| 序号 | 专利名 | 申请号 | 申请日 | 公开（公告）号 | 公开（公告）日 | 发明人 |
|---|---|---|---|---|---|---|
| 101 | Method for forming components using additive manufacturing and re-melt | US14706659 | 2015-05-07 | US09435211B2 | 2016-09-06 | JinQuan Xu |
| A method of manufacturing a component includes additively manufacturing a crucible; directionally solidifying a metal material within the crucible; and removing the crucible to reveal the component. A component for a gas turbine engine includes a directionally solidified metal material component, the directionally solidified metal material component having been additively manufactured of a metal material concurrently with a core, the metal material having been remelted and directionally solidified. | ||||||
| 102 | METHODS AND SYSTEMS FOR JOINING MATERIALS | US14867525 | 2015-09-28 | US20160016196A1 | 2016-01-21 | Qi ZHAO; Robert John ZABALA; Laurent CRETEGNY; Jeffrey Jon SCHOONOVER; Mark Kevin MEYER; Keith Anthony LAURIA; William R. CATLIN |
| A method for joining a filler material to a substrate material includes melting the filler material within a melting chamber of a crucible such that the filler material is molten. The crucible has an outlet fluidly connected to the melting chamber. The method also includes holding the filler material within the melting chamber of the crucible by applying a first pressure differential across the outlet of the crucible, and releasing the filler material from the melting chamber of the crucible by applying a second pressure differential across the outlet of the crucible to deliver the filler material to a target site of the substrate material. The second pressure differential has a different value than the first pressure differential. | ||||||
| 103 | Electroslag and electrogas repair of superalloy components | US13571708 | 2012-08-10 | US09186724B2 | 2015-11-17 | Gerald J. Bruck |
| Superalloy component castings, such as turbine blades and vanes, are fabricated or repaired by an electroslag or electrogas welding process that at least partially replicates the crystal structure of the original cast substrate in a cast-in-place substrate extension. The process re-melts the base substrate surface and grows it with new molten filler material. As the base substrate and the filler material solidify, the newly formed “re-cast” component has a directionally solidified uniaxial substrate extension portion that at least in part replicates the crystalline structure of the base substrate. The “re-cast” component can be fabricated with a unified single crystal structure, including the extension portion. In other applications, a substrate extension can replicate a directionally solidified uniaxial crystal structure of an original base substrate casting. Polycrystalline substrate base structures can be re-cast with a substrate extension that replicates base substrate crystals that are most parallel to the uniaxial casting direction. | ||||||
| 104 | METHOD FOR FORMING COMPONENTS USING ADDITIVE MANUFACTURING AND RE-MELT | US14706659 | 2015-05-07 | US20150322799A1 | 2015-11-12 | JinQuan Xu |
| A method of manufacturing a component includes additively manufacturing a crucible; directionally solidifying a metal material within the crucible; and removing the crucible to reveal the component. A component for a gas turbine engine includes a directionally solidified metal material component, the directionally solidified metal material component having been additively manufactured of a metal material concurrently with a core, the metal material having been remelted and directionally solidified. | ||||||
| 105 | Isothermal structural repair of superalloy components including turbine blades | US13414751 | 2012-03-08 | US09174314B2 | 2015-11-03 | Kazim Ozbaysal |
| Structural repair of cracks and other defects in superalloy components, such as steam or gas turbine blades in stationary or aero gas turbines, are performed by heating the blade substrate to an isothermal hold temperature below the substrate's incipient melting point and filling the crack with molten superalloy filler material. The molten filler solidifies into a casting and bonds with the component substrate at the isothermal hold temperature. Heat treatment processes are completed, so that the former crack is filled with cast superalloy material having identical or similar structural properties as the adjoining substrate superalloy material. The casting repair method may be utilized universally for all types of superalloy component defects, including those previously repaired by cosmetic, lower strength welding or brazing methods. | ||||||
| 106 | Methods and systems for joining materials | US13631162 | 2012-09-28 | US09144822B2 | 2015-09-29 | Qi Zhao; Robert John Zabala; Laurent Cretegny; Jeffrey Jon Schoonover; Mark Kevin Meyer; Keith Anthony Lauria; William R Catlin |
| A method is provided for joining a filler material to a substrate material. The method includes melting the filler material within a melting chamber of a crucible such that the filler material is molten. The crucible has an outlet fluidly connected to the melting chamber. The method also includes holding the filler material within the melting chamber of the crucible by applying a first pressure differential across the outlet of the crucible, and releasing the filler material from the melting chamber of the crucible by applying a second pressure differential across the outlet of the crucible to deliver the filler material to a target site of the substrate material. The second pressure differential has a different value than the first pressure differential. | ||||||
| 107 | METHODS AND SYSTEMS FOR JOINING MATERIALS | US13630874 | 2012-09-28 | US20140093658A1 | 2014-04-03 | Qi Zhao; Robert John Zabala; Laurent Cretegny; Jeffrey Jon Schoonover; Mark Kevin Meyer; Keith Anthony Lauria; William R. Catlin |
| A method is provided for joining a filler material to a substrate material. The method includes melting the filler material within a melting chamber of a crucible such that the filler material is molten, holding the filler material within the melting chamber of the crucible by electromagnetically levitating the filler material within the melting chamber, and releasing the filler material from the melting chamber of the crucible to deliver the filler material to a target site of the substrate material. | ||||||
| 108 | ELECTROSLAG AND ELECTROGAS REPAIR OF SUPERALLOY COMPONENTS | US13571708 | 2012-08-10 | US20140044991A1 | 2014-02-13 | Gerald J. Bruck |
| Superalloy component castings, such as turbine blades and vanes, are fabricated or repaired by an electroslag or electrogas welding process that at least partially replicates the crystal structure of the original cast substrate in a cast-in-place substrate extension. The process re-melts the base substrate surface and grows it with new molten filler material. As the base substrate and the filler material solidify, the newly formed “re-cast” component has a directionally solidified uniaxial substrate extension portion that at least in part replicates the crystalline structure of the base substrate. The “re-cast” component can be fabricated with a unified single crystal structure, including the extension portion. In other applications, a substrate extension can replicate a directionally solidified uniaxial crystal structure of an original base substrate casting. Polycrystalline substrate base structures can be re-cast with a substrate extension that replicates base substrate crystals that are most parallel to the uniaxial casting direction. | ||||||
| 109 | Restoration process for porosity defects in metal cast products | US12194096 | 2008-08-19 | US08220124B1 | 2012-07-17 | Kevin Morasch; Douglas M. Woehlke; Kevin R. Anderson; Raymond J. Donahue |
| A restoration process for restoring surface porosity defects on a component surface. The areas of a component surface having surface porosity defects are identified for restoration. The restoration surface is subsequently sprayed with a restoration spray to restore the surface porosity defects. The component surface is then finished to create a final component substantially free of surface porosity. | ||||||
| 110 | Metal mold repair method and metal mold repair paste agent | US12086595 | 2006-11-06 | US07927653B2 | 2011-04-19 | Michiharu Hasegawa; Noriyuki Miyazaki; Masafumi Nakamura; Naoji Yamamoto; Kazuo Ueda |
| Providing a metal mold repair method and a metal mold repair paste agent which are capable of repairing cracks with simple work.A repair paste agent containing components that become an alloy is directly applied to a surface of a metal mold having a crack so as to cover the crack part, subsequently a surface of the repair paste agent is coated with an oxidation inhibitor and the repair paste agent is made to penetrate the inside of the crack by heating and becomes an alloy, thereby filling up the crack. | ||||||
| 111 | PROCESS FOR REPAIRING INLET PORTS OF AN EXTRUDER DIE | US12567280 | 2009-09-25 | US20110073268A1 | 2011-03-31 | Charles E. Bates |
| A process for repairing one or more worn inlet ports on an interior or exterior surface of an extruder die wherein each inlet port provides an opening into an extrusion channel. The worn inlet port has a funnel shape and a diameter greater than that of the extrusion channel. The worn inlet port is repaired by placing a fused silicon oxide insert into one or more extrusion channels so that an external surface of the insert engages the interior surface of the extrusion channel, thereby forming a pocket around the insert between the circumference or perimeter of the worn inlet port and the external surface of the insert. The pocket is filled with molten metal, and the insert prevents the molten metal from entering the extrusion channel. When the molten metal hardens the inserts are removed. New inlet ports are thereby formed having the same diameter as the extrusion channels. | ||||||
| 112 | Metal Mold Repair Method and Metal Mold Repair Paste Agent | US12086595 | 2006-11-06 | US20100159130A1 | 2010-06-24 | Michiharu Hasegawa; Noriyuki Miyazaki; Masafumi Nakamura; Naoji Yamamoto; Kazuo Ueda |
| Providing a metal mold repair method and a metal mold repair paste agent which are capable of repairing cracks with simple work.A repair paste agent containing components that become an alloy is directly applied to a surface of a metal mold having a crack so as to cover the crack part, subsequently a surface of the repair paste agent is coated with an oxidation inhibitor and the repair paste agent is made to penetrate the inside of the crack by heating and becomes an alloy, thereby filling up the crack. | ||||||
| 113 | Restoration process for porosity defects in metal cast products | US11638544 | 2006-12-13 | US07712216B1 | 2010-05-11 | Douglas M. Woehlke; Raymond J. Donahue; Kevin R. Anderson |
| A restoration process for restoring surface porosity defects resulting from the casting process in metal cast products. The areas of a cast product having surface porosity defects are identified and the areas not containing surface porosity defects are masked using an adhesive, reusable, rubberized mask. The masked surface is subsequently cleaned and a metal spray is applied to the surface porosity defects. The mask is removed and the restored surface porosity defects are hand finished to create a cast product having less than 0.05% surface porosity. | ||||||
| 114 | Process and apparatus for producing a turbine component, turbine component and use of the apparatus | US10794459 | 2004-03-05 | US07690112B2 | 2010-04-06 | Georg Bostanjoglo; Nigel-Philip Cox; Rolf Wilkenhöner |
| Process and apparatus for producing a turbine component, turbine component and use of the apparatusTurbine components have to withstand high thermal and mechanical loads. It therefore proves advantageous for them to be made from a material with a preferred crystal orientation. Hitherto, the turbine components with a preferred crystal orientation have been produced as a single piece, with relatively high scrap rates. The proposed concept makes it possible to produce a preferred turbine component (9, 10) in a particularly simple way by assembling a turbine component (9, 10) at least from a first base part (1) and a build-up material (8), the subregion (7) of the joining zone having a preferred crystal orientation (2), so that disadvantageous properties of a joining zone without a preferred crystal orientation (2) which have hitherto been encountered are avoided. | ||||||
| 115 | Method for casting a component | US11731459 | 2007-03-30 | US20080241579A1 | 2008-10-02 | Christopher A. Kinney |
| A cast component having localized areas of improved physical properties is disclosed. The component may initially be produced having a void portion in a predetermined area requiring improved physical properties. A second molten material may be added to the void portion such that it chemically bonds to the void portion. The component may then be finished such to a final shape with a localized area of improved physical properties. | ||||||
| 116 | Bimetallic plate | US10308675 | 2002-12-03 | US20030141034A1 | 2003-07-31 | Teunis Heijkoop; Ian Robert Dick; Bernard Bednarz; Geoffrey Martin Goss; Philip David Pedersen; Robert Sidney Brunton; William Trickett Wright |
| Bimetallic plate is produced by providing a substrate of a first metal and, with the preheated substrate positioned in a mold cavity with a major surface of the substrate facing upwardly and to fill a portion of the depth of the cavity, a second metal is cast against that surface to form a cladding component and, with the substrate, to form the bimetallic plate. Prior to the cladding being cast, the major surface is rendered substantially oxide-free and is protected against oxidation. The cladding is cast by a melt, of a composition required for it, being poured at a superheated temperature whereby, with the preheating of the substrate, an overall heat energy balance is achieved between the substrate and the cladding. The heat energy balance causes a diffusion bond to be achieved between the major surface of the substrate and the cladding, and attainment of the energy balance is facilitated by causing the melt to enter the mold cavity through a series of gates which provide communication between at least one runner and the mold cavity. The series of gates is disposed laterally with respect to flow of the melt therethrough whereby the melt forms a laterally extending melt front. Attainment of the heat energy balance is further facilitated by causing the melt front to advance away from the gates, over the substrate surface, at a rate which is substantially uniform across the lateral extent of the front. | ||||||
| 117 | Solidification of an article extension from a melt using an integral mandrel and ceramic mold | US669793 | 1996-06-27 | US5676191A | 1997-10-14 | Bernard Patrick Bewlay; Melvin Robert Jackson; Ann Melinda Ritter; Wayne Alan Demo; Stephen Joseph Ferrigno |
| An extension is formed directly on an article by dipping a portion or end of the article having an attached integral mandrel into a molten bath of a compatible alloy, followed by withdrawal of the end under controlled conditions sufficient to cause an integral extension to solidify on the article. A ceramic mold is utilized over the dipped end of the article and the integral mandrel with a mold cavity that generally defines the shape of the extension to be formed. The mold may be formed in situ on the mandrel, or preformed and attached to the subject article over the mandrel. The integral mandrel is melted within the mold by dipping the mandrel into the molten alloy. The mandrel acts as a buffer between the molten material and the article while permitting melting of the article end and solidification of the integral extension. Extensions formed by the method of this invention have a microstructure that is continuous and compatible with that of the article. Such microstructures may include epitaxial growth of the extension from the microstructure of the article. The method establishes a temperature gradient within the article during solidification that may be further controlled by auxiliary heating and/or cooling of the article and/or extension during the practice of the method. | ||||||
| 118 | Method for forming an article extension by melting of an alloy preform in a ceramic mold | US672156 | 1996-06-27 | US5673745A | 1997-10-07 | Melvin Robert Jackson; Bernard Patrick Bewlay; Ann Melinda Ritter |
| An extension is formed directly on an article by melting a compatible alloy preform within a ceramic mold, followed by cooling of the end under controlled conditions sufficient to cause an integral extension to solidify on the article. A ceramic mold is attached on the end of the article with a mold cavity that generally defines the shape of the extension to be formed. The mold may be formed in situ on a removable mandrel, or preformed and attached to the subject article. Extensions formed by the method of this invention have a microstructure that is continuous and compatible with that of the article. Such microstructures may include epitaxial growth of the extension from the microstructure of the article. The method establishes a temperature gradient within the article during solidification that may be further controlled by auxiliary heating and/or cooling of the article and/or extension during the practice of the method. | ||||||
| 119 | Resurfaced worn flask walls | US577289 | 1990-09-04 | US5103891A | 1992-04-14 | James L. Sylvester; Alan P. Gould |
| Worn interior wall surfaces of a sand casting flask cope or drag frame are resurfaced by covering the surfaces with thin, metal liner plates. The liner plates are bolted to the flask walls by bolts that extend through bolt holes in the liner plates and walls. The bolt holes through the plates are provided with deep countersinks for receiving the bolt heads and spacing the bolt heads beneath the exposed inner faces of the plates. Molten weld material is applied in such spaces for welding the bolts to the plates. A thin, hard coating of metal, such as chrome plating, is applied over the liner plate inner face and exposed weld material at the countersinks. Thereafter, the liner plate is removably fastened upon the inner surfaces of the flask frame by extending the bolts through the bolt holes in the frame wall and securing them in place with suitable nuts. | ||||||
| 120 | Method for resurfacing flask walls | US474939 | 1990-02-05 | US4972567A | 1990-11-27 | James L. Sylvester; Alan P. Gould |
| Worn interior wall surfaces of a sand casting flask cope or drag frame are resurfaced by covering the surface with thin, metal liner plates. The liner plates are bolted to the flask walls by bolts that extend through bolt holes in the liner plates and walls. The bolt holes through the plates are provided with deep countersinks for receiving the bolt heads and spacing the bolt heads beneath the exposed inner faces of the plates. Molten weld material is applied in such spaces for welding the bolts to the plates. A thin, hard coating of metal, such as chrome plating, is applied over the liner plate inner face and exposed weld material at the countersinks. Thereafter, the liner plate is removably fastened upon the inner surfaces of the flask frame by extending the bolts through the bolt holes in the frame wall and securing them in place with suitable nuts. | ||||||
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