Abstract: The present disclosure relates to composite airfoils bonded to a metallic root. A composite body (510) may be formed with a metallic co-molded detail (520). The co-molded detail (520) may be transient liquid phase (TLP) bonded to an attachment feature (530). The attachment feature (530) may allow the composite body (510) to be attached to a rotor (200). The airfoil (500) may also have a metallic edge (550) which is TLP bonded to the composite body (510) via a co-molded edge (540).

Abstract: The disclosure provides downhole tools with shaft regions that are hardened by a compressive residual stress created when an allotropic material in a precursor region transforms from a first allotrope to a second allotrope in response to heat, while continuing to occupy the same physical space. The disclosure further provides methods of forming such downhole tools.

Abstract: The disclosure provides rotary drill bits with bit head regions or other downhole tools with regions in which an allotropic material in a precursor region has been transformed from a first allotrope to a second allotrope in response to a trigger. The disclosure further provides methods of forming such downhole tools and methods of triggering an allotropic phase transformation during their use.

Abstract: A drill bit having reinforced binder zones and method of forming same are disclosed. The method includes the steps of mixing reinforcing particles with a binder-reinforcing material, placing the mixture of reinforcing particles and binder-reinforcing material in a mold used in forming a body of the drill bit, placing a universal binder in the mold, and heating the mold. The binder-reinforcing material is infiltrated with the universal binder which thereby forms reinforced binder zones.

Abstract: Drill bits and associated methods of manufacture and use employ a pre-diffused mandrel bonded to a composite metal-matrix material. The pre-diffused mandrel includes a chemically altered surface composition that enhances the bond with the composite metal-matrix component formed by infiltrating a metal-matrix component with a binder. The chemically altered surface may be configured to reduce binder-rich zones adjacent the mandrel, mechanically interlock the with the composite metal-matrix component or prevent the formation of brittle intermetallic particles along the bond.

Abstract: A means for attaching a metallic component to a non-metallic component using a compliant material having thermal properties intermediate those of the metallic component to a non-metallic component is provided. The method can accommodate CTE mismatches and wear-type problems common to many assemblies of dissimilar materials. In particular, the method provides a sufficient wear surface to accommodate relative motion and provide a durable wear surface that does not excessively wear/gall/mico-weld itself together and provides the necessary damping and motion for proper operation in aeronautical applications.

Abstract: An example insulation enclosure includes a support structure having a top end, a bottom end, and an opening defined at the bottom end for receiving a mold within an interior of the support structure, and a thermal mass arranged at the top end of the support structure to thermally communicate with a top of the mold and resist heat flow from the top of the mold in an axial direction.

Abstract: An example system for fabricating an infiltrated downhole tool includes a mold assembly having one or more component parts and defining an infiltration chamber to receive and contain matrix reinforcement materials and a binder material used to form the infiltrated downhole tool. One or more thermal conduits are positioned within the one or more component parts for circulating a thermal fluid through at least one of the one or more component parts and thereby placing the thermal fluid in thermal communication with the infiltration chamber.

Abstract: An example insulation enclosure for cooling a mold includes a support structure having a top end, a bottom end, and an interior, the bottom end defining an opening for receiving a mold within the interior of the support structure, and insulation material supported by the support structure and extending at least from the bottom end to the top end, wherein one or more thermal properties of at least one of the support structure and the insulation material varies longitudinally from the bottom end to the top end. In some cases, the one or more thermal properties are further varied about a circumference of the support structure.

Abstract: An example insulation enclosure includes an outer shell having an open end and a top end, and an inner shell arranged within the outer shell and including a plurality of sidewall members and a top member. Each sidewall member is independently moveable relative to one another and to the top member, and the plurality of sidewall members and the top member each include a support member and insulation material positioned on the support member. One or more compliant devices arranged between the outer shell and at least one of the plurality of sidewall members and the top member, the one or more compliant devices biasing the at least one of the plurality of sidewall members and the top member against adjacent outer surfaces of a mold disposable within the inner shell.

Abstract: An example insulation enclosure includes a support structure having at least an inner frame and providing a top end, a bottom end, and an opening defined in the bottom end for receiving a mold within an interior of the support structure, and a radiant barrier positioned within the interior of the support structure, the radiant barrier including a front surface arranged to face the mold and a back surface facing the support structure, wherein the radiant barrier interposes the mold and the support structure to redirect thermal energy radiated from the mold back towards the mold.

Abstract: A method for forming localized binder in a drilling tool is disclosed. A method includes placing a reinforcement material in a matrix bit body mold, placing a localized binder material within the reinforcement material at a selected location in the matrix bit body mold, wherein the localized binder material confers a selected physical property at the selected location, placing a universal binder material in the matrix bit body mold on top of the reinforcement material, heating the matrix bit body mold, the reinforcement material, the localized binder material, and the universal binder material to a temperature above the melting point of the universal binder material, infiltrating the reinforcement material and the localized binder material with the universal binder material, and cooling the matrix bit body mold, the reinforcement material, the localized binder material, and the universal binder material to form a matrix drill bit body.

Abstract: In accordance with embodiments of the present disclosure, systems and methods for manufacturing a macroscopically reinforced metal-matrix composite (MMC) fixed-cutter bit are provided. The reinforced drill bit may include a bit body constructed from an infiltrated MMC material and featuring several blade portions extending radially outward and downward from a shank of the drill bit. These blade portions are designed for contacting a subterranean formation. The drill bit also includes the shank, which is coupled to an end of the bit body opposite the blade portions, to connect the bit body to an upstream component of a drill string. The drill bit further includes a number of macroscopic bit reinforcements that are at least partially enclosed within the bit body. These bit reinforcements are each disposed in and aligned substantially with a corresponding blade portion of the bit body.

Abstract: A plated tubular lattice structure is described. The plated tubular lattice structure may comprise a backbone structure which may include a plurality of axial posts and a plurality of pyramidal structures extending laterally from the axial posts and connecting the axial posts at nodes. The plated tubular lattice structure may further comprise a metal plating layer plated on an outer surface of the backbone structure.

Abstract: A metal matrix composite tool includes a body having hard composite portion that includes reinforcing particles dispersed in a binder material. At least some of the reinforcing particles comprise a monolithic particle structure including a core having irregular outer surface features integral with the core.

Abstract: An example mold assembly system includes a mold assembly including a mold forming a bottom of the mold assembly, a funnel operatively coupled to the mold, and an infiltration chamber defined at least partially by the mold and the funnel, the infiltration chamber being used for forming an infiltrated downhole tool. A mold assembly cap is positionable on the mold assembly and including a sidewall extendable about an outer periphery of the mold assembly at least partially along a height of the mold assembly. The sidewall exhibits a horizontal cross-sectional shape that accommodates a shape of the mold assembly and the sidewall is made of a thermal material that promotes directional solidification of the infiltrated downhole tool during fabrication.

Abstract: A method for joining engine components includes positioning a first plurality of thermal protection structures across a thermal protection space between a first thermal protection surface and a second thermal protection surface. The first and second engine components are locally joined by forming a first plurality of transient liquid phase (TLP) or partial transient liquid phase (PTLP) bonds along corresponding ones of the first plurality of thermal protection structures between the first thermal protection surface and the second thermal protection surface. The second thermal protection surface is formed from a second surface material different from a first surface material of the first thermal protection surface.

Abstract: Tools, for example, fixed cutter drill bits, may be manufactured to include hard composite portions having reinforcing particles dispersed in a continuous binder phase and auxiliary portions that are more machinable than the hard composite portions. For example, a tool may include a hard composite portion having a machinability rating 0.2 or less; and an auxiliary portion having a machinability rating of 0.6 or greater in contact with the hard composite portion. The boundary or interface between the hard composite portion and the auxiliary portion may be designed so that upon removal of the most or all of the auxiliary portion the resultant tool has a desired geometry without having to machine the hard composite portion.

Abstract: A component comprises a non-metallic core having an outer surface, a first catalyst deposited onto at least a first portion of the outer surface of the non-metallic core, a second catalyst deposited onto at least a second portion of the outer surface of the non-metallic core, an electrical interface, and a metallic coating. The electrical interface is plated onto the first catalyst, and includes a first interface layer electroless plated onto the first catalyst. The metallic coating is plated onto the second catalyst.

Abstract: An example insulation enclosure includes a support structure having a top end, a top wall provided at the top end, a bottom end, and an opening defined at the bottom end for receiving a mold within an interior of the support structure. Rigid insulation material may be supported by the support structure and extending between the top and bottom ends and across the top end. The rigid insulation material may extend between the top and bottom ends and consist of one or more sidewall insulation loops that extend along a circumference of the insulation enclosure.