1386results about "Turbines" patented technology

A component includes a body having a coupon opening defined therein, and an additively manufactured (AM) metal coupon including a dense region, a porous region adjacent the dense region, and a coupon outer surface. The porous region has a first cross-sectional area at a first location at or near the coupon outer surface and a second cross-sectional area less than the first cross-sectional area at a second location distal from the coupon outer surface. A braze material couples the metal coupon in the coupon opening and infiltrates into the porous region, e.g., based at least on a characteristic of the porosity thereof. The dense region may have a third cross-sectional area at the first location and a fourth cross-sectional area greater than the third cross-sectional area at the second location so it can direct the braze material in the porous region toward an inner surface of the coupon opening.

A metal coupon (200) for repairing a component (202) includes an additively manufactured (AM) metal member (210) having at least two porous regions (300) and a braze material infiltration barrier (304) positioned between the at least two porous regions (300). The braze material infiltration barrier (304) has a lower porosity than the at least two porous regions (300). A component (202) using the metal coupon (200) may also include a braze material (310) coupling the metal coupon (200) in a coupon opening (204) in the body (206). The braze material (310) infiltrates at least one of the two porous regions (300), and the braze material infiltration barrier (304) separates the braze material (310) in the at least one of the two porous regions (300) from at least one other of the at least two porous regions (300). Different braze materials may be used in each porous region.

An additive manufactured (AM) metal coupon for a turbomachine component is provided. The component includes an airfoil body having a pressure side, a suction side, a trailing edge, and a coupon opening. The AM metal coupon has an AM metal member with at least one slanted coupon side wall at an angle of less than 90° with an exterior surface of the AM metal member. The AM metal member also has a first porous region having a first porosity and a second porous region having a second porosity different than the first porosity. A braze material couples the AM metal coupon in the coupon opening in the airfoil body and infiltrates into at least one of the first porous region based at least on a characteristic of the first porosity and the second porous region based at least on a characteristic of the second porosity.

A metal coupon includes an additively manufactured (AM) metal member having a porous region having between 2% to 50% open space volume to total volume. The metal coupon includes a first section of an anchor configured to interact with a second section of the anchor in a coupon opening of a body of a component. A component including the metal coupon may include the body including the coupon opening, and an anchor including a first section in or on one of the AM metal coupon and the body and a second section in or on the other of the AM metal coupon and the body. At least the first and second sections cooperatively hold the AM metal coupon in the coupon opening in the body. Braze material couples the coupon in the coupon opening in the body. The braze material infiltrates into the porous region.

A metal coupon for repairing a component includes an additively manufactured (AM) metal member having a conduit in an interior of the AM metal member, and a first porous region around the conduit. The conduit is hollow. The porous metal coupon with conduit allows a braze material to be directed based on characteristics of the first porous region. A second porous region may be provided inside the conduit to increase heat rejection of the conduit.

The present disclosure relates to a method of using a metal specimen block having a porous region for a component. A method of coupling a metal sample block (200) to a component (202) may include additive manufacturing a metal sample block (200) having a first porous region (300A) having a first porosity and a second porous region (300B) having a second porosity different from the first porosity. A metal specimen block (200) is positioned in a specimen block opening (204) in a body (206) of the component (202). The metallic sample block (200) may be infiltrated with a braze material (310) to couple the metallic sample block (200) in a sample block opening (204) in the body (206). The one or more brazing materials (310) are infiltrated into at least one of the first porous region (300A) and the second porous region (300B) based at least on a characteristic of the first porosity and at least on a characteristic of the second porosity. The cured braze material (310) includes different segments having different physical properties based on different porosities and / or different braze materials.

A component includes a dense base region, a dense replacement region and an additively manufactured (AM) porous region between the dense base region and the dense replacement region. The porous region has a porosity between 2% to 50% open space volume to total volume of the AM porous region. The porous region can be printed onto the base region or the replacement region. A braze material couples the base region, the porous region and the replacement region together, and infiltrates into the porous region based at least on a characteristic of the porosity. The porous region reduces stress at a joint between the dense regions and can be customized to create different physical characteristic(s) than just those of the base and replacement regions.

A component (202) is disclosed that includes a body (206) and an additive manufactured (AM) metal mass (200) that includes a first section (292) and a stress relief section (294). The stress relief section (294) includes a porous region (300) having a porosity in which an open spatial volume accounts for 2% to 50% of the total volume of the stress relief section (294). The stress relief section (294) has a smaller at least one of thermal conductivity, tensile strength, ductility, and fatigue strength than the first section (292). A braze material (310) couples the AM metal specimen block (200) to a specimen block opening (204) in the body (206). The stress relief section (294) creates a low stress zone in the metal specimen block (200), which can be located near or adjacent to a high stress zone. The stress relief section (294) reduces residual stress in the metal sample block (200), which reduces related challenges to couple the metal sample block (200) to the body (206) of the component (202), particularly in the case of the use of superalloy materials.

A component includes a body and an additively manufactured (AM) metal coupon that includes at least one first porous region having a first porosity and may include any number of second porous regions having a second porosity different than the first porosity. A braze material couples the metal coupon in a coupon opening in the body. The braze material infiltrates into at least one of the first porous region based at least on a characteristic of the first porosity or any second porous region based at least on a characteristic of the second porosity. The different porosities can be customized to provide the first porous region and the second porous region with the braze material therein with different physical characteristic(s).

A metal coupon for repairing a component includes an additively manufactured (AM) metal member having a low porosity region in an interior of the AM metal member, and a porous region around the low porosity region. The low porosity region may have a porosity in a range of 0% to 5%, so is solid or nearly solid. The porous metal coupon with low porosity region allows braze material to be directed based on characteristics of the porous region.

A metal coupon (200) for repairing a component (202) includes an additively manufactured (AM) metal member (330) having a sealed cavity (296) in an interior of the AM metal member (330), and a porous region (300) around the sealed cavity (296). A metal coupon system (210) may include at least two AM metal parts (292) with each AM metal part (292) including at least a section (294) of a sealed cavity (296) therein and a porous region (300) around the at least a section (294) of the sealed cavity (296). The AM metal parts (292) combine to form the metal coupon (200), i.e., AM metal member (330), with the sealed cavity (296) in an interior thereof and the porous region (300) around the sealed cavity (296). In any event, the sealed cavity (296) is hollow. The porous metal coupon (300) with sealed cavity (296) provides reduced mass and allows braze material (310) to be directed based on characteristics of the porous region (300).

The invention relates to a metal sample block with a porous area for a component and the component with the metal sample block. A component (202) includes a body (206) and an additive manufactured (AM) metal sample block (200) that includes at least one first porous region (300A) having a first porosity and can include any number of second porous regions (300B) having a second porosity different from the first porosity. A braze material (310) couples the metallic sample block (200) in a sample block opening (204) in the body (206). The braze material (310) is infiltrated into at least one of the first porous region (300A) and any second porous region (300B) based at least on a characteristic of the first porosity and at least on a characteristic of the second porosity. Different porosities can be tailored to provide different physical characteristics for the first porous region (300A) and the second porous region (300B) having the braze material (310) therein.

An additive manufactured (AM) metal coupon (200) for a turbomachine component (202) is provided. The component (202) includes an airfoil body (206) having a pressure side (152, 178), a suction side (154, 180), a trailing edge (158, 184), and a coupon opening (204). The AM metal coupon (200) has an AM metal member (290) with at least one slanted coupon side wall (292, 294) at an angle of less than 90° with an exterior surface (296) of the AM metal member (290). The AM metal member (290) also has a first porous region (300A) having a first porosity and a second porous region (300B) having a second porosity different than the first porosity. A braze material (310) couples the AM metal coupon (200) in the coupon opening (204) in the airfoil body (206) and infiltrates into at least one of the first porous region (300A) based at least on a characteristic of the first porosity and the second porous region (300B) based at least on a characteristic of the second porosity.

The invention relates to a porous metal sample block with a pipeline for repairing a component, the component with the porous metal sample block and a related method. A metal sample block (200) for repairing a component (202) includes an additive manufactured (AM) metal component (330) having a conduit (296) inside the AM metal component (330) and a first porous region (300) surrounding the conduit (296). The duct (296) is hollow. A porous metal sample block (200) with conduits (296) allows the brazing material (310) to be directed based on characteristics of the first porous region (300). The second porous region (350) can be disposed within the conduit (296) to increase heat dissipation of the conduit (296).

A component including a body, and an additively manufactured (AM) metal coupon including a first section and a stress-relief section, is disclosed. The stress-relief section includes a porous region having a porosity between 2% to 50% open space volume to total volume of the stress-relief section. The stress-relief section has at least one of thermal conductivity, tensile strength, ductility, or fatigue strength less than first section. A braze material couples the AM metal coupon to a coupon opening in the body. The stress-relief section creates a low-stress zone in the metal coupon that can be located near or adjacent to a high-stress zone. The stress-relief section reduces residual stress in the metal coupon, which reduces the related challenges of coupling the metal coupon to the body of the component, especially where superalloy materials are used.

A metal coupon for repairing a component includes an additively manufactured (AM) metal member having at least two porous regions and a braze material infiltration barrier positioned between the at least two porous regions. The braze material infiltration barrier has a lower porosity than the at least two porous regions. A component using the metal coupon may also include a braze material coupling the metal coupon in a coupon opening in the body. The braze material infiltrates at least one of the two porous regions, and the braze material infiltration barrier separates the braze material in the at least one of the two porous regions from at least one other of the at least two porous regions. Different braze materials may be used in each porous region.

A gas turbine engine includes a gearbox assembly that includes a gearbox and a gutter for collecting a gearbox lubricant scavenge flow from the gearbox. The gutter is characterized by a lubricant extraction volume ratio between 0.01 and 0.3, inclusive of the endpoints. The lubricant extraction volume ratio defined by:VGVG⁢B·VGis a gutter volume of the gutter and VGB is a gearbox volume. The gas turbine engine includes a lubricant flow control system that includes a variable flow lubricant pump that generates a pump variable flow of lubricant to the gearbox assembly. The gearbox assembly has a variable consumption demand for delivery of lubricant. A lubricant flow controller is configured to generate a pump control command for the variable flow lubricant pump to produce the pump variable flow of lubricant based on the variable consumption demand.

A gas turbine engine includes a gearbox assembly that includes a gearbox and a gutter for collecting a gearbox lubricant scavenge flow from the gearbox. The gutter is characterized by a lubricant extraction volume ratio between 0.01 and 0.3, inclusive of the endpoints. The lubricant extraction volume ratio defined by:VGVG⁢B·VGis a gutter volume of the gutter and VGB is a gearbox volume. The gas turbine engine includes a lubricant flow control system that includes a variable flow lubricant pump that generates a pump variable flow of lubricant to the gearbox assembly. The gearbox assembly has a variable consumption demand for delivery of lubricant. A lubricant flow controller is configured to generate a pump control command for the variable flow lubricant pump to produce the pump variable flow of lubricant based on the variable consumption demand.

The invention belongs to the technical field of powder metallurgy, and particularly relates to a titanium-based composite workpiece and a preparation method and application thereof. High-entropy alloy powder with fine granularity is preferably selected as reinforcing phase powder after being prepared by adopting a gas atomization method and subjected to vibration screening, the particle size of the reinforcing phase powder and internal crystal grains of particles are fine, and after the reinforcing phase powder and titanium alloy powder are uniformly mixed, hot isostatic pressing low-temperature sintering treatment is performed, so that the high-entropy titanium alloy is obtained. Fine grain structures in reinforced phase powder particles are reserved in the titanium-based composite master alloy bar, and then a secondary plasma rotating electrode method is used for preparing powder, so that the titanium-based composite powder with uniform components and smaller grain structures is obtained; after mixing, the homogenized titanium-based composite mother alloy bar is prepared into powder through a secondary plasma rotating electrode method, chemical components are further dispersed and homogenized, reinforcing phases are distributed in all titanium-based composite powder particles, and the reinforcing effect can be further improved through an unconventional surface contact type reinforcing mode.

A combustor for a gas turbine (GT) system includes a combustor body including a non-additively manufactured (non-AM) part having corrosion at a first level and a replacement additively manufactured (AM) part coupled to the non-AM part. The replacement AM part has corrosion at a second level less than the first level. The replacement AM part includes at least an aft section of a tapered transition portion and an aft frame of the combustor body, and a plurality of shared parallel, sintered metal layers extending into the aft section of the tapered transition portion and the aft frame. The replacement AM part may also include a receiving element in a forwardmost end thereof configured to receive a rearwardmost remaining end of the non-AM part. The replacement AM part may also optionally include an AFS injector mount and part of a cylindrical portion of a combustion liner.

Inventive techniques for forming unique compositions of matter are disclosed, as well as associated physical characteristics and properties of the materials. In particular, particles comprising a metal lattice are characterized by having carbon (preferably graphene) disposed within the crystalline lattice structure thereof. The carbon is at least partially disposed in interstitial sites of the metal lattice, and may be present in amounts ranging from about 15 wt % to about 90 wt % of the total particle mass, with about 15 wt % to about 60 wt % being disposed in the interstitial sites, e.g., between basal planes, of the metal lattice. The carbon, moreover, is substantially homogeneously dispersed throughout the resultant material, conveying unique and advantageous properties such as strength-to-weight ratio, density, mechanical toughness, sheer strength, flex strength, hardness, anti-corrosiveness, electrical and / or thermal conductivity, etc. as described herein. In some approaches, the graphene is pristine, and has corresponding physical characteristics as described herein.

A hollow vane assembly including an open body including an interior; at least one cover support structure formed in said open body proximate the interior; a cover brazed to the open body to form at least one flow passage; and the open body and the cover configured as two piece substantially symmetrical halves.

Systems and methods for generating a shape-based graded lattice structure that can be used in additive manufacturing. A slicer computer system generates the lattice structure by simulating the packing of a planar region with variable-sized packing shapes, where packing shape sizes correspond to intensity values of a non-uniform physical field expected to be experienced by the article. An intermediate lattice structure is then generated using a first set of polygonal cells, followed by a second set of polygonal cells that refine the final lattice structure. Tailored sectioning and field-based smoothing can modify polygon packing algorithms to adapt lattice generation. The resultant multi-stage graded lattice structures, which may include multiple lattice patches and transition zones, from shape-based packing, tailored sectioning, field-based smoothing, and slicer-based additive manufacturing processing improve connectivity and manufacturability over traditional lattice structures.

A tooling support system is provided. The tooling support system includes tooling support elements. Each tooling support elements includes an anchor mountable to an external component of a body being drilled into, a tool guide supportable by the anchor and defining a tooling pathway and a guide sleeve disposed at an end of the tooling pathway. Each of the guide sleeves of the tooling support elements have varying dimensions.

A high-temperature alloy blade additive manufacturing repairing technology for improving an additive repairing interface comprises the steps that firstly, a damaged part of a blade is milled and removed, heat treatment is conducted on the blade, and then a to-be-repaired area is polished and the surface is cleaned; then, the blade is moved to additive manufacturing equipment, additive repairing is carried out on the to-be-repaired area, and the blade is moved out when deposition is carried out to the set height; carrying out laser shock peening on the repaired part of the top surface; then the blade is dried, and the surface to be repaired is cleaned again; then the blade is moved to the additive manufacturing equipment to continue additive repairing, and deposition is repeated until the blade is higher than the surface of the base body; and finally, the repaired part material higher than the surface of the base body is removed through milling, the repaired surface is polished to be consistent with the base body, and repairing is completed. According to the method, laser shock peening is preset in the to-be-repaired area, so that effective regulation and control of the microstructure of the repaired interface of the high-temperature alloy blade are achieved, and improvement of the microstructure of the interface layer is achieved.

A method comprising the steps of positioning a constraining member on a component to create a zone between the component and the constraining member. A first material composition is positioned in the zone between the component and the constraining member, and a second material composition is positioned in the zone between the component and the constraining member. The second material composition is positioned on the first material composition. Heat treating the component, the constraining member, the first material composition, and the second material composition occurs. The second material composition flows into the first material composition and forms a third material composition. The constraining member is removed from the component and the third material composition.

A method of repairing a stator stage is disclosed herein. The method includes receiving a stator stage including a plurality of stator vanes disposed between an outer diameter and an inner diameter, analyzing the stator stage for defects, determining based on the analysis that there is a first defect on an edge of a first stator vane of the plurality of stator vanes, removing a portion of the first stator vane including the first defect to form a first scallop on the edge of the first stator vane, repairing the first stator vane including filling the first scallop to fill the first stator vane to its original size and shape creating a repaired portion, and performing a blending process to the stator stage including the first stator vane and the repaired portion to smooth the plurality of stator vanes.

An oxyide dispersion-strengthened (ODS) alloy is disclosed that is compatible with melt-based additive manufacturing processes, such as laser powder bed fusion (L-PBF) while achieving material properties, such as resistance to frictional ignition, comparable to or better than wrought ODS alloys. This is accomplished, in part, by adjusting the composition of the ODS alloy and / or adjusting the operating parameters of the additive manufacturing process to reduce or, in some instances, mitigate dispersoid coarsening and slag formation. For example, a nickel (Ni)-based ODS alloy may include less than 0.3 wt % aluminum (Al) to reduce the formation of low melting point oxides that are prone to coarsening and slag formation. In another example, various processing parameters associated with a selective laser melting process, such as beam power, beam spot size, and scan speed, may be chosen to reduce a melt time associated with the additive manufacturing process.

A de-aerator is provided that includes a body, a cover panel, a fluid inlet, a helical fluid passage, at least one partition, and at least one fluid outlet. The body extends between opposing first and second axial ends. The body has a sidewall, a base panel, and an internal cavity. The fluid inlet is in communication with the body and is configured to direct fluid tangentially into the internal cavity. The helical fluid passage is disposed within the internal cavity and has entry and exit ends. The helical fluid passage has circumferential turns that each include an air passage. The at least one partition is disposed within the internal cavity at or below the passage exit end, spaced above the base panel. The at least one fluid outlet is configured to permit liquid passage from the internal cavity of the body to outside the body.

An aircraft engine assembly includes a gas turbine engine having an intake channel configured to receive an incoming flow of air and form an intake flow of air, the intake channel configured to turn the received incoming flow of air from an incoming flow direction to a first axial direction of the gas turbine engine, the incoming flow direction reverse of the first axial direction, and an electric machine coupled with the low pressure shaft and located at the aft end of the gas turbine engine proximate the intake channel, the electric machine in heat exchange communication with the intake flow of air such that the electric machine transfers heat to the incoming flow of air within the intake channel when the electric machine is operated.