Patents by Inventor Douglas J. Arrell

Douglas J. Arrell 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: 10247010
    Abstract: A turbine component includes an airfoil-shaped core having an outer peripheral surface. A plurality of channels is formed in the core, each opening to the outer peripheral surface. The channels extend substantially radially to be elongated in the radial direction. A first platform is attached to the core. The component also includes an airfoil-shaped non-permeable skin having a hollow interior, an inner peripheral surface and an outer peripheral surface. The skin is sized so that the core can be received in the hollow interior of the skin. A second platform is attached to the skin. The core is received in the hollow interior of the skin such that the outer peripheral surface of the core engages the inner peripheral surface of the skin such that a plurality of generally radial cooling channels are formed between the channels in the core and the inner peripheral surface of the skin.
    Type: Grant
    Filed: April 29, 2015
    Date of Patent: April 2, 2019
    Assignee: SIEMENS ENERGY, INC.
    Inventors: Douglas J. Arrell, Stefan Mazzola
  • Publication number: 20150247410
    Abstract: A turbine component includes an airfoil-shaped core having an outer peripheral surface. A plurality of channels is formed in the core, each opening to the outer peripheral surface. The channels extend substantially radially to be elongated in the radial direction. A first platform is attached to the core. The component also includes an airfoil-shaped non-permeable skin having a hollow interior, an inner peripheral surface and an outer peripheral surface. The skin is sized so that the core can be received in the hollow interior of the skin. A second platform is attached to the skin. The core is received in the hollow interior of the skin such that the outer peripheral surface of the core engages the inner peripheral surface of the skin such that a plurality of generally radial cooling channels are formed between the channels in the core and the inner peripheral surface of the skin.
    Type: Application
    Filed: April 29, 2015
    Publication date: September 3, 2015
    Inventors: Douglas J. Arrell, Stefan Mazzola
  • Patent number: 8846206
    Abstract: An intermediate component includes a first wall member, a leachable material layer, and a precursor wall member. The first wall member has an outer surface and first connecting structure. The leachable material layer is provided on the first wall member outer surface. The precursor wall member is formed adjacent to the leachable material layer from a metal powder mixed with a binder material, and includes second connecting structure.
    Type: Grant
    Filed: July 31, 2008
    Date of Patent: September 30, 2014
    Assignee: Siemens Energy, Inc.
    Inventors: Allister W. James, Douglas J. Arrell
  • Patent number: 8815371
    Abstract: A coated substrate with a subsurface cooling channel having no corner disposed proximate a seam between the substrate and the coating. A method for forming such a structure, including forming a groove in a surface of a substrate, forming a preform having a cooperating portion and a protruding portion, inserting the cooperating portion of the preform into the groove, leaving the protruding portion of the preform protruding beyond the surface of the substrate, applying a layer of a coating material to the surface of the substrate and the protruding portion of the perform, and removing the preform, thereby creating a cooling channel.
    Type: Grant
    Filed: April 8, 2009
    Date of Patent: August 26, 2014
    Assignee: Siemens Energy, Inc.
    Inventors: Douglas J. Arrell, Allister W. James, Anand A. Kulkarni
  • Patent number: 8459951
    Abstract: A rotor for an axial flow turbomachine is provided. The rotor includes a plurality of rotor discs that are arranged in stacks and clamped together with at least one tie rod. At least one of the rotor discs of the rotor comprises a smaller outer diameter than one of the neighboring rotor discs and that the difference in diameter is compensated by a drum surrounding the rotor disc with the smaller outer diameter as a ring. The drum may be made of a heat resistant material. The rotor discs surrounded by the drum may be made of a less expensive material. Furthermore, the drum may include at least one more blade ring than the rotor discs that are surrounded by the drum.
    Type: Grant
    Filed: August 8, 2008
    Date of Patent: June 11, 2013
    Assignee: Siemens Aktiengesellschaft
    Inventors: Douglas J. Arrell, Harald Hoell, David W. Hunt, Karsten Kolk, Harald Nimptsch
  • Patent number: 8132325
    Abstract: A method of forming a rotor for a turbine engine such that the rotor is formed of two materials including: an inner disk formed from a first material, such as steel, and an outer ring formed from a second material, such as a nickel alloy, having a larger thermal expansion coefficient than the first material forming the inner disk. The ring may include an inner aperture having a conical shape, and the disk may have an outer surface with a conical shape and a diameter with a portion that is larger than a portion of the ring. The ring may be heated such that the aperture expands to a size greater than the largest diameter of the inner disk. The ring may be positioned over the disk and allowed to cool to allow the ring to be attached to the disk. The ring and disk may then be co-forged.
    Type: Grant
    Filed: April 10, 2007
    Date of Patent: March 13, 2012
    Assignee: Siemens Energy, Inc.
    Inventors: Douglas J. Arrell, Allister W. James
  • Patent number: 8096751
    Abstract: A component for use in a turbine engine including a first member and a second member associated with the first member. The second member includes a plurality of connecting elements extending therefrom. The connecting elements include securing portions at ends thereof that are received in corresponding cavities formed in the first member to attach the second member to the first member. The connecting elements are constructed to space apart a first surface of the second member from a first surface of the first member such that at least one cooling passage is formed between adjacent connecting elements and the first surface of the second member and the first surface of the first member.
    Type: Grant
    Filed: July 31, 2008
    Date of Patent: January 17, 2012
    Assignee: Siemens Energy, Inc.
    Inventors: Douglas J. Arrell, Allister W. James
  • Publication number: 20110318184
    Abstract: A rotor for an axial flow turbomachine is provided. The rotor includes a plurality of rotor discs that are arranged in stacks and clamped together with at least one tie rod. At least one of the rotor discs of the rotor comprises a smaller outer diameter than one of the neighboring rotor discs and that the difference in diameter is compensated by a drum surrounding the rotor disc with the smaller outer diameter as a ring. The drum may be made of a heat resistant material. The rotor discs surrounded by the drum may be made of a less expensive material. Furthermore, the drum may include at least one more blade ring than the rotor discs that are surrounded by the drum.
    Type: Application
    Filed: August 8, 2008
    Publication date: December 29, 2011
    Inventors: Douglas J. Arrell, Harald Hoell, David W. Hunt, Karsten Kolk, Harald Nimptsch
  • Patent number: 8043717
    Abstract: A combustion turbine component (10) includes a combustion turbine component substrate (16) and an alloy coating (14) on the combustion turbine component substrate. The alloy coating (14) includes a first amount, by weight percent, of cobalt (Co) and a second amount, by weight percent, of nickel (Ni), the first amount being greater than the second amount. The alloy coating further includes chromium (Cr), aluminum (Al), at least one rare earth element, and an oxide of the at least one rare earth element.
    Type: Grant
    Filed: August 20, 2008
    Date of Patent: October 25, 2011
    Assignee: Siemens Energy, Inc.
    Inventors: Anand A. Kulkarni, Allister W. James, Douglas J. Arrell
  • Patent number: 8042268
    Abstract: A method for making a gas turbine component (100). A central core (20) is positioned to occupy a space that will define a central channel (42), and an outer channel core (30) is positioned spaced apart from the central core (20). A mold (35) is formed around the central core (20) and the outer channel core (30), so that an exterior wall (32) contacts the mold (35). A substrate material, such as a metal alloy (247) in liquid form, is added to the mold (35) to form an internal volume (41) of the component (100). The central core (20) and the outer channel core (30) are removed, and interconnect channels (44) are formed between the thus-formed central channel (42) and the inner portion (49) of the outer channel (62) thus far formed. A preform (55) is placed into the inner portion (49) and may have a desired outer surface (57) shape. An overlay material is applied to form an outer layer (60), thus defining the remainder of the outer channel (62), which is obtained upon removal of the preform (55).
    Type: Grant
    Filed: March 21, 2008
    Date of Patent: October 25, 2011
    Assignee: Siemens Energy, Inc.
    Inventors: Douglas J. Arrell, Allister W. James, Anand A. Kulkarni
  • Patent number: 8043718
    Abstract: A combustion turbine component (10) includes a combustion turbine component substrate (16) and an alloy coating (14) on the combustion turbine component substrate. The alloy coating (14) includes nickel (Ni), chromium (Cr), aluminum (Al), and yttrium (Y). Furthermore, the alloy coating includes at least one of titanium (Ti), tantalum (Ta), tungsten (W), and rhenium (Re). The alloy coating also includes at least one rare earth element, and an oxide of at least one of the yttrium (Y) and the at least one rare earth element.
    Type: Grant
    Filed: August 20, 2008
    Date of Patent: October 25, 2011
    Assignee: Siemens Energy, Inc.
    Inventors: Anand A. Kulkarni, Allister W. James, Douglas J. Arrell
  • Patent number: 8039117
    Abstract: A combustion turbine component (10) includes a combustion turbine component substrate (16) and an alloy coating (14) on the combustion turbine component substrate. The alloy coating (14) includes a first amount, by weight percent, of nickel (Ni) and a second amount, by weight percent, of cobalt (Co), the first amount being greater than the second amount. The alloy coating also includes chromium (Cr), aluminum (Al), and yttrium (Y). The alloy coating further includes at least one of titanium (Ti), tantalum (Ta), tungsten (W), and rhenium (Re). Moreover, the alloy coating includes at least one rare earth element, and an oxide of at least one of the yttrium the at least one rare earth element.
    Type: Grant
    Filed: August 20, 2008
    Date of Patent: October 18, 2011
    Assignee: Siemens Energy, Inc.
    Inventors: Anand A. Kulkarni, Allister W. James, Douglas J. Arrell
  • Patent number: 8029596
    Abstract: A method of manufacturing a metallic component includes atomizing, in an inert atmosphere, a metallic liquid having at least one rare-earth element and at least one non rare-earth element to form a metallic powder. A series of heat treating steps are performed on the metallic powder. A first heat treating step is performed in an oxidizing atmosphere, and a second heat treating step is performed in an inert atmosphere. A third heat treating step is performed in a reducing atmosphere to form a metallic power having an increased proportion of rare-earth oxides compared to non rare-earth oxides. The metallic component is formed from the metallic powder having the increased proportion of rare-earth oxides compared to non rare-earth oxides.
    Type: Grant
    Filed: August 19, 2008
    Date of Patent: October 4, 2011
    Assignee: Siemens Energy, Inc.
    Inventors: Douglas J. Arrell, Allister W. James, Anand A. Kulkarni
  • Patent number: 7968144
    Abstract: A system for forming a surface coating on an outer surface of a foam for use with cooling system of turbine engines. The system may include removing filler from the outer surface of the foam to expose a porous structure of the foam, whereby portions of the porous structure extend outwardly from a newly formed outer surface of the filler. A surface layer may be applied to the outer surface of the filler and exposed portions of the porous structure, whereby the surface layer is attached to the porous structure at least in part due to mechanical interaction with the portions of the porous structure extending outwardly from the newly formed outer surface of the filler. The filler material may then be removed from the porous structure.
    Type: Grant
    Filed: April 10, 2007
    Date of Patent: June 28, 2011
    Assignee: Siemens Energy, Inc.
    Inventors: Allister W. James, Douglas J. Arrell
  • Patent number: 7950146
    Abstract: A method of forming a rotor for a turbine engine such that the rotor is formed of two materials including: an outer ring formed from a first steel material, and a disk formed from a second material, such as a low alloy steel, having a larger thermal expansion coefficient than the first material forming the inner disk. The ring may include an inner aperture having a conical shape, and the disk may have an outer surface with a conical shape and a diameter with a portion that is larger than a portion of the ring. The ring may be heated such that the aperture expands to a size greater than the largest diameter of the inner disk. The ring may be positioned over the disk and allowed to cool to allow the ring to be attached to the disk. The ring and disk may then be co-forged.
    Type: Grant
    Filed: April 10, 2007
    Date of Patent: May 31, 2011
    Assignee: Siemens Energy, Inc.
    Inventors: Douglas J. Arrell, Allister W. James
  • Publication number: 20110110772
    Abstract: A turbine airfoil has an airfoil-shaped core and a skin extending about the outer peripheral surface of the core. The core and/or the skin are configured such that a plurality of cooling channels is formed between them. In one embodiment, the cooling channels are formed by a plurality of radially extending channels in the core. In another embodiment, the cooling channels are formed by providing a wave-shaped skin such that, when the skin is attached to the outer peripheral surface of the core, the cooling channels can be formed in the space between the outer peripheral surface of the core and each wave of the skin. Such airfoil constructions can allow the inclusion of different materials in the airfoil. Further, such constructions can allow greater flexibility in the formation of cooling channels. Moreover, such constructions can help to achieve thinner outer walls and near surface cooling of the airfoil.
    Type: Application
    Filed: November 11, 2009
    Publication date: May 12, 2011
    Inventors: Douglas J. Arrell, Stefan Mazzola
  • Patent number: 7905016
    Abstract: A turbine airfoil system for forming a turbine airfoil that is usable in a turbine engine. The airfoil may be formed from a porous material shaped into an outer airfoil shape. The porous material may include an inner central spar capable of supporting the turbine airfoil an outer porous region and an outer coating. The porous material facilitates efficient cooling of the turbine airfoil.
    Type: Grant
    Filed: April 10, 2007
    Date of Patent: March 15, 2011
    Assignee: Siemens Energy, Inc.
    Inventors: Allister W. James, Douglas J. Arrell
  • Patent number: 7867626
    Abstract: A combustion turbine component (10) includes a combustion turbine component substrate (16) and an alloy coating (14) on the combustion turbine component substrate. The alloy coating (14) includes iron (Fe), chromium (Cr), aluminum (Al), at least one of titanium (Ti) and molybdenum (Mo), at least one rare earth element, and an oxide of the at least one rare earth element.
    Type: Grant
    Filed: August 20, 2008
    Date of Patent: January 11, 2011
    Assignee: Siemens Energy, Inc.
    Inventors: Anand A. Kulkarni, Allister W. James, Douglas J. Arrell
  • Patent number: 7854809
    Abstract: A heat treatment process for a component of a turbine engine formed from multiple materials, such as steel and nickel. The heat treatment process includes two stages: a first stage for austinitizing the steel and solutioning the nickel, and a second stage for ageing and tempering the materials. The heat treatment process may include heating a component formed from a steel portion and a nickel portion such that the steel portion austinitizes and the nickel portion undergoes solutioning, cooling the component to prevent the excessive formation of gamma prime ({grave over (y)}), and subjecting the component to a temper heat treatment during which martensite tempering occurs.
    Type: Grant
    Filed: April 10, 2007
    Date of Patent: December 21, 2010
    Assignee: Siemens Energy, Inc.
    Inventors: Douglas J. Arrell, Allister W. James
  • Publication number: 20100278680
    Abstract: A method of making a combustion turbine component includes forming a metallic powder including at least one metal and at least one rare-earth element and processing the metallic powder including at least one metal and at least one rare-earth element to form a cohesive metallic mass. A primary aging heat treatment may be performed on the cohesive metallic mass. A homogenization heat treatment may be performed on the cohesive metallic mass prior to the primary aging heat treating. Furthermore, a secondary aging heat treatment may be performed on the cohesive metallic mass after the primary aging heat treating.
    Type: Application
    Filed: September 24, 2008
    Publication date: November 4, 2010
    Applicant: SIEMENS POWER GENERATION, INC.
    Inventors: Anand A. Kulkarni, Allister W. James, Douglas J. Arrell