公开(公告)号：US10807165B2

公开(公告)日：2020-10-20

申请号：US15111378

申请日：2015-01-22

Applicant: United Technologies Corporation

Inventor： Aaron T. Nardi ,  Zissis Dardas

IPC: B22F3/24 ,  B22F3/105 ,  B28B1/00 ,  B22F7/06 ,  B22F7/08 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B23K26/12 ,  B23K26/342 ,  B23K26/70 ,  B23K15/00 ,  B23K26/00 ,  B23K26/16 ,  C23C8/02 ,  C23C8/08 ,  C23C8/24

Abstract: A manufacturing process is provided. During this process, material is solidified together within a chamber to form an object using an additive manufacturing device. At least a portion of the solidified material is conditioned within the chamber using a material conditioning device.

公开(公告)号：US10782245B2

公开(公告)日：2020-09-22

申请号：US16047957

申请日：2018-07-27

Applicant: United Technologies Corporation

Inventor： Lawrence Binek ,  Aaron T. Nardi

IPC: G01N21/88 ,  B05B7/14 ,  B05D1/12 ,  C23C24/04 ,  B33Y10/00 ,  B33Y40/00 ,  B33Y50/02

Abstract: A health monitoring system for monitoring a lifecycle of an additively manufactured component having a microcrystalline structure that can be subjected to a cyclic operational stress is disclosed. The health monitoring system includes a plurality of additively manufactured health monitoring coupons disposed on the component in a representative position that is subjected to the cyclic operational stress, with the health monitoring coupons configured to be individually removable from the health monitoring system by precision machining. A lifecycle monitoring method includes the steps of monitoring one or more operational parameters of the additively manufactured component, calculating a sample trigger, removing a health monitoring coupon by a precision machining process based on the sample trigger, analyzing the health monitoring coupon by an inspection process, determining whether the additively manufactured component is usable and if so, resuming operating the additively manufactured component, otherwise replacing the additively manufactured component.

公开(公告)号：US20200254518A1

公开(公告)日：2020-08-13

申请号：US16700057

申请日：2019-12-02

Applicant: United Technologies Corporation

Inventor： Ying She ,  John A. Sharon ,  James T. Beals ,  Aaron T. Nardi

IPC: B22F1/02 ,  B29C64/153 ,  B22F3/105 ,  B23K15/00 ,  B23K26/00 ,  B23K26/342 ,  B22F1/00

Abstract: A powder material includes spherical metal particles and a spaced-apart distribution of ceramic nanoparticles attached to the surfaces of the particles.

公开(公告)号：US10376961B2

公开(公告)日：2019-08-13

申请号：US15021575

申请日：2014-07-30

Applicant: United Technologies Corporation

Inventor： Michael A. Klecka ,  Ying She ,  Tahany Ibrahim El-Wardany ,  Aaron T. Nardi

IPC: B22F9/04 ,  B01J8/18 ,  B22F1/00 ,  B01J2/16 ,  B33Y10/00 ,  B33Y70/00

Abstract: One embodiment includes a powder spheroidizing method. The method includes loading a powder into a fluidized bed assembly, fluidizing at least some of the powder in the fluidized bed assembly using an inert gas, and heating the powder while fluidized in the fluidized bed assembly.

公开(公告)号：US10272382B2

公开(公告)日：2019-04-30

申请号：US15169124

申请日：2016-05-31

Applicant: United Technologies Corporation

Inventor： Ying She ,  Aaron T. Nardi ,  Lawrence Binek ,  Andrzej Ernest Kuczek ,  Zissis A. Dardas

IPC: B01D53/22 ,  B01D53/30 ,  B01D53/053 ,  B01D53/047 ,  B33Y40/00 ,  B29C64/357 ,  C23C24/04

Abstract: A carrier gas recovery system for use in cold spray manufacturing recovers carrier gas utilized during the cold spray process and recycles the carrier gas for immediate use or stores the carrier gas for future use. The carrier gas recovery system includes an enclosure subsystem, a filtration subsystem, a reclamation subsystem, and a compensation subsystem. An article is placed in the enclosure and particulate matter is carried to the article on a carrier gas stream. Carrier gas in the enclosure is filtered through the filtration subsystem to remove particulate from the carrier gas, and the filtered carrier gas is fed to the reclamation subsystem. The carrier gas either flows to a gas separator, to increase the concentration of carrier gas, or to the compensation subsystem if the carrier gas concentration is sufficiently high. The carrier gas can be stored in the compensation subsystem or used in further cold spray manufacturing.

公开(公告)号：US09990576B2

公开(公告)日：2018-06-05

申请号：US15106529

申请日：2015-01-23

Applicant: United Technologies Corporation

Inventor： Aaron T. Nardi ,  Joseph V. Mantese ,  Michael A. Klecka ,  Daniel V. Viens

IPC: G06K19/077 ,  G01D11/24

CPC classification number: G06K19/07722 ,  G01D9/005 ,  G01D11/245 ,  H01L23/04 ,  H01L23/24 ,  H01L2924/0002 ,  H01L2924/00

Abstract: A component may be self-monitoring having a sensor assembly located on a surface of a substrate and covered by an encapsulating layer additively manufactured over the sensor assembly and thereby bonded to the substrate. The sensor may be wireless, self-powered, and embedded into the substrate such that it is unobtrusive and may not limit the performance or function of the component.

公开(公告)号：US09938624B2

公开(公告)日：2018-04-10

申请号：US15025427

申请日：2014-10-17

Applicant: United Technologies Corporation

Inventor： Aaron T. Nardi ,  Tahany Ibrahim El-Wardany ,  William Werkheiser ,  Michael A. Klecka

IPC: C23C24/04 ,  B32B15/01 ,  B24C1/10

CPC classification number: C23C24/04 ,  B24C1/10 ,  B32B15/01

Abstract: One embodiment includes a method for enhancing bond strength between a powder deposit and a substrate. Powder is deposited on the substrate. Powder is shot peened with peening media that is harder than both the powder and the substrate to produce bond strength between the powder and the substrate that is at least twice bond strength between the powder and the substrate without shot peening.

公开(公告)号：US09890460B2

公开(公告)日：2018-02-13

申请号：US15023253

申请日：2014-08-04

Applicant: United Technologies Corporation

Inventor： Michael A. Klecka ,  Aaron T. Nardi

IPC: C23C24/04 ,  B24C1/10 ,  B24C1/00

CPC classification number: C23C24/04 ,  B24C1/003 ,  B24C1/10

Abstract: The invention provides a self-peening feedstock material for cold spray deposition comprising a higher ductility matrix material and a hardened particle.

公开(公告)号：US20180002816A1

公开(公告)日：2018-01-04

申请号：US15706188

申请日：2017-09-15

Applicant: UNITED TECHNOLOGIES CORPORATION

Inventor： Matthew B. Kennedy ,  Justin R. Hawkes ,  Aaron T. Nardi ,  Michael A. Klecka

IPC: C23C24/04 ,  B05B7/14 ,  G01F11/24 ,  B05D1/12

CPC classification number: C23C24/04 ,  B05B7/144 ,  B05B7/1463 ,  B05D1/12 ,  G01F11/24

Abstract: A powder feeder for a cold spray system includes a rotatable drum body, a housing surrounding the drum body, and a support structure. The support structure couples to the housing and supports the housing such that the drum body rotates about a rotation axis to provide in-situ blending of powder disposed within an interior of the drum body.

公开(公告)号：US20170368602A1

公开(公告)日：2017-12-28

申请号：US15678260

申请日：2017-08-16

Applicant: United Technologies Corporation

Inventor： Ying She ,  John A. Sharon ,  James T. Beals ,  Aaron T. Nardi

IPC: B22F1/02 ,  B23K26/00 ,  B29C64/153 ,  B22F1/00 ,  B22F3/105 ,  B23K15/00 ,  B23K26/342 ,  B23K103/14 ,  B23K103/00 ,  B23K103/02 ,  B23K103/08 ,  B23K103/10 ,  C22C32/00

CPC classification number: B22F1/02 ,  B22F1/0085 ,  B22F3/1055 ,  B22F2998/10 ,  B23K15/0086 ,  B23K15/0093 ,  B23K26/0006 ,  B23K26/342 ,  B23K2103/02 ,  B23K2103/08 ,  B23K2103/10 ,  B23K2103/14 ,  B23K2103/52 ,  B29C64/153 ,  C22C32/0015 ,  Y02P10/295 ,  B22F1/0088 ,  B22F1/0062

Abstract: A method for processing a powder material includes feeding a powder material through an additive processing machine to deposit multiple layers of the powder material onto one another and using an energy beam to thermally fuse selected portions of the layers to one another with reference to data relating to a particular cross-section of an article being formed. The powder material has spherical metal particles and a spaced-apart distribution of ceramic nanoparticles attached to the surfaces of the particles. The ceramic nanoparticles form a dispersion of reinforcement through the formed article.