the object during or after construction.

Spatial difference measurement

A method includes accessing a first model defining a shape of a part. The shape of the part is segregated into a plurality of predefined shapes selected from a library of predefined shapes. The predefined models for each of plurality of predefined shapes are assembled into a second model defining the shape of the part. The part is additively manufactured according to the second model.

Library of predefined shapes for additive manufacturing processes

A method of providing additive manufacturing includes the steps of (a) developing a plurality of layers to result in a final shape product, (b) developing a space filling algorithm to develop a path, (c) estimating a temperature at a location along the path in an existing direction of the path, and (d) comparing the estimated temperature to a desired temperature and altering the existing direction of the path should the estimated temperature differ from the desired temperature by a predetermined amount. An additive manufacturing system is also disclosed.

Path planning for additive manufacturing

A rotating tool system attachment on the spindle of a computer numerical control ('CNC') machine includes a rotating assembly mounted on a static assembly. The rotating assembly provides a continuous supply of a wire material for deposition on a substrate during an additive manufacturing process. The rotating assembly includes a material supply housing a feedstock of wire mounted on a rotating spindle and a wire feeder configured to draw the wire from the wire supply and provide the wire for application during the additive manufacturing process. The tool system can be attached to the spindle of CNC machine to provide additive manufacturing capabilities to the CNC machine.

Continuous feed spindle attachment

An additive manufacturing (AM) system comprising a process distortion compensation computing system configured to determine a digital nominal model that represents a physical target object excluding a distortion, and a digital distortion model that represents the physical target object including at least one distortion. The AM system further comprises an AM peripheral device configured to form a three-dimensional physical object based on a digital compensation model. The process distortion compensation computing system determines a material volume difference between the digital nominal model and the digital distortion model, and generates the digital compensation model that compensates for the material volume difference.

Additive manufacturing process distortion compensation system

An additively manufactured alloy component has a first portion formed of the alloy and having a first grain size, and a second portion formed of the alloy and having a second grain size smaller than the first grain size. In an embodiment, the alloy component is an alloy turbine disk, the first portion is a rim region of the alloy turbine disk, and the second portion is a hub region of the alloy turbine disk. The first and second grain sizes may be achieved by controllably varying the laser power and/or scan speed during additive manufacturing.

Grain size control in laser based additive manufacturing of metallic articles

A method of producing a heat exchanger includes designing the heat exchanger to include a wall with a target thickness. A model is created relating process parameters to geometry of a single track melt pool and relating the single track melt pool geometry to a heat exchanger wall thickness. At least one variable process parameter is defined. The model, heat exchanger wall target thickness, and variable process parameters are used to identify a set of process parameters to produce the heat exchanger wall target thickness. The melt pool geometry is predicted based on the model and process parameters. The heat exchanger wall target thickness is predicted based on the melt pool geometry. The process parameters that will produce the heat exchanger wall target thickness are identified. The additive manufacturing process is controlled based upon the identified set of process parameters to create the heat exchanger wall target thickness.

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Rocky Hill, CT, United States of America

Ranadip Acharya