Abstract:
The present disclosure generally relates to a sealed metal laminate structure comprising: a metal layer having a first surface and an opposite second surface; a first enamel layer laminated on the first surface of the metal layer, except at an exposed metal protrusion at a perimeter edge of the sealed metal laminate structure; a second enamel layer laminated on the second surface of the metal layer, except at the exposed metal protrusion at the perimeter edge of the sealed laminate structure; and a phosphate sealer deposited on the exposed metal protrusion of the sealed metal laminate structure. The present disclosure also relates to a metal laminate structure without a phosphate sealer. In addition, systems and methods for treating workpieces, including metal laminate structures, are discussed.
Abstract:
An electrical discharge machining (EDM) system according to embodiments includes: a guide structure; a plurality of electrode devices positioned at least partially within the guide structure, the plurality of electrode devices aligned to provide a plurality of electrical discharges to a workpiece, each of the plurality of electrode devices including: an electrode for positioning proximate the workpiece; an electrode holder coupled to the electrode for holding the electrode proximate the workpiece; and a driver coupled to the electrode holder, the driver adapted to modify a position of the electrode holder and the electrode; and a control system operably connected with the driver, the control system configured to provide instructions to the driver of at least one of the plurality of electrode devices to modify a position of the at least one of the plurality of electrodes independently of at least one other one of the plurality of electrodes.
Abstract:
Systems and methods for controlled and precise EDM manufacturing of a component are disclosed. In one embodiment, a system includes: a tank for holding a fluid; a first electrode array in the tank, the first electrode array including a plurality of electrodes configured to shape a workpiece; a workpiece fixture for positioning the workpiece at least partially immersed in the fluid and proximate the first electrode array; a pulse generator for creating an electric discharge between the workpiece and the first electrode array to remove material from the workpiece; a gap sensing circuit communicatively connected to the workpiece and the first electrode array, the gap sensing circuit configured to monitor the electric discharge between the workpiece and the first electrode array; and a computing device communicatively connected to the gap sensing circuit and the workpiece fixture, the computing device manipulating a position of the workpiece in the tank relative the first electrode array based upon data obtained from the gap sensing circuit.
Abstract:
A seal assembly between a rotor and a stator is disclosed. In one embodiment, the seal assembly includes: a rotor; a stator positioned around the rotor; and a plurality of seal leaves positioned between the rotor and the stator, the plurality of seal leaves circumferentially stacked around the rotor to define a seal ring between the rotor and the stator, wherein gaps between adjacent seal leaves are partially filled, such that contact faces and residual gaps are between adjacent seal leaves, wherein the contact faces generate friction to dampen vibrations during operation. Such damping effects still allow the compliant motion of the seal leaves with minimal leaf vibration. Also, thicker and more resilient leaves may be applied with reduced leakage through the root gaps.
Abstract:
Tool electrodes for and methods of electrical discharge machining are provided. In one exemplary aspect, a tool electrode for machining features into a workpiece is provided that allows for increased machining speed without sacrificing the quality of the machined features. Moreover, a tool electrode is provided that eliminates or reduces the high cost associated with customized tool electrodes. In particular, a tool electrode is provided that includes a plurality of electrode elements arranged and spaced apart in a digitized matrix representative of a tooling shape for machining features into a workpiece. The plurality of electrode elements are spaced apart from one another and arranged in the digitized matrix by digitizing an analog electrode tool configured to machine the feature into the workpiece or a volume of the feature to be machined into the workpiece.
Abstract:
Described herein a bucket for use in the last stage of a steam turbine engine. The bucket includes a titanium-based alloy having a leading edge wherein the leading edge includes titania having a plurality of pores and a top sealing layer filling the plurality of pores, the sealing layer selected from the group consisting of: chromium, cobalt, nickel, polyimide, polytetrafluoroethylene and polyester.
Abstract:
Tool electrodes for and methods of electrical discharge machining are provided. In one exemplary aspect, a tool electrode for machining features into a workpiece is provided that allows for increased machining speed without sacrificing the quality of the machined features. Moreover, a tool electrode is provided that eliminates or reduces the high cost associated with customized tool electrodes. In particular, a tool electrode is provided that includes a plurality of electrode elements arranged and spaced apart in a digitized matrix representative of a tooling shape for machining features into a workpiece. The plurality of electrode elements are spaced apart from one another and arranged in the digitized matrix by digitizing an analog electrode tool configured to machine the feature into the workpiece or a volume of the feature to be machined into the workpiece.
Abstract:
Electrodes for and methods of electrical discharge machining are provided. For example, a method for forming a feature in a ceramic matrix composite (CMC) component comprises repeatedly advancing an electrode into and retracting the electrode from the CMC component until a desired depth is reached, where the electrode has a head end, a tip end, and a shaft extending from the head end to the tip end. The shaft has a first side and a second side each recessed inward such that the head end and the tip end are wider than the shaft. A method for forming a feature in a CMC component also may include feeding a dielectric fluid into the feature utilizing the recessed sides. In some embodiments, electrodes may include a shaft extending from a head end to a tip end and a central plane, where the shaft is recessed widthwise toward the central plane.
Abstract:
Provided are a manufacturing system and a method for fabricating a component. The manufacturing system includes a wire delivery assembly arranged and disposed to deliver a wire feed to a fabrication assembly arrangement; the fabrication assembly arrangement includes a wire manipulation assembly, the wire manipulation assembly being arranged and disposed to convert the wire feed into a wire segment and position the wire segment on a workpiece positioner to form a workpiece stack; an energy beam source assembly arranged and disposed to direct one or more energy beams toward one or more aligned surfaces of adjacent wire segments within the workpiece stack, to weld the wire segments together. The method includes delivering a wire feed to a fabrication assembly; cutting and positioning a wire segment; and directing an energy beam toward one or more aligned surfaces of adjacent wire segments to weld the wire segments together.
Abstract:
Methods of Electrical Discharge Machining (EDM) ceramic components are provided. In one aspect, a method includes electrical discharge machining a ceramic component, such as a Ceramic Matrix Composite (CMC) component. The ceramic component is electrical discharge machined while a contact matrix is positioned so that electrically conductive compliant and pressurized contacts of the contact matrix engage the ceramic component and so that an electrically conductive member of the contact matrix is in electrical conduction to a grounding structure.