公开(公告)号：US09656344B2

公开(公告)日：2017-05-23

申请号：US14911173

申请日：2014-08-04

Applicant: United Technologies Corporation

Inventor： Lexia Kironn ,  Sergey Mironets ,  Wendell V. Twelves, Jr. ,  Agnes Klucha

IPC: B23K20/10 ,  B23K20/22 ,  B23K26/40 ,  B33Y10/00 ,  B33Y30/00 ,  B23K26/08 ,  B23K26/38 ,  B33Y40/00 ,  B23K101/18 ,  B23K103/18 ,  B23K103/16

CPC classification number: B23K20/103 ,  B23K20/1215 ,  B23K20/22 ,  B23K26/083 ,  B23K26/0869 ,  B23K26/38 ,  B23K26/40 ,  B23K2101/185 ,  B23K2103/172 ,  B23K2103/18 ,  B29C64/141 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00

Abstract: A method of forming an object includes installing multiple foil drums within a processing chamber of an ultrasonic consolidation system. The multiple foil drums each include different materials than the other foil drums. The multiple foil drums are positioned so that one of the foils is selected to be placed on top of the build platform. The selected foil is welded onto the build platform or onto a previously processed layer. A portion of the welded foil is then cut. The multiple foil drums are retracted away from the build platform. The portion of the welded foil that was just cut is then consolidated to the object. The build platform is incrementally lowered before the process is repeated to form the next layer of the object.

公开(公告)号：US20160193688A1

公开(公告)日：2016-07-07

申请号：US14911173

申请日：2014-08-04

Applicant: UNITED TECHNOLOGIES CORPORATION

Inventor： Lexia Kironn ,  Sergey Mironets ,  Wendell V. Twelves, JR. ,  Agnes Klucha

IPC: B23K20/10 ,  B23K26/40 ,  B23K26/38 ,  B23K20/22 ,  B23K26/08

CPC classification number: B23K20/103 ,  B23K20/1215 ,  B23K20/22 ,  B23K26/083 ,  B23K26/0869 ,  B23K26/38 ,  B23K26/40 ,  B23K2101/185 ,  B23K2103/172 ,  B23K2103/18 ,  B29C64/141 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00

Abstract: A method of forming an object includes installing multiple foil drums within a processing chamber of an ultrasonic consolidation system. The multiple foil drums each include different materials than the other foil drums. The multiple foil drums are positioned so that one of the foils is selected to be placed on top of the build platform. The selected foil is welded onto the build platform or onto a previously processed layer. A portion of the welded foil is then cut. The multiple foil drums are retracted away from the build platform. The portion of the welded foil that was just cut is then consolidated to the object. The build platform is incrementally lowered before the process is repeated to form the next layer of the object.

Abstract translation: 形成物体的方法包括在超声波固结系统的处理室内安装多个箔鼓。 多个箔鼓每个包括与其它箔鼓不同的材料。 多个箔鼓被定位成使得一个箔被选择为放置在构建平台的顶部上。 所选箔被焊接到构建平台上或者先前处理的层上。 然后将焊接的箔的一部分切割。 多个箔鼓从构建平台缩回。 然后将刚被切割的焊接箔的部分固结到物体上。 在重复该过程以形成对象的下一层之前，构建平台被递增地降低。

公开(公告)号：US20160303798A1

公开(公告)日：2016-10-20

申请号：US15102249

申请日：2014-12-05

Applicant: UNITED TECHNOLOGIES CORPORATION

Inventor： Sergey Mironets ,  Agnes Klucha

IPC: B29C67/00 ,  B33Y30/00 ,  B33Y50/02 ,  B33Y80/00 ,  F01D5/28 ,  B23K28/00 ,  B22F3/105 ,  B22F5/00 ,  B28B1/00 ,  B28B17/00 ,  B33Y10/00 ,  H05B3/00

CPC classification number: H05B3/0061 ,  B22F3/1055 ,  B22F5/009 ,  B22F2003/1056 ,  B22F2003/1057 ,  B22F2998/10 ,  B22F2999/00 ,  B23K28/00 ,  B28B1/001 ,  B28B17/0081 ,  B29C64/153 ,  B29C64/386 ,  B29C64/40 ,  B29L2031/085 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B33Y80/00 ,  F01D5/28 ,  F05D2220/30 ,  F05D2230/13 ,  F05D2230/22 ,  F05D2230/31 ,  H05B3/0057 ,  Y02P10/295 ,  B22F1/0085 ,  B22F2202/13

Abstract: A method of forming a component includes preparing a starting powder and spreading the powder on a platform to form a first layer. A first mask with a plurality of openings is placed over the platform and the platform is irradiated with an energy source, such that the energy passes through the openings in the mask and transforms selected regions of the first layer into a denser form of matter according to a 3-D model of the component stored in a control system of the device. The platform is then indexed down one layer of thickness and a second layer of powder is spread on the first layer. A second mask with a plurality of openings is positioned between the energy source and the first layer and the first layer is irradiated with energy that passes through the mask and transforms selected regions of the second layer into a denser form of matter. The platform is indexed down one layer of thickness again and the process repeated until the component is formed.

Abstract translation: 形成组分的方法包括制备起始粉末并将粉末铺展在平台上以形成第一层。 具有多个开口的第一掩模放置在平台上并且平台被能量源照射，使得能量通过掩模中的开口，并且根据第一层的选定区域将其转化为更密集的物质形式 存储在设备的控制系统中的组件的3-D模型。 然后将该平台分离成一层厚度，并将第二层粉末铺展在第一层上。 具有多个开口的第二掩模位于能量源和第一层之间，并且第一层被穿过掩模的能量照射并且将第二层的选定区域转换成更密集的物质。 该平台再次向下索引一层厚度，并重复该过程，直到该部件形成为止。

公开(公告)号：US20140169981A1

公开(公告)日：2014-06-19

申请号：US13714561

申请日：2012-12-14

Applicant: UNITED TECHNOLOGIES CORPORATION

Inventor： Daniel A. Bales ,  Agnes Klucha ,  Gregory M. Dolansky

IPC: B22F5/04

CPC classification number: B22F5/04 ,  B22F3/1055 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/00 ,  B33Y80/00 ,  Y02P10/295 ,  Y10T29/49339 ,  Y10T29/49341

Abstract: A gas turbine airfoil having internal cooling passages is formed by additive manufacturing. Layers of superalloy powder are fused by an energy beam using a two-dimensional pattern providing unmelted areas forming passageways therein. Layers of the powder are added and fused using sufficient two-dimensional patterns to form the entire airfoil with the desired pattern of internal cooling passages. After completion of the formation of the airfoil, it may be hot isostatic pressed, directionally recrystallized, bond coated, and covered with a thermal barrier layer.

Abstract translation: 具有内部冷却通道的燃气轮机翼型通过附加制造形成。 超级合金粉末的层通过能量束熔合，使用二维图案，提供在其中形成通道的未熔化区域。 使用足够的二维图案加入并熔化粉末层，以形成具有所需图案的内部冷却通道的整个翼型。 在翼型形成完成之后，可以进行热等静压，定向重结晶，粘结涂层，并覆盖有热障层。

公开(公告)号：US20140093384A1

公开(公告)日：2014-04-03

申请号：US13718134

申请日：2012-12-18

Applicant: UNITED TECHNOLOGIES CORPORATION

Inventor： Sergey Mironets ,  Wendell V. Twelves ,  Grant O. Cook, III ,  Robert P. Delisle ,  Agnes Klucha ,  William J. Ward

IPC: F01D5/14

CPC classification number: F01D5/147 ,  B22F5/009 ,  B22F5/04 ,  B22F2998/10 ,  B23P15/006 ,  B29C64/00 ,  B33Y10/00 ,  B33Y80/00 ,  C25D1/02 ,  F01D5/34 ,  F05D2230/22 ,  B29C67/00 ,  C25D1/00 ,  B22F2005/103 ,  B22F3/115 ,  B22F3/15

Abstract: A method of forming a complex shaped part includes the steps of forming a polymer core by an additive manufacturing process. A metal is plated about surfaces of the polymer core, and the polymer core is removed, leaving hollows within a plate core. Metal powder is deposited within the hollows. An integral blade rotor is also disclosed.

Abstract translation: 形成复杂成形部件的方法包括通过添加剂制造工艺形成聚合物芯的步骤。 金属围绕聚合物芯的表面被镀覆，并且聚合物芯被去除，留下中空在板芯内。 金属粉末沉积在凹槽内。 还公开了一体的叶片转子。

公开(公告)号：US10549520B2

公开(公告)日：2020-02-04

申请号：US15287776

申请日：2016-10-07

Applicant: United Technologies Corporation

Inventor： Sergey Mironets ,  Lyutsia Dautova ,  Joseph Ott ,  Christopher F. O'Neill ,  Robert P. Delisle ,  Jesse R. Boyer ,  Agnes Klucha ,  Louis Porretti

IPC: F01D25/28 ,  B33Y80/00 ,  F04D29/54 ,  F16B5/00

Abstract: A structure includes a first body section that has a wall that spans in a vertical direction. The wall has a relatively thin thickness with respect to a length and a width of the wall. A second body section is arranged next to, but spaced apart from, the first body section. A gusset connects the first body section and the second body section. The gusset extends obliquely from the wall of the first body section with respect to the vertical direction such that the gusset is self-supporting. The first body section has a geometry that corresponds to an end-use component exclusive of the gusset.

公开(公告)号：US09770866B2

公开(公告)日：2017-09-26

申请号：US14541184

申请日：2014-11-14

Applicant: United Technologies Corporation

Inventor： Sergey Mironets ,  Agnes Klucha ,  Wendell V. Twelves, Jr. ,  Benjamin T. Fisk

IPC: B29C67/00 ,  B23K15/00 ,  B28B11/00 ,  F02C7/00 ,  B22F3/105 ,  B33Y30/00 ,  B29C35/08 ,  B33Y10/00

CPC classification number: B29C64/153 ,  B22F3/1055 ,  B23K15/0086 ,  B28B11/00 ,  B29C64/371 ,  B29C2035/0838 ,  B33Y10/00 ,  B33Y30/00 ,  F02C7/00 ,  F05D2230/00 ,  F05D2230/31 ,  Y02P10/295

Abstract: An example multi-dimensional component building system includes a first chamber having at least one base disposed therein, a second chamber adjacent to and in fluid communication with the first chamber through a first door, and a third chamber adjacent to and in fluid communication with the second chamber through a second door. The second chamber is fluidly sealed from the first chamber if the first door is in a closed position. The second chamber is configured to receive the at least one base via a first transfer mechanism if the fluid parameters of the first chamber are approximately equal to the fluid parameters of the second chamber. The second chamber includes a directed heat source and a build-up material configured to form a component on the at least one base by melting or sintering. The third chamber is fluidly sealed from the second chamber if the first door is in a closed position. The third chamber is configured to receive the at least one base, having a formed component disposed thereon, via a second transfer mechanism if the second door is in an open position. The fluid parameters of the second chamber are not substantially affected by fluid communication with the first chamber or the third chamber.

公开(公告)号：US09393620B2

公开(公告)日：2016-07-19

申请号：US13714561

申请日：2012-12-14

Applicant: United Technologies Corporation

Inventor： Daniel A. Bales ,  Agnes Klucha ,  Gregory M. Dolansky

IPC: B22F5/04 ,  B33Y10/00 ,  B22F3/105 ,  B33Y30/00 ,  B33Y80/00

CPC classification number: B22F5/04 ,  B22F3/1055 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/00 ,  B33Y80/00 ,  Y02P10/295 ,  Y10T29/49339 ,  Y10T29/49341

Abstract: A gas turbine airfoil having internal cooling passages is formed by additive manufacturing. Layers of superalloy powder are fused by an energy beam using a two-dimensional pattern providing unmelted areas forming passageways therein. Layers of the powder are added and fused using sufficient two-dimensional patterns to form the entire airfoil with the desired pattern of internal cooling passages. After completion of the formation of the airfoil, it may be hot isostatic pressed, directionally recrystallized, bond coated, and covered with a thermal barrier layer.

Abstract translation: 具有内部冷却通道的燃气轮机翼型通过附加制造形成。 超级合金粉末的层通过能量束熔合，使用二维图案，提供在其中形成通道的未熔化区域。 使用足够的二维图案加入并熔化粉末层，以形成具有所需图案的内部冷却通道的整个翼型。 在翼型形成完成之后，可以进行热等静压，定向重结晶，粘结涂层，并覆盖有热障层。

公开(公告)号：US20150069668A1

公开(公告)日：2015-03-12

申请号：US14541184

申请日：2014-11-14

Applicant: United Technologies Corporation

Inventor： Sergey Mironets ,  Agnes Klucha ,  Wendell V. Twelves, JR. ,  Benjamin T. Fisk

IPC: B28B11/00 ,  B23K26/34 ,  B23K15/00 ,  F02C7/00

CPC classification number: B29C64/153 ,  B22F3/1055 ,  B23K15/0086 ,  B28B11/00 ,  B29C64/371 ,  B29C2035/0838 ,  B33Y10/00 ,  B33Y30/00 ,  F02C7/00 ,  F05D2230/00 ,  F05D2230/31 ,  Y02P10/295

Abstract: An example multi-dimensional component building system includes a first chamber having at least one base disposed therein, a second chamber adjacent to and in fluid communication with the first chamber through a first door, and a third chamber adjacent to and in fluid communication with the second chamber through a second door. The second chamber is fluidly sealed from the first chamber if the first door is in a closed position. The second chamber is configured to receive the at least one base via a first transfer mechanism if the fluid parameters of the first chamber are approximately equal to the fluid parameters of the second chamber. The second chamber includes a directed heat source and a build-up material configured to form a component on the at least one base by melting or sintering. The third chamber is fluidly sealed from the second chamber if the first door is in a closed position. The third chamber is configured to receive the at least one base, having a formed component disposed thereon, via a second transfer mechanism if the second door is in an open position. The fluid parameters of the second chamber are not substantially affected by fluid communication with the first chamber or the third chamber.

Abstract translation: 示例性多维部件构建系统包括具有设置在其中的至少一个基座的第一腔室，与第一腔室相邻并与第一腔室流体连通的第二腔室，以及与第一腔室相邻并与其流体连通的第三腔室 第二室通过第二扇门。 如果第一个门处于关闭位置，第二个室与第一个室流体密封。 如果第一室的流体参数近似等于第二室的流体参数，则第二室被构造成经由第一传送机构接纳至少一个底座。 第二室包括定向热源和构建成通过熔化或烧结在至少一个基底上形成组分的积聚材料。 如果第一个门处于关闭位置，则第三个室与第二个室流体密封。 如果第二门处于打开位置，则第三室被构造成经由第二传送机构接收具有设置在其上的成形部件的至少一个基座。 第二室的流体参数基本上不受与第一室或第三室的流体连通的影响。

公开(公告)号：US20140178241A1

公开(公告)日：2014-06-26

申请号：US14066013

申请日：2013-10-29

Applicant: United Technologies Corporation

Inventor： Sergey Mironets ,  Michael C. Reiter ,  Agnes Klucha ,  Youping Gao

IPC: B22F1/00 ,  B22F3/00 ,  B22F3/105

CPC classification number: B22F1/0085 ,  B22F3/1055 ,  B22F2003/1056 ,  B22F2999/00 ,  Y02P10/295 ,  Y10T137/0318 ,  Y10T137/8593 ,  B22F1/0088 ,  B22F2201/01 ,  B22F2201/10

Abstract: A pulverant material supply system has an outer shell, an inner shell, and a plurality of openings to a passage within the inner shell to allow a reducing fluid into the pulverant material contained therein. The liner is made from a non-evaporable getter alloy.

Abstract translation: 粉料供应系统具有外壳，内壳和多个开口，以通向内壳内的通道，以允许还原流体进入包含在其中的粉碎材料。 内衬由不可蒸发的吸气剂合金制成。