Metal fusion bonding – Process – Diffusion type
Reexamination Certificate
1999-04-28
2001-06-19
Dunn, Tom (Department: 1725)
Metal fusion bonding
Process
Diffusion type
C228S262100, C029S889200, C029S889230, C029S889700, C029S469000
Reexamination Certificate
active
06247638
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates generally to the design and fabrication of a ring or disk comprising select regions reinforced with metal matrix composite (MMC) material. More particularly, the present invention has one form defined by a method of making an internally reinforced metal matrix composite thrust disk for use in an electromagnetic thrust bearing. The selectively reinforced regions of the thrust disk contain a high strength iron cobalt metal matrix composite material. Although the present invention was developed for use in gas turbine engines, certain applications may be outside this field.
It is well known that a gas turbine engine integrates a compressor and a turbine having components that rotate at extremely high speeds in a high temperature environment. One component is a rotor disk that carries a plurality of airfoils utilized to influence the gaseous flow within the engine. The rotating components typically cooperate with a rotatable shaft and are supported by radial bearings and a thrust bearing that must withstand significant dynamic and static loads within a hostile environment. During operation of the gas turbine engine, the bearings are subjected to forces including: shock loads, such as from landings; maneuver loads, such as associated with sudden change in direction; and, centrifugal loads attendant with the mass of the rotating components.
The desire to increase efficiency and power output from gas turbine engines has caused many engine designers to consider the application of magnetic bearings for supporting the rotor and rotatable shaft. The integration of magnetic bearings into an engine will enable the rotor and rotatable shaft to be supported by magnetic forces, eliminate frictional forces, eliminate mechanical wear and allow the removal of the lubrication system.
Magnetic thrust bearings include a magnetic flux field and a rotatable thrust disk that is acted upon by the magnetic flux field. The application of magnetic thrust bearings in flight weight gas turbine engines require compactactness of bearing design, which ultimately equates to lighter weight. Prior designers of gas turbine engines have utilized materials for the rotating thrust disk that experience a loss of mechanical properties at elevated temperatures. This loss of mechanical properties limits the maximum rotational speed that the thrust disk can be operated at, thereby effectively limiting the maximum rotational speed of the engine.
Heretofore, there has been a need for a method of producing a ring or disk internally reinforced with metal matrix composite materials. The present invention satisfies this need in a novel and unobvious way.
SUMMARY OF THE INVENTION
One form of the present invention contemplates a method of making a selectively reinforced member.
Another form of the present invention contemplates a member having a composite reinforcement therein.
Yet another form of the present invention contemplates an apparatus, comprising: a metallic first member having a space defined therein; a metallic second member coupled to the first member and enclosing the space; a pair of metallic third members positioned within the space; and a composite first reinforcing member positioned between and abutting the pair of third members.
Yet another form of the present invention contemplates a method, comprising: providing a monolithic first member having a space defined therein, a monolithic cap, a pair of monolithic second members, and a composite reinforcing third member; forming a pre-assembly by positioning the reinforced composite third member between the pair of monolithic second members within the space in the first member; positioning the cap adjacent the first member so as to enclose the space within the first member; evacuating the space within the first member and forming a fluid tight enclosure around the space; and joining the monolithic components together.
On aspect of the present invention contemplates an apparatus, comprising: a metallic first member having a space defined therein; a second metallic member coupled to the first member and enclosing the space; and an unconsolidated composite reinforcing third member positioned within the space, the composite reinforcing third member comprising an elongated high strength member portion and a metallic portion.
Another aspect of the present invention contemplates an apparatus, comprising: a structure formed of a metallic material; and a plurality of spaced composite reinforcing members positioned within the structure, each of the plurality of composite reinforcing members including a plurality of high strength fibers and a matrix holding the plurality of fibers together, the matrix is defined by the metallic material and is metallurgically bonded to the structure.
Yet another aspect of the present invention contemplates a method, comprising: providing a first metallic member having a space defined therein, a second metallic member, and an unconsolidated metallic composite reinforcing member including a plurality of fibers; placing the unconsolidated metallic composite reinforcing member within the space; positioning the second member against the first member to enclose the space after the placing to define an assembly, evacuating the space within the first member; forming a fluid tight enclosure around the space; and subjecting the assembly to a hot isostatic pressing process to consolidate the composite reinforcing member and metallurgically bond the first and second members and the composite reinforcing member together.
One object of the present invention is to provide a unique method for producing an internally reinforced member.
Related objects and advantages of the present invention will be apparent from the following description.
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Allison Advanced Development Company
Cooke Colleen
Dunn Tom
Woodard Emhardt Naughton Moriarty & McNett
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