Abstract:
A foil bearing assembly for supporting a rotating member that rotates about an axis including a stationary mount member spaced from the rotating member so that a gap is defined between the stationary mount member and the rotating member. A foil member is disposed in the gap between the rotating member and the stationary mount member. At least one of the rotating member, the stationary mount member or the foil member includes a wear resistant coating layer.
Abstract:
The present invention provides a composition that includes a rhenium-based alloy and a solid film lubricant. The rhenium-based alloy comprises an alloying substance including at least one constituent having a stronger affinity to oxygen than does Re when exposed to an atmosphere at a temperature of at least about 285° C.
Abstract:
A solid free form fabrication (SFF) system and method is used to fabricate a three-dimensional structure in a continuous manner from successive layers of feedstock material. The system includes a gas shielding structure that is configured to protect a targeted region from oxidation. The system further includes a positioning arm coupled to the deposition head and moveable to align the deposition head with a targeted region of the three-dimensional structure and a plurality of control components coupled to the positioning arm for controlling a position of the positioning arm and operation of the deposition head. The gas shielding structure is formed as either a parallelepiped structure or a half disc structure and may be conformable to at least one surface of the three-dimensional structure.
Abstract:
A method for making aerospace face seal rotors reinforced by rhenium metal, alloy, or composite in combination with silicon carbide or other ceramic. The resulting rotor also is disclosed. Ceramic grains, preferably silicon carbide (SiC), are mixed with powdered metallic (PM) binder that may be based on a refractory metal, preferably rhenium. The mixture is applied to a rotor substrate. The combined ceramic-metal powder mixture is heated to sintering temperature under pressure to enable fusion of the ceramic in the resulting metal-based substrate. A load may then be applied under an elevated temperature. The resulting coated rotor can exhibit high hot hardness, increased durability and/or high hot wear resistance, as well as high thermal conductivity.
Abstract:
A method for making aerospace face seal rotors reinforced by rhenium metal, alloy, or composite in combination with silicon carbide or other ceramic. The resulting rotor also is disclosed. Ceramic grains, preferably silicon carbide (SiC), are mixed with powdered metallic (PM) binder that may be based on a refractory metal, preferably rhenium. The mixture is applied to a rotor substrate. The combined ceramic-metal powder mixture is heated to sintering temperature under pressure to enable fusion of the ceramic in the resulting metal-based substrate. A load may then be applied under an elevated temperature. The resulting coated rotor can exhibit high hot hardness, increased durability and/or high hot wear resistance, as well as high thermal conductivity.
Abstract:
An erosion resistant torch for use in a solid free form fabrication system for manufacturing a component from successive layers of metal feedstock material. The erosion resistant torch includes a torch structure defining a torch nozzle formed of a highly conductive bulk material. The erosion resistant torch further includes a gas flow channel and an orifice defined therein. An arc electrode is disposed within the gas flow channel. An erosion resistant material is disposed between the torch nozzle and the arc electrode in the form of a coating layer or an erosion resistant insert. The erosion resistant material is formed of one of a refractory material or a ceramic material.
Abstract:
A variable orifice torch for use in a solid free form fabrication system for manufacturing a component from successive layers of metal feedstock material. The variable orifice torch includes a torch structure defining a torch nozzle formed of a highly conductive bulk material. The variable orifice torch further includes a gas flow channel and a variable orifice defined therein. An arc electrode is disposed within the gas flow channel. The variable orifice is defined in the torch nozzle and in alignment with the arc electrode. The variable orifice is coupled to the torch structure in a manner operable to control a flow gas therethrough by varying the size of an aperture defined by the variable orifice.
Abstract:
An erosion resistant torch for use in a solid free form fabrication system for manufacturing a component from successive layers of metal feedstock material. The erosion resistant torch includes a torch structure defining a torch nozzle formed of a highly conductive bulk material. The erosion resistant torch further includes a gas flow channel and an orifice defined therein. An arc electrode is disposed within the gas flow channel. An erosion resistant material is disposed between the torch nozzle and the arc electrode in the form of a coating layer or an erosion resistant insert. The erosion resistant material is formed of one of a refractory material or a ceramic material.
Abstract:
An ion fusion formation (IFF) system and method is used to fabricate a large scale three-dimensional structure in a continuous manner from successive layers of feedstock material. The system includes a moveable positioning arm coupled to a control platform. The positioning arm includes a deposition head, including a high energy beam and a feedstock feed mechanism mounted thereto. The deposition head is positioned relative to a targeted region by positioning and repositioning the moveable positioning arm, thereby providing a means for fabricating a large scale three-dimensional structure in a continuous manner. A plurality of control components coupled to the control platform are programmable to control the positioning arm whereby a plurality of customizable control parameters are input into the control components and provide positioning and repositioning of the positioning arm to align the deposition head relative to the predetermined targeted region.
Abstract:
A solid free form fabrication system for manufacturing a component by successively building feedstock layers representing successive cross-sectional component slices includes a platform for receiving and supporting the feedstock layers, a feedstock supplying apparatus that deposits the feedstock into a predetermined region to form the feedstock layers, an energy source directed toward the predetermined region to modify the feedstock in the predetermined region and thereby manufacture the component, and a temperature control block disposed on the platform and directly in contact with the deposited feedstock layers to modify the feedstock temperature while manufacturing the component. A solid free form fabrication method uses the system to manufacture the component from the feedstock material