Patents by Inventor Don Mittendorf

Don Mittendorf has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 10669617
    Abstract: Methods for processing bonded dual alloy rotors are provided. In one embodiment, the method includes obtaining a bonded dual alloy rotor including rotor blades bonded to a hub disk. The rotor blades and hub disk are composed of different alloys. A minimum processing temperature (TDISK_PROCESS_MIN) for the hub disk and a maximum critical temperature for the rotor blades (TBLADE_MAX) is established such that TBLADE_MAX is less than TDIsK_PROCESS_MIN. A differential heat treatment process is then performed during which the hub disk is heated to processing temperatures equal to or greater than TDISK_PROCESS_MIN, while at least a volumetric majority of each of the rotor blades is maintained at temperatures below TBLADE_MAX. Such a targeted differential heat treatment process enables desired metallurgical properties (e.g., precipitate hardening) to be created within the hub disk, while preserving the high temperature properties of the rotor blades and any blade coating present thereon.
    Type: Grant
    Filed: August 1, 2019
    Date of Patent: June 2, 2020
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Christopher David Gatto, Jude Miller, Benjamin Dosland Kamrath, Don Mittendorf, Jason Smoke, Mark C. Morris
  • Publication number: 20200140983
    Abstract: Methods for processing bonded dual alloy rotors are provided. In one embodiment, the method includes obtaining a bonded dual alloy rotor including rotor blades bonded to a hub disk. The rotor blades and hub disk are composed of different alloys. A minimum processing temperature (TDISK_PROCESS_MIN) for the hub disk and a maximum critical temperature for the rotor blades (TBLADE_MAX) is established such that TBLADE_MAX is less than TDISK_PROCESS_MIN. A differential heat treatment process is then performed during which the hub disk is heated to processing temperatures equal to or greater than TDISK_PROCESS_MIN, while at least a volumetric majority of each of the rotor blades is maintained at temperatures below TBLADE_MAX. Such a targeted differential heat treatment process enables desired metallurgical properties (e.g., precipitate hardening) to be created within the hub disk, while preserving the high temperature properties of the rotor blades and any blade coating present thereon.
    Type: Application
    Filed: August 1, 2019
    Publication date: May 7, 2020
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Christopher David Gatto, Jude Miller, Benjamin Dosland Kamrath, Don Mittendorf, Jason Smoke, Mark C. Morris
  • Publication number: 20200078867
    Abstract: A method of forming an abrasive nickel-based alloy on a turbine blade tip includes producing or obtaining a metal powder that is mixed with a carbon powder to form a carbon-enriched metal powder. The metal powder includes a refractory element. The method further includes bonding the carbon-enriched metal powder to the turbine blade tip. The step of bonding includes raising the temperature of the carbon-enriched metal powder past its melting point, thereby causing the carbon to combine with the refractory elements to form abrasive carbide particles.
    Type: Application
    Filed: September 10, 2018
    Publication date: March 12, 2020
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Don Mittendorf, Vladimir K Tolpygo
  • Publication number: 20200040745
    Abstract: Cladding material is applied by laser to a net-shape. A method of cladding a host component includes installing the component in a fixture. A shroud component is located against the host component adjacent a select location for the cladding. Cladding is applied to the host component to the select location and adjacent to shroud component so that the shroud component defines an edge of the cladding as applied. The edge of the cladding as defined by the shroud component defines a desired cladding profile requiring no/approximately no post-cladding processing to remove over-cladded material.
    Type: Application
    Filed: August 1, 2018
    Publication date: February 6, 2020
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Brent Ludwig, Don Mittendorf, David R. Waldman, Malak Fouad Malak
  • Publication number: 20200009646
    Abstract: A method of manufacturing a directionally solidified article of the present disclosure includes providing a collection of particulate material and additively manufacturing a first article with an outer wall from the particulate material. The outer wall defines at least part of a cavity. The cavity contains an amount of the particulate material. The method also includes encasing at least a portion of the first article with an outer member. The outer member defines an internal cavity that corresponds to the first article. The method further includes heating the outer member and the first article to melt the first article into a molten mass within the internal cavity of the outer member. Additionally, the method includes solidifying the molten mass along a predetermined solidification path within the outer member to form a second article that corresponds to at least a portion of the internal cavity of the outer member.
    Type: Application
    Filed: August 23, 2019
    Publication date: January 9, 2020
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Don Mittendorf, Tho X. Bui, Will Otaluka, Edwin Martinez, John Woodward, Yathiraj Kasal
  • Patent number: 10399176
    Abstract: Dual alloy turbine rotors and methods for manufacturing the same are provided. The dual alloy turbine rotor comprises an assembled blade ring and a hub bonded to the assembled blade ring. The assembled blade ring comprises a first alloy selected from the group consisting of a single crystal alloy, a directionally solidified alloy, or an equi-axed alloy. The hub comprises a second alloy. The method comprises positioning a hub within a blade ring to define an interface between the hub and the blade ring. The interface is a non-contacting interface or a contacting interface. The interface is enclosed by a pair of diaphragms. The interface is vacuum sealed. The blade ring is bonded to the hub after the vacuum sealing step.
    Type: Grant
    Filed: July 13, 2017
    Date of Patent: September 3, 2019
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Amandine Miner, David K. Jan, Don Mittendorf, Jason Smoke
  • Patent number: 10385433
    Abstract: Methods for processing bonded dual alloy rotors are provided. In one embodiment, the method includes obtaining a bonded dual alloy rotor including rotor blades bonded to a hub disk. The rotor blades and hub disk are composed of different alloys. A minimum processing temperature (TDISK_PROCESS_MIN) for the hub disk and a maximum critical temperature for the rotor blades (TBLADE_MAX) is established such that TBLADE_MAX is less than TDISK_PROCESS_MIN. A differential heat treatment process is then performed during which the hub disk is heated to processing temperatures equal to or greater than TDISK_PROCESS_MIN, while at least a volumetric majority of each of the rotor blades is maintained at temperatures below TBLADE_MAX. Such a targeted differential heat treatment process enables desired metallurgical properties (e.g., precipitate hardening) to be created within the hub disk, while preserving the high temperature properties of the rotor blades and any blade coating present thereon.
    Type: Grant
    Filed: March 16, 2016
    Date of Patent: August 20, 2019
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Christopher David Gatto, Jude Miller, Benjamin Dosland Kamrath, Don Mittendorf, Jason Smoke, Mark C. Morris
  • Patent number: 10036254
    Abstract: Dual alloy bladed rotors are provided, as are methods for manufacturing dual alloy bladed rotors. In one embodiment, the method includes arranging bladed pieces in a ring formation such that contiguous bladed pieces contact along shank-to-shank bonding interfaces. The ring formation is positioned around a hub disk, which is contacted by the bladed pieces along a shank-to-hub bonding interface. A metallic sealing material is deposited between contiguous bladed pieces utilizing, for example, a laser welding process to produce an annular seal around the ring formation. A hermetic cavity is then formed, which is circumferentially bounded by the annular seal and which encloses the shank-to-shank and shank-to-hub bonding interface. Afterwards, a Hot Isostatic Pressing process is performed during which the ring formation and the hub disk are exposed to elevated pressures external to the hermetic cavity sufficient to diffusion bond the shank-to-shank and shank-to-hub bonding interface.
    Type: Grant
    Filed: November 12, 2015
    Date of Patent: July 31, 2018
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Jason Smoke, David K. Jan, Don Mittendorf, Brent Ludwig, Amandine Miner, Deanna Pinar Chase
  • Patent number: 9951632
    Abstract: Hybrid bonded turbine rotors and methods for manufacturing the same are provided.
    Type: Grant
    Filed: July 23, 2015
    Date of Patent: April 24, 2018
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: David R Waldman, Don Mittendorf, Mark C. Morris, Michael Vinup
  • Patent number: 9914182
    Abstract: A method for transient liquid phase bonding two metallic substrate segments together including the steps of forming a joined component by bringing together the two substrate segments along a bond line with a brazing alloy comprising a melting point depressant disposed between the two segments at the bond line and performing a first thermal treatment including heating the joined component at a brazing temperature of the brazing alloy for a first period of time. The method further includes performing a second thermal treatment including heating the joined component at an intermediate temperature that is above the brazing temperature but below a gamma prime solvus temperature of the substrate segments for a second period of time and performing a third thermal treatment including heating the joined component at a super-solvus temperature that is above the gamma prime solvus temperature of the two metallic substrate segments for a third period of time.
    Type: Grant
    Filed: September 17, 2015
    Date of Patent: March 13, 2018
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Don Mittendorf, Christopher David Gatto, Leticia Lara, Megan Kemp, Andy Szuromi
  • Patent number: 9896943
    Abstract: Gas path components of gas turbine engines and methods for cooling the same using porous medium cooling systems are provided. The gas path component comprises a wall at least partially defining a cooling plenum and a porous medium cooling system. The wall includes a wall surface comprising a gas path surface and an opposing wall surface proximate the cooling plenum. The porous medium cooling system is disposed between the cooling plenum and the opposing wall surface. The porous medium cooling system comprises a perforated baffle and a porous material layer disposed between and adjacent the perforated baffle and the opposing wall surface. The wall includes a plurality of openings in fluid communication with the cooling plenum via the porous medium cooling system.
    Type: Grant
    Filed: May 12, 2014
    Date of Patent: February 20, 2018
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Lorenzo Crosatti, Shezan Kanjiyani, Don Mittendorf
  • Publication number: 20180036796
    Abstract: A method of manufacturing a directionally solidified article of the present disclosure includes providing a collection of particulate material and additively manufacturing a first article with an outer wall from the particulate material. The outer wall defines at least part of a cavity. The cavity contains an amount of the particulate material. The method also includes encasing at least a portion of the first article with an outer member. The outer member defines an internal cavity that corresponds to the first article. The method further includes heating the outer member and the first article to melt the first article into a molten mass within the internal cavity of the outer member. Additionally, the method includes solidifying the molten mass along a predetermined solidification path within the outer member to form a second article that corresponds to at least a portion of the internal cavity of the outer member.
    Type: Application
    Filed: August 8, 2016
    Publication date: February 8, 2018
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Don Mittendorf, Tho X. Bui, Will Otaluka, Edwin Martinez, John Woodward, Yathiraj Kasal
  • Publication number: 20170304929
    Abstract: Dual alloy turbine rotors and methods for manufacturing the same are provided. The dual alloy turbine rotor comprises an assembled blade ring and a hub bonded to the assembled blade ring. The assembled blade ring comprises a first alloy selected from the group consisting of a single crystal alloy, a directionally solidified alloy, or an equi-axed alloy. The hub comprises a second alloy. The method comprises positioning a hub within a blade ring to define an interface between the hub and the blade ring. The interface is a non-contacting interface or a contacting interface. The interface is enclosed by a pair of diaphragms. The interface is vacuum sealed. The blade ring is bonded to the hub after the vacuum sealing step.
    Type: Application
    Filed: July 13, 2017
    Publication date: October 26, 2017
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Amandine Miner, David K. Jan, Don Mittendorf, Jason Smoke
  • Publication number: 20170268089
    Abstract: Methods for processing bonded dual alloy rotors are provided. In one embodiment, the method includes obtaining a bonded dual alloy rotor including rotor blades bonded to a hub disk. The rotor blades and hub disk are composed of different alloys. A minimum processing temperature (TDISK_PROCESS_MIN) for the hub disk and a maximum critical temperature for the rotor blades (TBLADE_MAX) is established such that TBLADE_MAX is less than TDISK_PROCESS_MIN. A differential heat treatment process is then performed during which the hub disk is heated to processing temperatures equal to or greater than TDISK_PROCESS_MIN, while at least a volumetric majority of each of the rotor blades is maintained at temperatures below TBLADE_MAX. Such a targeted differential heat treatment process enables desired metallurgical properties (e.g., precipitate hardening) to be created within the hub disk, while preserving the high temperature properties of the rotor blades and any blade coating present thereon.
    Type: Application
    Filed: March 16, 2016
    Publication date: September 21, 2017
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Christopher David Gatto, Jude Miller, Benjamin Dosland Kamrath, Don Mittendorf, Jason Smoke, Mark C. Morris
  • Patent number: 9764384
    Abstract: Methods of forming dispersoid hardened metallic materials are provided. In an exemplary embodiment, a method of producing dispersoid hardened metallic materials includes forming a starting composition with a base metal component and a dispersoid forming component. The starting composition includes the base metal component in an amount from about 50 to about 99.999 weight percent and the dispersoid forming component in an amount from about 0.001 to about 1 weight percent, based on the total weight of the starting composition. A starting powder is formed from the starting composition, and the starting powder is fluidized with a fluidizing gas for a period of time sufficient to oxidize the dispersoid forming component to form the dispersoid hardened metallic material. The dispersoid forming component is oxidized while the starting powder is a solid.
    Type: Grant
    Filed: April 14, 2015
    Date of Patent: September 19, 2017
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Don Mittendorf, Vladimir K. Tolpygo
  • Patent number: 9724780
    Abstract: Dual alloy turbine rotors and methods for manufacturing the same are provided. The dual alloy turbine rotor comprises an assembled blade ring and a hub bonded to the assembled blade ring. The assembled blade ring comprises a first alloy selected from the group consisting of a single crystal alloy, a directionally solidified alloy, or an equi-axed alloy. The hub comprises a second alloy. The method comprises positioning a hub within a blade ring to define an interface between the hub and the blade ring. The interface is a non-contacting interface or a contacting interface. The interface is enclosed by a pair of diaphragms. The interface is vacuum sealed. The blade ring is bonded to the hub after the vacuum sealing step.
    Type: Grant
    Filed: June 5, 2014
    Date of Patent: August 8, 2017
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Amandine Miner, David K Jan, Don Mittendorf, Jason Smoke
  • Patent number: 9726022
    Abstract: Embodiments of an axially-split radial turbine, as are embodiments of a method for manufacturing an axially-split radial turbine. In one embodiment, the method includes the steps of joining a forward bladed ring to a forward disk to produce a forward turbine rotor, fabricating an aft turbine rotor, and disposing the forward turbine rotor and the aft turbine rotor in an axially-abutting, rotationally-fixed relationship to produce the axially-split radial turbine.
    Type: Grant
    Filed: May 15, 2015
    Date of Patent: August 8, 2017
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Don Mittendorf, David K. Jan, Jason Smoke, Amandine Miner
  • Patent number: 9702252
    Abstract: Embodiments of a turbine nozzle are provided, as are embodiments of methods for the manufacture of turbine nozzles. In one embodiment, the turbine nozzle includes a support ring and a slip joint ring, which is substantially concentric with the support ring and radially spaced apart therefrom. The slip joint ring has a plurality of slots therein. A plurality of vanes is fixedly coupled to the support ring and extends radially therefrom into the plurality of slots. A plurality of radial slip joints is formed between the plurality of vanes and the plurality slots. Each slip joint extends around a different one of the plurality of vanes to permit relative radial movement between the plurality of vanes and the slip joint ring during operation of the turbine nozzle.
    Type: Grant
    Filed: December 19, 2012
    Date of Patent: July 11, 2017
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Shezan Kanjiyani, Natalie Wali, Don Mittendorf, Lorenzo Crosatti
  • Publication number: 20170138206
    Abstract: Dual alloy bladed rotors are provided, as are methods for manufacturing dual alloy bladed rotors. In one embodiment, the method includes arranging bladed pieces in a ring formation such that contiguous bladed pieces contact along shank-to-shank bonding interfaces. The ring formation is positioned around a hub disk, which is contacted by the bladed pieces along a shank-to-hub bonding interface. A metallic sealing material is deposited between contiguous bladed pieces utilizing, for example, a laser welding process to produce an annular seal around the ring formation. A hermetic cavity is then formed, which is circumferentially bounded by the annular seal and which encloses the shank-to-shank and shank-to-hub bonding interface. Afterwards, a Hot Isostatic Pressing process is performed during which the ring formation and the hub disk are exposed to elevated pressures external to the hermetic cavity sufficient to diffusion bond the shank-to-shank and shank-to-hub bonding interface.
    Type: Application
    Filed: November 12, 2015
    Publication date: May 18, 2017
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Jason Smoke, David K. Jan, Don Mittendorf, Brent Ludwig, Amandine Miner, Deanna Pinar Chase
  • Publication number: 20170080521
    Abstract: A method for transient liquid phase bonding two metallic substrate segments together including the steps of forming a joined component by bringing together the two substrate segments along a bond line with a brazing alloy comprising a melting point depressant disposed between the two segments at the bond line and performing a first thermal treatment including heating the joined component at a brazing temperature of the brazing alloy for a first period of time. The method further includes performing a second thermal treatment including heating the joined component at an intermediate temperature that is above the brazing temperature but below a gamma prime solvus temperature of the substrate segments for a second period of time and performing a third thermal treatment including heating the joined component at a super-solvus temperature that is above the gamma prime solvus temperature of the two metallic substrate segments for a third period of time.
    Type: Application
    Filed: September 17, 2015
    Publication date: March 23, 2017
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Don Mittendorf, Christopher David Gatto, Leticia Lara, Megan Kemp, Andy Szuromi