Patents by Inventor Michael J Wallis

Michael J Wallis 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: 20190039210
    Abstract: A method of manufacturing a part comprises providing a component for cutting and directing a water jet at the component so as to cut the component. The water jet comprises water and abrasive particles having a nucleus made from a first substance and a second substance surrounding the nucleus, the first substance being denser than the second substance.
    Type: Application
    Filed: July 31, 2018
    Publication date: February 7, 2019
    Applicant: ROLLS-ROYCE plc
    Inventors: Daniel CLARK, Michael J. WALLIS, Robert J. SMITH
  • Publication number: 20160311052
    Abstract: A method of manufacturing a hollow aerofoil component for a gas turbine engine includes using a capping panel to cover a pocket in a pocketed aerofoil body. An activation material is placed between the capping panel and the pocketed aerofoil body, and the temperature of the assembly is raised to a bonding temperature. The capping panel and pocketed aerofoil assembly are thereby joined together using activated diffusion bonding to form the hollow aerofoil component.
    Type: Application
    Filed: April 6, 2016
    Publication date: October 27, 2016
    Applicant: ROLLS-ROYCE plc
    Inventors: Michael J. WALLIS, Philip S. WOOD, Kate WHITTAKER, Neil ANTROBUS
  • Publication number: 20160047248
    Abstract: A composite fan blade for a gas turbine engine, the blade comprises a root portion for connecting the blade to a hub and an aerofoil portion. The aerofoil portion comprises an external cover formed from a non-metallic material and an internal structure enclosed within the cover. The internal structure comprises a plurality of support members extending generally from a pressure side of the internal structure to a suction side of the internal structure, and wherein the plurality of support members define a plurality of cells or channels.
    Type: Application
    Filed: July 28, 2015
    Publication date: February 18, 2016
    Inventors: Michael J. WALLIS, Martin McELHONE, Christian SEYDEL, Peter D. SMOUT
  • Patent number: 8764404
    Abstract: A diffusion bonded and superplastically formed turbomachine blade, the turbomachine blade comprising: a first layer (4); a second layer (6); and a membrane (2) disposed between the first and second layers (4, 6); wherein the membrane (2) is diffusion bonded to the first layer (4) along a plurality of first strips (10) and the membrane (2) is diffusion bonded to the second layer (6) along a plurality of second strips (12), wherein the first and second strips (10, 12) are offset from one another so that the membrane (2) is bonded to the first and second layers (4, 6) in an alternating pattern; wherein the membrane (2) has a recess (28) which extends into an area between an adjacent pair of first or second strips (10, 12).
    Type: Grant
    Filed: December 16, 2011
    Date of Patent: July 1, 2014
    Assignee: Rolls-Royce PLC
    Inventors: Simon M. Barlow, Michael J. Wallis
  • Patent number: 8661669
    Abstract: A ducted fan gas turbine engine aerofoil is made by electron beam welding together at least two metal sheets (10) and (12) and electron beam welding that sub assembly via an end to a root that has been manufactured in a separate operation, and then heating the whole to a temperature that will convert the electron beam welds to diffusion bonds.
    Type: Grant
    Filed: December 14, 2010
    Date of Patent: March 4, 2014
    Assignee: Rolls-Royce PLC
    Inventors: Ian J. Andrews, David Rugg, Michael J. Wallis
  • Patent number: 8512002
    Abstract: A method of manufacturing an aerofoil structure capable of being diffusion bonded and superplastically formed to create a substantially hollow cavity within the aerofoil structure, the method comprising: providing two metallic panels; assembling and joining the two metallic panels to one another to form the aerofoil structure; wherein the two metallic panels each comprise a surface capable of forming an aerofoil and further comprise a root or section thereof which is either integral with or fixed to the aerofoil surface; and incorporating a section of a different material into a part, the said section being made from a material which is different from the material of another part of the aerofoil structure.
    Type: Grant
    Filed: February 9, 2010
    Date of Patent: August 20, 2013
    Assignee: Rolls-Royce, PLC
    Inventor: Michael J. Wallis
  • Patent number: 8496440
    Abstract: A method of manufacturing an aerofoil structure capable of being diffusion bonded and superplastically formed to create a substantially hollow cavity within the aerofoil structure, the method comprising: providing a metallic plate for forming the aerofoil structure; joining mounting elements to opposing end surfaces of said metallic plate; dividing said plate along a plane extending substantially in a span-wise direction so as to produce two metallic panels each with one of said mounting elements joined thereto; assembling the two metallic panels so that the surfaces of the panels opposite to the surfaces which have been divided are facing each other; and joining the two metallic panels to one another to form the aerofoil structure; wherein the mounting elements are joined to one another to form the root of the aerofoil.
    Type: Grant
    Filed: February 9, 2010
    Date of Patent: July 30, 2013
    Assignee: Rolls-Royce PLC
    Inventor: Michael J. Wallis
  • Publication number: 20120163983
    Abstract: A diffusion bonded and superplastically formed turbomachine blade, the turbomachine blade comprising: a first layer (4); a second layer (6); and a membrane (2) disposed between the first and second layers (4, 6); wherein the membrane (2) is diffusion bonded to the first layer (4) along a plurality of first strips (10) and the membrane (2) is diffusion bonded to the second layer (6) along a plurality of second strips (12), wherein the first and second strips (10, 12) are offset from one another so that the membrane (2) is bonded to the first and second layers (4, 6) in an alternating pattern; wherein the membrane (2) has a recess (28) which extends into an area between an adjacent pair of first or second strips (10, 12).
    Type: Application
    Filed: December 16, 2011
    Publication date: June 28, 2012
    Applicant: ROLLS-ROYCE PLC
    Inventors: Simon M. BARLOW, Michael J. WALLIS
  • Publication number: 20110088261
    Abstract: A ducted fan gas turbine engine aerofoil is made by electron beam welding together at least two metal sheets (10) and (12) and electron beam welding that sub assembly via an end to a root that has been manufactured in a separate operation, and then heating the whole to a temperature that will convert the electron beam welds to diffusion bonds.
    Type: Application
    Filed: December 14, 2010
    Publication date: April 21, 2011
    Applicant: ROLLS-ROYCE PLC
    Inventors: Ian J. Andrews, David Rugg, Michael J. Wallis
  • Patent number: 7896221
    Abstract: A method of manufacturing an aerofoil structure to have a portion with an increased erosion resistance, the method comprising: providing one or more titanium elements (2, 4, 6) and a beta-stabilizing material (8); wherein the one or more elements (2, 4, 6) have an alpha-beta microstructure; assembling the one or more elements (2, 4, 6) and the beta-stabilizing material (8) such that the beta-stabilizing material (8) is adjacent to the one or more elements (2, 4, 6); and heating the assembly such that the beta-stabilizing material (8) diffuses into an adjacent portion of the one or more elements (2, 4, 6), causing the adjacent portion of the one or more elements (2, 4, 6) to have a beta microstructure which provides an increased erosion resistance.
    Type: Grant
    Filed: April 9, 2010
    Date of Patent: March 1, 2011
    Assignee: Rolls-Royce PLC
    Inventor: Michael J Wallis
  • Publication number: 20100270360
    Abstract: A method of manufacturing an aerofoil structure to have a portion with an increased erosion resistance, the method comprising: providing one or more titanium elements (2, 4, 6) and a beta-stabilizing material (8); wherein the one or more elements (2, 4, 6) have an alpha-beta microstructure; assembling the one or more elements (2, 4, 6) and the beta-stabilizing material (8) such that the beta-stabilizing material (8) is adjacent to the one or more elements (2, 4, 6); and heating the assembly such that the beta-stabilizing material (8) diffuses into an adjacent portion of the one or more elements (2, 4, 6), causing the adjacent portion of the one or more elements (2, 4, 6) to have a beta microstructure which provides an increased erosion resistance.
    Type: Application
    Filed: April 9, 2010
    Publication date: October 28, 2010
    Applicant: ROLLS-ROYCE PLC
    Inventor: Michael J. WALLIS
  • Publication number: 20100226781
    Abstract: A method of manufacturing an aerofoil structure capable of being diffusion bonded and superplastically formed to create a substantially hollow cavity within the aerofoil structure, the method comprising: providing a metallic plate for forming the aerofoil structure; joining mounting elements to opposing end surfaces of said metallic plate; dividing said plate along a plane extending substantially in a span-wise direction so as to produce two metallic panels each with one of said mounting elements joined thereto; assembling the two metallic panels so that the surfaces of the panels opposite to the surfaces which have been divided are facing each other; and joining the two metallic panels to one another to form the aerofoil structure; wherein the mounting elements are joined to one another to form the root of the aerofoil.
    Type: Application
    Filed: February 9, 2010
    Publication date: September 9, 2010
    Applicant: ROLLS-ROYCE PLC
    Inventor: Michael J. WALLIS
  • Publication number: 20100226778
    Abstract: A method of manufacturing an aerofoil structure capable of being diffusion bonded and superplastically formed to create a substantially hollow cavity within the aerofoil structure, the method comprising: providing two metallic panels (8, 10, 16); assembling and joining the two metallic panels (8, 10, 16) to one another to form the aerofoil structure; wherein the two metallic panels each comprise a surface (8, 10, 16) capable of forming an aerofoil and further comprise a root or section thereof (4, 14) which is either integral with or fixed to the aerofoil surface; and incorporating a section of a different material into a part, the said section being made from a material which is different from the material of another part of the aerofoil structure.
    Type: Application
    Filed: February 9, 2010
    Publication date: September 9, 2010
    Applicant: ROLLS-ROYCE PLC
    Inventor: Michael J. Wallis
  • Patent number: 6467168
    Abstract: A method of manufacturing a gas turbine engine fan blade (10) comprises forming three metal workpieces (30,32,34). The metal workpieces (30,32,34) are assembled into a stack (36) so that the flat surfaces (38,42,46,48) are in mating abutment. Heat and pressure is applied across the thickness of the metal workpieces (30,32,34) to diffusion bond the metal workpieces (30,32,34) together to form an integral structure (80). The integral structure (80) is upset forged at one end (58) to produce an increase in thickness (82) for forming the blade root (26). The upset forged integral structure (80) is then hot creep formed and superplastically formed to produce the required aerofoil shape and the thickened end (82) is machined to form the blade root (26). The method enables thinner metallic workpieces with better microstructure to be used and increases the yield of metallic workpieces.
    Type: Grant
    Filed: March 6, 2001
    Date of Patent: October 22, 2002
    Assignee: Rolls-Royce plc
    Inventor: Michael J Wallis
  • Publication number: 20010022023
    Abstract: A method of manufacturing a gas turbine engine fan blade (10) comprises forming three metal workpieces (30, 32, 34). The metal workpieces (30, 32, 34) are assembled into a stack (36) so that the flat surfaces (38, 42, 46, 48) are in mating abutment. Heat and pressure is applied across the thickness of the metal workpieces (30, 32, 34) to diffusion bond the metal workpieces (30, 32, 34) together to form an integral structure (80). The integral structure (80) is upset forged at one end (58) to produce an increase in thickness (82) for forming the blade root (26). The upset forged integral structure (80) is then hot creep formed and superplastically formed to produce the required aerofoil shape and the thickened end (82) is machined to form the blade root (26). The method enables thinner metallic workpieces with better microstructure to be used and increases the yield of metallic workpieces.
    Type: Application
    Filed: March 6, 2001
    Publication date: September 20, 2001
    Inventor: Michael J. Wallis