Rolls-Royce Corporation

Rolls-Royce North American Technologies Inc.

Other

Rolls-Royce American Technologies, Inc.

Timothy Fuesting

Joseph Peter Henderkott

Raymond Ruiwen Xu

Douglas David Dierksmeier

Matthew T Kush

Michael D Wood

Quinlan Yee Shuck

Scott Nelson

Jeffrey F Rhodes

Ted Joseph Freeman

William J Brindley

Joseph Jefferson Beaman, Jr

Suman Das

Larry Allen Junod

Lawrence E Brown

Gangshu Shen

Eugene Sun

Pramod Khandelwal

Jonathan McCrory

Danny Ray Carr

Logan Kroneman

Ronald J Snyder

John F Click

A dual-walled component of a gas turbine engine includes a cold section part, such as a spar, and a hot section part, such as a coversheet. The cold section part includes a single crystal or directionally solidified metal alloy and defines an outer surface, a hot section part comprising a polycrystalline metal alloy formed using additive manufacturing. The hot section part includes a plurality of support structures forming a plurality of cooling channels and defining an inner surface. The outer surface of the cold section part and the inner surface of the plurality of support structures are diffusion bonded.

Dual-walled components for a gas turbine engine

A radial turbine rotor incorporating ceramic matrix composite turbine blades is disclosed. The radial turbine rotor can include a dovetail shape retention features for coupling the ceramic matrix composite turbine blades to a central hub.

Radial turbine assembly with ceramic matrix composite airfoils having dovetail retention

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 multi-piece radial turbine rotor includes a hub, turbine blades, and an intermediate ring that couples the turbine blades to the hub. Joints between the components of the rotor are adapted for inspection during manufacture to identify potential defects in the joints.

Radial turbine assembly with intermediate blade bonding ring

A multi-piece radial turbine rotor includes a hub, turbine blades, and a flowpath ring that couples the turbine blades to the hub. Joints between the components of the rotor are adapted for inspection during manufacture to identify potential defects in the joints.

Multi-piece radial turbine rotor

The disclosure describes example systems and techniques for controlling microstructure of a superalloy substrate by controlling temperature during forging and using multiple die forging stages to formation of grain boundary phases of the superalloy, and components formed by such example systems and techniques. The method includes heating a substrate to within a forging temperature range. The substrate includes a nickel-based superalloy, and the forging temperature range is below an eta phase solvus temperature of the substrate. The method includes applying a plurality of die forging stages to the substrate to form a component preform. The method includes maintaining the substrate within the forging temperature range during application of the plurality of die forging stages and cooling the component preform.

Controlled microstructure for superalloy components

A method for manufacturing a turbine shroud segment with at least one undercut region. The method includes forming a removable insert including an external surface corresponding to at least a portion of a wall of the undercut region in the turbine shroud segment; placing the removable insert in a mold including a mold cavity corresponding to a shape of the turbine shroud segment; injecting a metal injection molding (MIM) feedstock into the mold cavity and around the removable insert to form a shroud green body with the at least one undercut region; and, sintering the shroud green body to form the shroud body.

Method for making turbine engine components using metal injection molding

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 system is for bonding a cover sheet to a core to form or repair a dual wall structure. The system includes a cover sheet probe and an inner pedestal probe. A three dimensional contoured tip of the cover sheet probe abuts against a three dimensional contoured outer surface of the cover sheet opposite a pedestal of the core. The pedestal abuts the inner surface of the cover sheet. The inner pedestal probe may be coupled to the core to create a conductive electrical path from the cover sheet probe through at least part of the structure. A flow of electric power is controlled and supplied to the cover sheet probe to heat a junction between the area of the cover sheet abutting the pedestal and the pedestal. A heated area is created in the junction and fixedly couples the coversheet and the pedestal.

Bonding system for dual walled turbine components

A bonding probe is used for bonding a cover sheet to a core to form or repair a dual wall structure. The bonding probe includes a body, an attachment end at a distal end of the body, a head at an opposite end of the body, a tip extending from the head, and a cooling passageway. The attachment end couples the body to a resistance welder. The tip extends to form a proximate end of the body. The tip includes a contacting area having a predetermined three dimensional contoured surface. The contacting area aligns with a predetermined area of a three dimensional outer surface of a cover sheet of a dual walled structure. The cooling passageway provides a passageway for a flow of cooling fluid. The cooling passageway extends through the head, and into the tip.

Bonding probe for bonded dual walled turbine components

A method of diffusion bonding utilizing vapor deposition comprises depositing a coating from a vapor comprising a temperature suppressant element onto a surface of a first component comprising a metal alloy, thereby forming a vapor deposited coating comprising the temperature suppressant element; assembling the first component with a second component comprising a mating surface to form an assembly, the vapor deposited coating contacting the mating surface; and exposing the assembly to a bonding temperature and a compressive force, thereby diffusion bonding the first component to the second component and forming a monolithic third component.

Method of diffusion bonding utilizing vapor deposition

A bonding system is used for bonding a cover sheet to a core to form or repair a dual wall structure. The bonding system includes a plurality of bonding probes and controller circuitry. The bonding probes include a three dimensional (3D) contoured tip configured to align with a predetermined area of a 3D contoured cover sheet of a dual wall structure. The controller circuitry comprises processor circuitry and sensor circuitry. The sensor circuitry provides a location of an area of the 3D contoured cover sheet for bonding. The processor circuitry identifies a bonding probe having a contacting area that aligns with the 3D contour of the cover sheet in the location provided by the sensor circuitry.

A method of preparing a surface for diffusion bonding comprises contacting a binder material with a discontinuous surface comprising surface regions separated by gaps. The binder material is selectively deposited onto the surface regions and has a sufficient viscosity to form a self-supporting layer without flowing into the gaps. The self-supporting layer of binder material comprises a mass density in a range from about 0.001 g/into about 0.050 g/in. A braze powder is distributed over the self-supporting layer of binder material, and a predetermined amount of the braze powder is attached to the binder material. The discontinuous surface is then heated to remove the binder material and adhere the braze powder to the discontinuous surface. Thus, a prewet surface with a braze deposit thereon is formed.

Method of preparing a surface for diffusion bonding and method of diffusion bonding

In some examples, a method for nondestructive testing of a component may include flashing the component using a flash lamp configured for flash thermography, collecting first image data regarding the component using an infrared camera, flowing a fluid through the component, and collecting second image data regarding the component using the infrared camera. A system for nondestructive testing of a component may include a single inspection station and a flash lamp configured for flash thermography, means for supplying a fluid to the component, and an infrared camera disposed at the inspection station.

Growing community of inventors

Thorntown, IN, United States of America

Timothy Fuesting