Patents by Inventor Steven J. Bullied

Steven J. Bullied 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: 20200254511
    Abstract: A method of forming a component by investment casting includes disposing at least a portion of an investment casting pin within a core. The investment casting pin includes a ceramic base pin having a perimeter and a length extending perpendicular to the perimeter and a sacrificial coating disposed about the perimeter of the ceramic base pin along at least a portion of the length of the ceramic base pin. A metal casting is formed around the core. The core and the sacrificial coating are leached with a leaching solution and the investment casting pin is removed from the metal casting.
    Type: Application
    Filed: February 8, 2019
    Publication date: August 13, 2020
    Inventors: Steven J. Bullied, Russell A. Beers, Mario P. Bochiechio
  • Patent number: 10722939
    Abstract: A method of fabricating a casting is provided. The method includes creating a mixture of ceramic powder and a binder, pouring the mixture around sacrificial patterns, executing a first thermal treatment to set the mixture into a solid mold without damaging the sacrificial patterns, executing a second thermal treatment to remove the sacrificial patterns without removing any of the binder from the solid mold, executing at least one of a third thermal treatment and a chemical treatment to remove a quantity of the binder to transform the solid mold into a solid breakaway mold and pouring molten metallic material into the solid breakaway mold.
    Type: Grant
    Filed: June 29, 2018
    Date of Patent: July 28, 2020
    Assignee: RAYTHEON TECHNOLOGIES CORPORATION
    Inventors: John Joseph Marcin, Steven J. Bullied, Santosh Ranganath
  • Patent number: 10710154
    Abstract: A method of removing a core of a cast component includes providing a casting that includes a silica based ceramic core in a temperature controlled closed volume; cycling temperature between a first temperature and a second temperature within the temperature controlled closed volume that repeatedly subjects the silica based ceramic core to a beta-to-alpha cristobalite transition that induces microfractures in the silica based ceramic core; and after the cycling temperature, chemically dissolving the silica based ceramic core from the casting.
    Type: Grant
    Filed: March 9, 2018
    Date of Patent: July 14, 2020
    Assignee: Raytheon Technologies Corporation
    Inventors: Ryan C. Breneman, John E. Holowczak, John J. Marcin, Ingrid H. Kerscht, Steven J. Bullied, Dustin W. Davis
  • Patent number: 10695826
    Abstract: A method of producing an investment casting ceramic core is provided that includes: providing a core body consisting of a leachable material; surrounding the core body with a mold composition within a vessel, which mold composition is configured to solidify; leaching the core body from the mold composition subsequent to the mold composition solidifying, thereby leaving an internal cavity within the solidified mold composition; depositing a ceramic composition within the internal cavity of the solidified mold composition; sintering the ceramic composition to a solid ceramic core; and removing the solid ceramic core from the mold composition.
    Type: Grant
    Filed: July 17, 2017
    Date of Patent: June 30, 2020
    Assignee: Raytheon Technologies Corporation
    Inventors: Ryan C. Breneman, Steven J. Bullied
  • Patent number: 10633760
    Abstract: A process for casting a single crystal axis-symmetric thick walled tube comprising forming a axisymmetric single crystal ring seed around a circular internal core, wherein the ring seed has an inner diameter and a taper on the inner diameter, and wherein the internal core has an outer diameter and a matching taper on the outer diameter, the matching taper matching the taper of the inner diameter of the ring seed, and the internal core being free to translate in a vertical direction relative to the ring seed; and heating the ring seed so as to expand the ring seed relative to the internal core, and allowing the circular internal core to translate relative to the ring seed in a direction of the force of gravity, thereby maintaining contact between the circular internal core and the ring seed.
    Type: Grant
    Filed: April 5, 2018
    Date of Patent: April 28, 2020
    Assignee: United Technologies Corporation
    Inventors: Steven J. Bullied, Ryan C. Breneman, Dilip M. Shah, Shiela R. Woodard
  • Publication number: 20200086383
    Abstract: A conveyor furnace system is provided that includes a housing, a conveyor, a vacuum device, and at least one heating element. The housing may have a first end and a second end. The conveyor may be configured to transit one or more component molds from the first end to the second end. The vacuum device may be configured to selectively produce a below atmospheric pressure within the housing. The at least one heating element may be disposed in the housing, and has a first end disposed adjacent the first end of the housing and a second end adjacent the second end of the housing. The at least one heating element is configured to provide a vertically tapered heating exposure in a direction from the first end of the housing to the second end of the housing.
    Type: Application
    Filed: September 14, 2018
    Publication date: March 19, 2020
    Inventors: Steven J. Bullied, Carl R. Verner, Grant Rubin, Andrew Boyne
  • Patent number: 10576537
    Abstract: A casting mold has a pour cone, a downsprue, and a part-forming cavity having a lower end and an upper end. The downsprue extends from the pour cone toward the part-forming cavity and has: a lower portion having a plurality of ports in communication with the part-forming cavity; and an upper portion telescoping relative to the lower portion and coupling the lower portion to the pour cone.
    Type: Grant
    Filed: February 5, 2019
    Date of Patent: March 3, 2020
    Assignee: United Technologies Corporation
    Inventors: Steven J. Bullied, Dilip M. Shah, Alan D. Cetel, John J. Marcin, Jr.
  • Patent number: 10569327
    Abstract: A die casting system includes a die including at least one die component that defines a die cavity, a spar received within a portion of said die cavity, a shot tube in fluid communication with the die cavity, and a shot tube plunger moveable within the shot tube to communicate a molten metal into the die cavity to cast a hybrid component. The spar establishes an internal structure of the hybrid component, and one of the internal structures and an outer structure of said hybrid component is an equiaxed structure.
    Type: Grant
    Filed: February 9, 2018
    Date of Patent: February 25, 2020
    Assignee: United Technologies Corporation
    Inventors: Steven J. Bullied, John Joseph Marcin, Carl R. Verner
  • Publication number: 20200025467
    Abstract: A method of forming a cast heat exchanger plate includes forming at least one hot core plate defining internal features of a one piece heat exchanger plate and at least one first set of interlocking features. At least one cold core plate is formed defining external features of the heat exchanger plate and at least one second set of interlocking features. A core assembly is assembled wherein each hot core plate is directly interlocked to the at least one cold core plate. A wax pattern is formed with the core assembly. An external shell is formed over the wax pattern. The wax pattern is removed to form a space between the core assembly and the external shell. The space is filled with a molten material and cures the molten material. The external shell is removed. The core assembly is removed. A core assembly for a cast heat exchanger is also disclosed.
    Type: Application
    Filed: February 8, 2019
    Publication date: January 23, 2020
    Inventors: Michael A. Disori, Carl R. Verner, Steven J. Bullied, David Donald Chapdelaine
  • Publication number: 20200001353
    Abstract: A method of fabricating a casting is provided. The method includes creating a mixture of ceramic powder and a binder, pouring the mixture around sacrificial patterns, executing a first thermal treatment to set the mixture into a solid mold without damaging the sacrificial patterns, executing a second thermal treatment to remove the sacrificial patterns without removing any of the binder from the solid mold, executing at least one of a third thermal treatment and a chemical treatment to remove a quantity of the binder to transform the solid mold into a solid breakaway mold and pouring molten metallic material into the solid breakaway mold.
    Type: Application
    Filed: June 29, 2018
    Publication date: January 2, 2020
    Inventors: John Joseph Marcin, Steven J. Bullied, Santosh Ranganath
  • Patent number: 10456830
    Abstract: An alloy part is cast in a mold (280) having a part-forming cavity (292, 294, 296). The method comprises pouring a first alloy into the mold. The pouring causes: a surface (550) of the first alloy in the part-forming cavity to raise relative to the part-forming cavity; a branch flow of the poured first alloy to pass upwardly through a first portion (304) of a passageway; and the branch flow to pass downwardly through a second portion (310), of the passageway; solidifying some of the first alloy in the passageway to block the passageway while at least some of the first alloy in the part-forming cavity remains molten. A second alloy is poured into the mold atop the first alloy and solidified.
    Type: Grant
    Filed: May 25, 2017
    Date of Patent: October 29, 2019
    Assignee: United Technologies Corporation
    Inventors: Steven J. Bullied, Dilip M. Shah, Alan D. Cetel, John J. Marcin
  • Patent number: 10449605
    Abstract: A method casts a plurality of alloy parts in a mold (600; 700) having a plurality of part-forming cavities (601). The method comprises pouring a first alloy into the mold causing: the first alloy to branch into respective flows along respective first flowpaths (676, 684; 708) to the respective cavities; and a surface of the first alloy in the part-forming cavities to equilibrate. The method further comprises pouring a second alloy into the mold causing: the second alloy to branch into respective flows along respective second flowpaths (676, 680; 712) to the respective cavities.
    Type: Grant
    Filed: November 7, 2014
    Date of Patent: October 22, 2019
    Assignee: United Technologies Corporation
    Inventors: Steven J. Bullied, John J. Marcin, Jr., Emily K. Kreek, Carl R. Verner, Mario P. Bochiechio
  • Publication number: 20190309438
    Abstract: A process for casting a single crystal axis-symmetric thick walled tube comprising forming a axisymmetric single crystal ring seed around a circular internal core, wherein the ring seed has an inner diameter and a taper on the inner diameter, and wherein the internal core has an outer diameter and a matching taper on the outer diameter, the matching taper matching the taper of the inner diameter of the ring seed, and the internal core being free to translate in a vertical direction relative to the ring seed; and heating the ring seed so as to expand the ring seed relative to the internal core, and allowing the circular internal core to translate relative to the ring seed in a direction of the force of gravity, thereby maintaining contact between the circular internal core and the ring seed.
    Type: Application
    Filed: April 5, 2018
    Publication date: October 10, 2019
    Applicant: United Technologies Corporation
    Inventors: Steven J. Bullied, Ryan C. Breneman, Dilip M. Shah, Shiela R. Woodard
  • Publication number: 20190293365
    Abstract: A cast part includes an outermost wall, at least one inner wall defining at least two internal passages and at least one cast cooling fin extending from an outer surface. The cooling fin includes a ratio of fin height to an average fin thickness that is greater than 2.0 and no more than 18.0. A method is also disclosed.
    Type: Application
    Filed: February 8, 2019
    Publication date: September 26, 2019
    Inventors: Michael A. Disori, Steven J. Bullied, Ryan C. Breneman, John Marcin, David J. Hyland, William P. Stillman, Carl R. Verner
  • Patent number: 10421120
    Abstract: A cast work piece includes a cast metal component section and a sprue section connected to the cast metal component section. The cast metal component section and a portion of the sprue section have a first grain orientation and another portion of the sprue section has a second grain orientation such that there is a microstructural discontinuity where the first grain orientation meets the second grain orientation in the sprue section.
    Type: Grant
    Filed: October 18, 2016
    Date of Patent: September 24, 2019
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventors: Lea Dynnette Castle, Steven J. Bullied, Maria Arceo Herring
  • Publication number: 20190275583
    Abstract: A method of removing a core of a cast component includes providing a casting that includes a silica based ceramic core in a temperature controlled closed volume; cycling temperature between a first temperature and a second temperature within the temperature controlled closed volume that repeatedly subjects the silica based ceramic core to a beta-to-alpha cristobalite transition that induces microfractures in the silica based ceramic core; and after the cycling temperature, chemically dissolving the silica based ceramic core from the casting.
    Type: Application
    Filed: March 9, 2018
    Publication date: September 12, 2019
    Inventors: Ryan C. Breneman, John E. Holowczak, John J. Marcin, Ingrid H. Kerscht, Steven J. Bullied, Dustin W. Davis
  • Patent number: 10369625
    Abstract: A method for casting comprising: providing a seed, the seed characterized by: an arcuate form and a crystalline orientation progressively varying along an arc of the form; providing molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material.
    Type: Grant
    Filed: June 5, 2015
    Date of Patent: August 6, 2019
    Assignee: United Technologies Corporation
    Inventors: Dilip M. Shah, Paul D. Genereux, Alan D. Cetel, John J. Marcin, Jr., Steven J. Bullied, Mario P. Bochiechio, Kevin W. Schlichting, Bradford A. Cowles, Carl R. Verner, David U. Furrer, Venkatarama K. Seetharaman
  • Publication number: 20190218919
    Abstract: A blade (60; 60-2) comprises an airfoil (61) and an attachment root (63). The blade has a tipward zone (80; 80-2; 80-2, 81) and a rootward zone (82; 82-2, 81; 82). The rootward zone has a single crystal structure. The tipward zone has a single crystal structure. The crystalline orientations of the rootward zone and tipward zone are at least 15° out of registry with each other.
    Type: Application
    Filed: March 22, 2019
    Publication date: July 18, 2019
    Applicant: United Technologies Corporation
    Inventors: John J. Marcin, JR., Steven J. Bullied, Dilip M. Shah, Alan D. Cetel
  • Patent number: 10315241
    Abstract: A method comprises: providing a spiral metallic workpiece having a cast structure associated with such spiral; and at least partially flattening the workpiece.
    Type: Grant
    Filed: June 24, 2015
    Date of Patent: June 11, 2019
    Assignee: United Technologies Corporation
    Inventors: Dilip M. Shah, Alan D. Cetel, John J. Marcin, Jr., Steven J. Bullied, Carl R. Verner
  • Publication number: 20190168296
    Abstract: A casting mold has a pour cone, a downsprue, and a part-forming cavity having a lower end and an upper end. The downsprue extends from the pour cone toward the part-forming cavity and has: a lower portion having a plurality of ports in communication with the part-forming cavity; and an upper portion telescoping relative to the lower portion and coupling the lower portion to the pour cone.
    Type: Application
    Filed: February 5, 2019
    Publication date: June 6, 2019
    Applicant: United Technologies Corporation
    Inventors: Steven J. Bullied, Dilip M. Shah, Alan D. Cetel, John J. Marcin, JR.