Abstract: An investment casting pattern is formed by forming a metallic first core element including at least one recess. The first core element is engaged to at least a mating one of an element of the die and a second core element. The recess serves to retain the first core element relative to the mating one. The die is assembled and a sacrificial material is introduced to the die to at least partially embed the first core element. The recess may be pre-formed prior to cutting the first core element from a larger sheet of material.

Abstract: A sacrificial core is used for forming an interior space of a part and includes a ceramic core element and a first core element including a refractory metal element. The ceramic core element may be molded over the first core element or molded with assembly features permitting assembly with the first core element.

Abstract: To destructively remove a refractory metal casting core from a cast part the part is exposed to a combination of nitric acid and sulfuric acid.

Abstract: A thermal-oxidative process is used to remove a casting core from a cast part.

Abstract: Pre-molding of wax or similar sacrificial material over one or more cores facilitates a subsequent molding over a core assembly. Individual cores or groups thereof may be pre-molded in a wax body. One or more such wax bodies may be assembled with other bodies and/or other cores to facilitate a main wax molding of such assembly.

Abstract: A method for manufacturing a brush seal is provided including the steps of: (a) providing fiber; (b) providing a packing material; (c) providing a pair of backing plates; (d) arranging the fiber in a particular arrangement; (e) applying the packing material to selective areas of the arranged fiber; (f) cutting the fibers in bristle sections, wherein each of the bristle sections includes a plurality of bristles and one of the selective areas having applied packing material; (g) stacking the bristle sections, such that the selective areas of applied packing material are aligned between the backing plates; and (h) bonding the backing plates, the bristle sections, and the packing material together.

Abstract: In accordance with the present invention, a casting system is provided which broadly comprises a core and a wax die spaced from said core, a refractory metal core having a first end seated within a slot in the core and a second end contacting the wax die for positioning the core relative to the wax die, and the refractory metal core having at least one of a mechanism for providing spring loading when closed in the wax die and a mechanism for mechanically locking the wax die to the core.

Abstract: An investment casting pattern is formed by forming a metallic first core element including at least one recess. The first core element is engaged to at least a mating one of an element of the die and a second core element. The recess serves to retain the first core element relative to the mating one. The die is assembled and a sacrificial material is introduced to the die to at least partially embed the first core element. The recess may be pre-formed prior to cutting the first core element from a larger sheet of material.

Abstract: An at least two step heating process is used to strengthen the shell of an investment casting mold including a refractory metal core. The first stage may occur under otherwise oxidizing conditions at a low enough temperature to avoid substantial core oxidation. The second stage may occur under essentially non-oxidizing conditions at a higher temperature.

Abstract: A sacrificial core for forming an interior space of a part includes a ceramic core element and a first core element including a refractory metal element. The ceramic core element may be molded over the first core element or molded with assembly features permitting assembly with the first core element.

Abstract: A casting system for forming a gas turbine engine component is provided. The casting system, in a first embodiment, comprises a shaped refractory metal sheet having a plurality of features for forming a plurality of film cooling passages, which features are formed from refractory metal material bent out of the sheet. The casting system for forming a gas turbine engine component in a second embodiment comprises a metal wall having an airfoil shape and a refractory metal core adjacent the metal wall and having a shape corresponding to the shape of the metal wall.

Abstract: The present invention relates to a method for repairing components such as blades used in turbine engines. The method comprises the steps of placing a piece of refractory metal material over an area of the component to be repaired and depositing a repair filler metal material over the piece of refractory material in an amount sufficient to repair the component and welding the repair filler metal material in place. The refractory metal material may be selected from the group consisting of niobium, tantalum, molybdenum, tungsten, a metal having a melting point higher than the melting point of nickel, and alloys thereof and may be uncoated or coated.

Abstract: The present invention relates to a method for repairing components such as blades used in turbine engines. The method comprises the steps of placing a piece of refractory metal material over an area of the component to be repaired and depositing a repair filler metal material over the piece of refractory material in an amount sufficient to repair the component and welding the repair filler metal material in place. The refractory metal material may be selected from the group consisting of niobium, tantalum, molybdenum, tungsten, a metal having a melting point higher than the melting point of nickel, and alloys thereof and may be uncoated or coated.

Abstract: A tool with conformal cooling channels is made by diffusion bonding several tool sections together, which enables the cooling channels to be made in virtually any desired configuration. Once the desired configuration of the cooling channels is determined, a block of tool material in an annealed state is cut into layers. Grooves are formed in the surfaces of the layers or holes are formed through the layers such that the grooves and holes will form the cooling channels when the layers are reconstituted into the block. Indexing holes or equivalent structure fixedly locates adjacent layers when they are reconstituted, and the grooves and holes are precisely located relative to the indexing holes, thus ensuring that the grooves and holes in facing surfaces of the layers form the desired channels. The layers are then diffusion bonded by pressing them together at an elevated temperature.

Abstract: An elevator safety brake for stopping an elevator car is provided with a brake shoe having a molybdenum alloy friction surface for contacting an elevator guide rail surface to provide a stopping force. The molybdenum alloy contains 99.4 weight percent molybdenum, 0.5 weight percent titanium and 0.1 weight percent zirconium. The friction surface of the brake formed from the alloy exhibits a consistent high friction and low wear suitably accommodating high speed, high load elevators installed in very tall buildings.

Abstract: An elevator safety brake for stopping an elevator car is provided with a brake shoe having a carbon-carbon composite friction surface for contacting an elevator guide rail surface to provide a stopping force. The friction surface of the brake formed from the carbon-carbon composite exhibits a consistent high friction and low wear suitably accommodating high speed, high load elevators installed in very tall buildings.

Abstract: An elevator safety brake for stopping an elevator car is provided with a brake shoe having a fused sprayed friction coating for contacting an elevator guide rail surface to provide a stopping force. In a preferred embodiment, the coating is obtained by plasma spraying an admixture of 85 weight percent nickel-chromium alloy particles and 15 weight percent tungsten carbide particles on a substrate. The plasma sprayed admixture is fused. The fused sprayed friction surface of the brake exhibits a consistent high friction and low wear suitably accommodating high speed, high load elevators installed in very tall buildings.

Abstract: An elevator safety brake is provided comprising two cantilevers, a pivot, a spring, and a hold-off-engagement linkage. In one embodiment, the hold-off-engagement linkage is comprised of two upper struts, and two lower struts. When it is desired to slow or stop the elevator via the safety brake, the lower struts move from a first position in which the lower struts are substantially in alignment with one another and the cantilevers are in an open position, to a second position in which the lower struts are not substantially in alignment with one another and the cantilevers are in a closed position. When the cantilevers are in the closed position, the spring exerts a force via the cantilevers on the guide rail in order to decelerate the elevator.