Patents by Inventor Joshua Leigh Miller

Joshua Leigh Miller 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).

  • Publication number: 20210069777
    Abstract: Methods for creating a cast component, along with the resulting cast components, are provided. The method may provide for a controlled grain structure in the resulting cast component. The methods may include heating at least a first portion mold under controlled conditions, such as when the first portion of the mold is buried in a ceramic powder.
    Type: Application
    Filed: October 4, 2019
    Publication date: March 11, 2021
    Inventors: Brian David Przeslawski, Manuel Acosta, Douglas Gerard Konitzer, Joshua Leigh Miller, Adegboyega Masud Makinde
  • Publication number: 20200290117
    Abstract: Methods for creating a cast component, along with the resulting cast components, are provided. The method may include heating a mold having a cavity therein; supplying a first molten metal material into the cavity of the mold such that the first molten metal material is directed to a first portion of the cavity of the mold; supplying a second molten metal material into the cavity of the mold such that the second molten metal material is directed to a second portion of the cavity of the mold, wherein the first molten metal material is compositionally different than the second molten metal material; and thereafter, allowing the first molten metal material and the second molten metal material to form the cast component.
    Type: Application
    Filed: March 12, 2020
    Publication date: September 17, 2020
    Inventors: Douglas Gerard Konitzer, Brian David Przeslawski, Joshua Leigh Miller
  • Patent number: 10280486
    Abstract: A nickel-based superalloy composition includes from about 5 to about 7 wt % aluminum, from about 4 to about 8 wt % tantalum, from about 3 to about 8 wt % chromium, from about 3 to about 7 wt % tungsten, from 1 to about 5 wt % molybdenum, from 1.5 to about 5 wt % rhenium, from 5 to about 14 wt % cobalt, from about 0 to about 1 wt % hafnium, from about 0.01 to about 0.03 wt % carbon, from about 0.002 to about 0.006 wt % boron, and balance nickel and incidental impurities. The composition may exhibit a sustained peak low cycle fatigue life at 1800° F./45 ksi of at least about 4000 cycles. The nickel-based superalloy composition may be used in single-crystal or directionally solidified superalloy articles, such as a blade, nozzle, a shroud, a splash plate, and a combustor of a gas turbine engine.
    Type: Grant
    Filed: September 10, 2014
    Date of Patent: May 7, 2019
    Assignee: General Electric Company
    Inventors: Wei-Jun Zhang, Douglas Gerard Konitzer, Joshua Leigh Miller
  • Patent number: 8974656
    Abstract: A method for surface roughening a metal work piece includes disposing a region of the workpiece to be roughened proximate to a counter electrode. The region of the workpiece to be roughened and the counter electrode are subsequently disposed together in an electrolyte. An electric potential with current flow is applied between the work piece and the counter electrode to roughen the metal surface to a desired roughness.
    Type: Grant
    Filed: June 30, 2011
    Date of Patent: March 10, 2015
    Assignee: General Electric Company
    Inventors: Andrew Lee Trimmer, Bin Wei, Joshua Leigh Miller, Nicholas Joseph Kray, Michael Scott Lamphere
  • Publication number: 20140377125
    Abstract: A nickel-based superalloy composition includes from about 5 to about 7 wt % aluminum, from about 4 to about 8 wt % tantalum, from about 3 to about 8 wt % chromium, from about 3 to about 7 wt % tungsten, from 1 to about 5 wt % molybdenum, from 1.5 to about 5 wt % rhenium, from 5 to about 14 wt % cobalt, from about 0 to about 1 wt % hafnium, from about 0.01 to about 0.03 wt % carbon, from about 0.002 to about 0.006 wt % boron, and balance nickel and incidental impurities. The composition may exhibit a sustained peak low cycle fatigue life at 1800° F./45 ksi of at least about 4000 cycles. The nickel-based superalloy composition may be used in single-crystal or directionally solidified superalloy articles, such as a blade, nozzle, a shroud, a splash plate, and a combustor of a gas turbine engine.
    Type: Application
    Filed: September 10, 2014
    Publication date: December 25, 2014
    Inventors: Wei-Jun Zhang, Douglas Gerard Konitzer, JOSHUA LEIGH MILLER
  • Patent number: 8858876
    Abstract: A nickel-based superalloy composition includes from about 5 to about 7 wt % aluminum, from about 4 to about 8 wt % tantalum, from about 3 to about 8 wt % chromium, from about 3 to about 7 wt % tungsten, from 1 to about 5 wt % molybdenum, from 1.5 to about 5 wt % rhenium, from 5 to about 14 wt % cobalt, from about 0 to about 1 wt % hafnium, from about 0.01 to about 0.03 wt % carbon, from about 0.002 to about 0.006 wt % boron, and balance nickel and incidental impurities. The composition may exhibit a sustained peak low cycle fatigue life at 1800° F./45 ksi of at least about 4000 cycles. The nickel-based superalloy composition may be used in single-crystal or directionally solidified superalloy articles, such as a blade, nozzle, a shroud, a splash plate, and a combustor of a gas turbine engine.
    Type: Grant
    Filed: October 31, 2012
    Date of Patent: October 14, 2014
    Assignee: General Electric Company
    Inventors: Wei-Jun Zhang, Douglas Gerard Konitzer, Joshua Leigh Miller
  • Publication number: 20140119979
    Abstract: A nickel-based superalloy composition includes from about 5 to about 7 wt % aluminum, from about 4 to about 8 wt % tantalum, from about 3 to about 8 wt % chromium, from about 3 to about 7 wt % tungsten, from 1 to about 5 wt % molybdenum, from 1.5 to about 5 wt % rhenium, from 5 to about 14 wt % cobalt, from about 0 to about 1 wt % hafnium, from about 0.01 to about 0.03 wt % carbon, from about 0.002 to about 0.006 wt % boron, and balance nickel and incidental impurities. The composition may exhibit a sustained peak low cycle fatigue life at 1800° F./45 ksi of at least about 4000 cycles. The nickel-based superalloy composition may be used in single-crystal or directionally solidified superalloy articles, such as a blade, nozzle, a shroud, a splash plate, and a combustor of a gas turbine engine.
    Type: Application
    Filed: October 31, 2012
    Publication date: May 1, 2014
    Applicant: General Electric Company
    Inventors: Wei-Jun Zhang, Douglas Gerard Konitzer, Joshua Leigh Miller
  • Publication number: 20120021243
    Abstract: A metallic sheath for a mounting on a component is disclosed. The metallic sheath comprises a nose portion extending in a chordwise direction, a first side-wall extending in the chordwise direction from the nose portion and a second side-wall extending in the chordwise direction from the nose portion wherein the second side-wall is bonded to the nose portion such that the nose portion, the first side-wall and the second side-wall form a cavity capable of receiving a portion of the component.
    Type: Application
    Filed: July 14, 2011
    Publication date: January 26, 2012
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Nicholas Joseph KRAY, Joshua Leigh MILLER, Tod Winton DAVIS, Peter Christopher SCHUMACHER, John Robert KELLEY
  • Patent number: 8051565
    Abstract: A method of reducing crack propagation in an airfoil includes: providing an airfoil having a root spaced apart from a tip, spaced-apart leading and trailing edges, a suction side extending from the leading edge to the trailing edge, and an opposed pressure side extending from the leading edge and the trailing edge, supporting the airfoil against bending loads; and burnishing the airfoil using a burnishing element, so as to create at least one burnished section of residual compressive stress, the at least one burnished section being located adjacent the leading edge and spaced from the leading edge by an offset distance selected so as to avoid deformation of the leading edge.
    Type: Grant
    Filed: December 30, 2006
    Date of Patent: November 8, 2011
    Assignee: General Electric Company
    Inventors: Alberto Luna, Joshua Leigh Miller, William Terence Dingwell, Michael Jay Brunck, William Lee Imhoff, Paul Moncelle, Dale Robert Lombardo, Andrew Philip Woodfield
  • Publication number: 20110262771
    Abstract: A method for surface roughening a metal work piece includes disposing a region of the workpiece to be roughened proximate to a counter electrode. The region of the workpiece to be roughened and the counter electrode are subsequently disposed together in an electrolyte. An electric potential with current flow is applied between the work piece and the counter electrode to roughen the metal surface to a desired roughness.
    Type: Application
    Filed: June 30, 2011
    Publication date: October 27, 2011
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Andrew Lee Trimmer, Bin Wei, Joshua Leigh Miller, Nicholas Joseph Kray, Michael Scott Lamphere
  • Patent number: 8038764
    Abstract: A method of recovering rhenium from rhenium-containing superalloy scrap is provided. The superalloy is usually a nickel-based superalloy. The method includes the steps of forming an oxidation feedstock of flaky morphology of the superalloy scrap, and oxidizing the oxidation feedstock to convert rhenium into a volatile rhenium oxide. The flaky morphology of the oxidation feedstock is achieved by increasing the surface area of the superalloy scrap.
    Type: Grant
    Filed: November 30, 2009
    Date of Patent: October 18, 2011
    Assignee: General Electric Company
    Inventors: Biju Dasan, Barath Palanisamy, Don Mark Lipkin, Leonardo Ajdelsztajn, Joshua Leigh Miller, Srinidhi Sampath
  • Patent number: 7976694
    Abstract: An apparatus and method for hybrid machining a workpiece is disclosed. The workpiece is powered as an anode, a cutter is powered as a cathode and a cutting fluid or coolant is circulated therebetween. The cutter is made of a conductive material and a non-conductive abrasive material. The hybrid machine performs a roughing pass machining operation in which material is removed from the workpiece at a relatively high rate using a high-speed electro-erosion (HSEE) process. Then, the hybrid machine performs a finish pass machining operation in which material is removed from the workpiece using precision electro-grinding (PEG) process at a different differential electrical potential and/or flushing rate than the roughing pass machining operation to provide a smooth finish without thermal effects on the workpiece.
    Type: Grant
    Filed: July 17, 2007
    Date of Patent: July 12, 2011
    Assignee: General Electric Company
    Inventors: Andrew Lee Trimmer, Nicholas Joseph Kray, Joshua Leigh Miller, Michael Scott Lamphere, Bin Wei
  • Publication number: 20110126673
    Abstract: A method of recovering rhenium from rhenium-containing superalloy scrap is provided. The superalloy is usually a nickel-based superalloy. The method includes the steps of forming an oxidation feedstock of flaky morphology of the superalloy scrap, and oxidizing the oxidation feedstock to convert rhenium into a volatile rhenium oxide. The flaky morphology of the oxidation feedstock is achieved by increasing the surface area of the superalloy scrap.
    Type: Application
    Filed: November 30, 2009
    Publication date: June 2, 2011
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Biju Dasan, Barath Palanisamy, Don Mark Lipkin, Leonardo Ajdelsztajn, Joshua Leigh Miller, Srinidhi Sampath
  • Patent number: 7910173
    Abstract: A thermal barrier coating and deposition process for a component intended for use in a hostile thermal environment, such as the turbine, combustor and augmentor components of a gas turbine engine. The TBC has a first coating portion on at least a first surface portion of the component. The first coating portion is formed of a ceramic material to have at least an inner region, at least an outer region overlying the inner region, and a columnar microstructure whereby the inner and outer regions comprise columns of the ceramic material. The columns of the inner region are more closely spaced than the columns of the outer region so that the inner region of the first coating portion is denser than the outer region of the first coating portion, wherein the higher density of the inner region promotes the impact resistance of the first coating portion.
    Type: Grant
    Filed: July 31, 2008
    Date of Patent: March 22, 2011
    Assignee: General Electric Company
    Inventors: Irene Spitsberg, Brett Allen Rohrer Boutwell, Robert William Bruce, Curtis Alan Johnson, Bangalore Aswatha Nagaraj, William Scott Walston, Rudolfo Viguie, Joshua Leigh Miller, Roger Dale Wustman
  • Publication number: 20100329921
    Abstract: A superalloy composition comprising, in weight percent: about 6.2-6.6 Al, about 6.5-7.0 Ta, about 6.0-7.0 Cr, about 6.25-7.0 W, about 1.5-2.5 Mo, about 0.15-0.60 Hf, 0.0-1.0 Re, 6.5-9.0 Co, optionally, 0.03-0.06 C, optionally, up to about 0.004 B, optionally up to about 0.03 total of one or more rare earth elements selected from yttrium (Y), lanthanum (La), or cerium (Ce), balance nickel, such that the superalloy composition exhibits a stress rupture capability improvement of at least 15% over a base stress rupture capability of a base composition nominally comprising, in weight percent: 6.5 Al, 6.6 Ta, 6.0 Cr, 6.25 W, 1.5 Mo, 0.15 Hf, 0.0 Re, 7.5 Co. Articles incorporating the superalloy composition include a gas turbine engine component such as a high pressure turbine nozzle or nozzle segment.
    Type: Application
    Filed: June 4, 2010
    Publication date: December 30, 2010
    Inventors: JOSHUA LEIGH MILLER, Brian Thomas Hazel, Douglas Gerard Konitzer, Paul John Fink
  • Patent number: 7811396
    Abstract: A method for repairing a nickel-base superalloy article, such as a gas turbine stationary flowpath shroud having flowpath cooling holes therein that has previously been in service, includes the steps of providing the nickel-base superalloy article that has previously been in service; and applying a restoration to a surface of the article. The restoration is applied by the steps of providing a restoration nickel-base alloy, wherein the restoration nickel-base alloy preferably has no more than about 15 weight percent chromium and no more than about 0.01 percent yttrium, thereafter applying a restoration coating of the restoration nickel-base alloy to the surface of the article by a hyper-velocity oxyfuel metal spray process or a low-pressure plasma spray process, and thereafter heating the article with the restoration coating applied to the surface thereof to a sufficiently high temperature to diffusion bond the restoration coating to the surface of the article. The article is then returned to service.
    Type: Grant
    Filed: August 27, 2007
    Date of Patent: October 12, 2010
    Assignee: General Electric Company
    Inventors: David Edwin Budinger, Brent Ross Tholke, Matthew Nicklus Miller, Warren Davis Grossklaus, Jr., Joshua Leigh Miller, Melvin Robert Jackson
  • Publication number: 20100136247
    Abstract: A method for repairing a nickel-base superalloy article, such as a gas turbine stationary flowpath shroud having flowpath cooling holes therein that has previously been in service, includes the steps of providing the nickel-base superalloy article that has previously been in service; and applying a restoration to a surface of the article. The restoration is applied by the steps of providing a restoration nickel-base alloy, wherein the restoration nickel-base alloy preferably has no more than about 15 weight percent chromium and no more than about 0.01 percent yttrium, thereafter applying a restoration coating of the restoration nickel-base alloy to the surface of the article by a hyper-velocity oxyfuel metal spray process or a low-pressure plasma spray process, and thereafter heating the article with the restoration coating applied to the surface thereof to a sufficiently high temperature to diffusion bond the restoration coating to the surface of the article. The article is then returned to service.
    Type: Application
    Filed: August 27, 2007
    Publication date: June 3, 2010
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: David Edwin Budinger, Brent Ross Tholke, Matthew Nicklus Miller, Warren Davis Grossklaus, Jr., Joshua Leigh Miller, Melvin Robert Jackson
  • Patent number: 7530792
    Abstract: A method of reducing crack propagation includes: providing a metallic component having an exterior surface, and using a burnishing element to apply a varying to the exterior surface within a selected area, within which the component has a varying thickness, so as to create a region of residual compressive stress of surrounded by an interior boundary. The distance from the interior boundary to the exterior surface at any location within the selected area is independent of the thickness of the component at that location, and may be controlled by changing the pressure and/or an amount of overlap between burnished segments.
    Type: Grant
    Filed: June 30, 2006
    Date of Patent: May 12, 2009
    Assignee: General Electric Company
    Inventors: Alberto Luna, Joshua Leigh Miller
  • Publication number: 20090020509
    Abstract: An apparatus and method for hybrid machining a workpiece is disclosed. The workpiece is powered as an anode, a cutter is powered as a cathode and a cutting fluid or coolant is circulated therebetween. The cutter is made of a conductive material and a non-conductive abrasive material. The hybrid machine performs a roughing pass machining operation in which material is removed from the workpiece at a relatively high rate using a high-speed electro-erosion (HSEE) process. Then, the hybrid machine performs a finish pass machining operation in which material is removed from the workpiece using precision electro-grinding (PEG) process at a different differential electrical potential and/or flushing rate than the roughing pass machining operation to provide a smooth finish without thermal effects on the workpiece.
    Type: Application
    Filed: July 17, 2007
    Publication date: January 22, 2009
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Andrew Lee Trimmer, Nicholas Joseph Kray, Joshua Leigh Miller, Michael Scott Lamphere, Bin Wei
  • Publication number: 20080305264
    Abstract: A thermal barrier coating and deposition process for a component intended for use in a hostile thermal environment, such as the turbine, combustor and augmentor components of a gas turbine engine. The TBC has a first coating portion on at least a first surface portion of the component. The first coating portion is formed of a ceramic material to have at least an inner region, at least an outer region overlying the inner region, and a columnar microstructure whereby the inner and outer regions comprise columns of the ceramic material. The columns of the inner region are more closely spaced than the columns of the outer region so that the inner region of the first coating portion is denser than the outer region of the first coating portion, wherein the higher density of the inner region promotes the impact resistance of the first coating portion.
    Type: Application
    Filed: July 31, 2008
    Publication date: December 11, 2008
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Irene Spitsberg, Brett Allen Rohrer Boutwell, Robert William Bruce, Curtis Alan Johnson, Bangalore Aswatha Nagaraj, William Scott Walston, Rudolfo Viguie, Joshua Leigh Miller, Roger D. Wustman