Hamilton Sundstrand Corporation

Delavan Inc.

Sundstrand Corporation

Rosemount Aerospace Limited

Collins Engine Nozzles, Inc.

William Louis Wentland

Eric W Karlen

Sergey Mironets

Robert Bianco

Diana Giulietti

Debabrata Pal

Dhaval S Patel

Andrew R Wilkinson

Colette Opsahl Fennessy

John Horowy

Thomas J Ocken

William T Dill

Craig R LeGros

Matthew Donovan

Daniel O Ursenbach

Kiley James Versluys

Roy D Rasmussen

John F Bangura

Matthew Paul Anderson

Alexander Madinger

Jong-Yeong Yung

Kevin L Dickerson

Kavithas Ponnampalam

Davis S Behling

Robert M Riordan

Matthew P Anderson

Eric Karlen

A method for making an article is disclosed. According to the method, a digital model of the article is generated. The digital model is inputted into an additive manufacturing apparatus comprising an energy source. The additive manufacturing apparatus applies energy from the energy source to successively applied incremental quantities of a powder to fuse the powder to form the article corresponding to the digital model. The powder particles individually include a composite core including a first phase of a first metal and a second phase of a ceramic. A first shell including a second metal is disposed over the core.

Method of manufacturing metal articles

A heat exchanger includes a body defining a flow channel, and a pin extending across the flow channel, the pin including an at least partially non-cylindrical shape. The pin can be a double helix pin including two spiral branches defining a double helix shape. The two branches can include a uniform winding radius. The two branches include a non-uniform winding radius. The non-uniform winding radius can include a base radius and a midpoint radius, wherein the midpoint radius is smaller than the base radius. The two branches can be joined together by one or more cross-members.

Pins for heat exchangers

An aluminum alloy comprising greater than 2.00 and less than 4.00 wt. % cerium, 0.25-3.00 wt. % silicon, 0.25-0.75 wt. % magnesium, 0-0.75 wt. % iron, 0-0.05 wt. % other alloying elements, and the balance of aluminum, based on the total weight of the aluminum alloy aluminum alloy.

Aluminum alloy articles

A method of manufacturing a component includes making a preform from a powdered material, the preform having a density in a range from 70 to 95% of theoretical density of the material, The method also includes sintering the preform using a Field Assisted Sintering Technique (FAST) process to produce a component having a density of greater than 97% of the theoretical density of the material. Components, in particular low aspect components, formed by said method are also described.

Components having low aspect ratio

A method for making an article is disclosed. The method involves inputting a digital model of an article into an additive manufacturing apparatus comprising an energy source. The additive manufacturing apparatus applies energy from the energy source to successively applied incremental quantities of a powder to fuse the powder to form the article corresponding to the digital model. The powder includes an aluminum alloy having 2.00-10.00 wt. % cerium, 0.50-2.50 wt. % titanium, 0-3.00 wt. % nickel, 0-0.75 wt. % nitrogen, 0-0.05 wt. % other alloying elements, and the balance of aluminum, based on the total weight of the aluminum alloy.

Method of manufacturing aluminum alloy articles

A heat exchanger can include a monolithically formed body defining at least two channels configured to allow fluid to flow therethrough, at least one of the at least two channels at least partially wrapping around or within at least one other of the at least two channels. In certain embodiments, the at least two channels can include a first channel and a second channel, wherein the first channel is at least partially wound around or within the second channel.

Heat exchangers with multiple flow channels

A method for making an article is disclosed. The method involves inputting a digital model of an article into an additive manufacturing apparatus comprising an energy source. The additive manufacturing apparatus applies energy from the energy source to successively applied incremental quantities of a powder to fuse the powder to form the article corresponding to the digital model. The powder includes an aluminum alloy having 2.00-9.00 wt. % cerium, 0.25-3.00 wt. % silicon, 0.25-0.75 wt. % magnesium, 0-0.75 wt. % iron, 0-0.05 wt. % other alloying elements, and the balance of aluminum, based on the total weight of the aluminum alloy.

A method of making an article is disclosed. According to the method, an energy beam is directed to a build location on a substrate, and a first powder material is delivered to the build location on the substrate and melted with the energy beam. A second powder material is delivered to the build location on the substrate over the first material and melted with the energy beam. The direction of the energy beam and delivery and melting of the first and second powders is repeated at multiple build locations on the substrate to form a solid surface of the article of the second material. The solid surface comprising the second material is subjected to a finishing process.

Additive manufacturing method

A method of manufacturing a rotor of an electric motor or an electric generator includes positioning a plurality of amortisseur bars and using additive manufacturing to place electrically conductive material. More specifically, positioning the amortisseur bars may include circumferentially positioning the bars around a rotor stack and using additive manufacturing to place electrically conductive material may include forming a non-solid pattern of electrically conductive material, such as a pattern of electrically conductive traces, across opposite axial ends of the rotor stack to electrically interconnect an amortisseur circuit.

Additive amortisseur circuit

An airfoil assembly includes an airfoil body extending from a root to a tip defining a longitudinal axis therebetween. The airfoil body includes a leading edge between the root and the tip. A sheath is direct deposited on the airfoil body. The sheath includes at least one metallic material layer conforming to a surface of the airfoil body. In accordance with another aspect, a method for assembling an airfoil assembly includes directly depositing a plurality of material layers on an airfoil body to form a sheath. In accordance with some embodiments, the method includes partially curing the airfoil body.

Airfoil systems and methods of assembly

An example method of making a component includes providing a digital model of a component to a software program, the software program operable to slice the digital model into digital layers and raster each digital layer into digital segments, the digital segments delineated by digital raster lines. The method further includes depositing a first layer of powdered material onto a platform, compacting the first layer of powered material into a first compacted layer, sintering the first compacted layer along lines corresponding to the digital raster lines using a laser, wherein the laser operates at a first power and a first scan speed, and sintering the first compacted layer along a perimeter of the first compacted layer using the laser to form a first unitary layer, wherein the laser operates at a second power and a second scan speed, wherein the ratio of the first power to the second power is less than about 3. An apparatus for making a component is also disclosed.

Growing community of inventors

Rockford, IL, United States of America

William Louis Wentland