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).

  • Variable Diameter Investment Casting Mold For Casting of Reticulated Metal Foams
    Publication number: 20170001238
    Abstract: A method to manufacture reticulated metal foam via a dual investment solid mold, includes pre-investing a precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor; and investing the encapsulated precursor with a ceramic plaster within an mold of a varied cross-section. A varied cross-section mold includes a mold thickness adjacent to an outer periphery of a pattern at a top of the varied cross-section mold is between 200-500% a thickness between the outer periphery of the pattern at a base of the varied cross-section mold. A varied cross-section mold includes a trapezoidal prism shape with a pour cone in a top, the top larger than the base.
    Type: Application
    Filed: June 30, 2015
    Publication date: January 5, 2017
    Inventors: Ryan C. Breneman, Steven J. Bullied, John F. Blondin, Ryan B. Noraas
  • Metal casting apparatus, cast work piece and method therefor
    Patent number: 9498823
    Abstract: A metal casting apparatus includes a feeder for providing a molten metallic material. A mold includes a sprue and a component cavity. The sprue is arranged to receive the molten metallic material from the feeder and the component cavity is arranged to receive the molten metallic material from the sprue. A starter is arranged adjacent the component cavity and is operable to induce a first grain orientation upon solidification of the molten metallic material. The sprue includes an aborter that is arranged to induce a second grain orientation upon solidification of the molten metallic material.
    Type: Grant
    Filed: November 7, 2011
    Date of Patent: November 22, 2016
    Assignee: United Technologies Corporation
    Inventors: Lea Kennard Castle, Steven J. Bullied, Maria Arceo Herring
  • Casting of thin wall hollow airfoil sections
    Patent number: 9486853
    Abstract: A casting mold assembly includes an airfoil defining section and a casting core. The airfoil defining section includes an outer mold wall and a direct-shelled inner mold wall. The direct-shelled inner mold wall is disposed within a forward chordwise portion of the airfoil defining section. The direct-shelled inner mold wall includes an aft end having an external radius measuring more than about 0.075 in. (1.9 mm). The casting core is secured within an aft chordwise portion of the airfoil defining section, and includes an aft end with an external radius measuring less than about 0.075 in. (1.9 mm). A cast component and a method for making the casting mold assembly are also disclosed.
    Type: Grant
    Filed: September 14, 2012
    Date of Patent: November 8, 2016
    Assignee: United Technologies Corporation
    Inventors: Steven J. Bullied, Carl R. Verner, Steven D. Porter, James B. Park
  • CASTING WITH REUSABLE PRECISION, MOTION-CONTROLLED, WITHDRAWABLE CORES
    Publication number: 20160311016
    Abstract: A method of manufacturing includes providing a casting assembly, providing a material having solid, transition, and liquid phases, heating the material to form the liquid phase, supplying the material to the casting assembly, cooling the material, monitoring the solidification of the material from the liquid phase through the transition phase, and moving one of the casting mold or the reusable core in a first direction relative to the other when a substantial portion of the reusable core contacts the transition phase. The casting assembly comprises a casting mold and a reusable core inserted within the casting mold.
    Type: Application
    Filed: April 24, 2015
    Publication date: October 27, 2016
    Applicant: United Technologies Corporation
    Inventors: Dilip M. Shah, John Joseph Marcin, Steven J. Bullied, Carl R. Verner, Ryan C. Breneman
  • Method and Apparatus for Manufacturing a Multi-Alloy Cast Structure
    Publication number: 20160288201
    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: Application
    Filed: November 7, 2014
    Publication date: October 6, 2016
    Applicant: United Technologies Corporation
    Inventors: Steven J. Bullied, John J. Marcin, JR., Emily K. Kreek, Carl R. Verner, Mario P. Bochiechio
  • Open-Cell Reticulated Foam
    Publication number: 20160228913
    Abstract: A foam for use in a lost-foam casting process utilized in the manufacture of a component for a gas turbine engine, the foam having a void fraction less than or equal to ninety five percent, is disclosed. The foam may include a first layer comprising polymer foam having an open-cell structure and a void fraction greater than ninety five percent. A second layer, comprising adhesive, may be adhered to the first layer. A third layer comprising particulate material may be adhered to the second layer.
    Type: Application
    Filed: February 9, 2015
    Publication date: August 11, 2016
    Inventors: Ryan B. Noraas, Steven J. Bullied
  • DUAL INVESTMENT SHELLED SOLID MOLD CASTING OF RETICULATED METAL FOAMS
    Publication number: 20160221072
    Abstract: A method to manufacture reticulated metal foam via a dual investment, includes pre-investment of a precursor with a diluted pre-investment ceramic plaster then applying an outer mold to the encapsulated precursor as a shell-mold.
    Type: Application
    Filed: December 7, 2015
    Publication date: August 4, 2016
    Inventors: Ryan C. Breneman, Steven J. Bullied, David R. Scott
  • Turbine Blades and Manufacture Methods
    Publication number: 20160222801
    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: August 13, 2014
    Publication date: August 4, 2016
    Applicant: United Technologies Corporation
    Inventors: John J. Marcin, Steven J. Bullied, Dilip M. Shah, Alan D. Cetel
  • Dual Investment Technique for Solid Mold Casting of Reticulated Metal Foams
    Publication number: 20160207100
    Abstract: A method to manufacture reticulated metal foam via a dual investment solid mold, includes pre-investment of a precursor with a diluted pre-investment ceramic plaster then investing the encapsulated precursor with a ceramic plaster.
    Type: Application
    Filed: January 20, 2015
    Publication date: July 21, 2016
    Inventors: Ryan B. Noraas, Steven J. Bullied, Mark F. Bartholomew
  • Investment Technique For Solid Mold Casting of Reticulated Metal Foams
    Publication number: 20160207097
    Abstract: A method to manufacture reticulated metal foam includes coating a precursor in a molten wax to increase ligament thickness; and investment coating the molten wax coated precursor with a ceramic plaster.
    Type: Application
    Filed: February 11, 2015
    Publication date: July 21, 2016
    Inventors: Ryan B. Noraas, Steven J. Bullied, Mark F. Bartholomew, John F. Blondin, John Joseph Marcin
  • DIE CASTING SYSTEM AND CELL
    Publication number: 20160158835
    Abstract: A method of manufacturing a component in a die casting cell that includes a die casting system according to an exemplary aspect of the present disclosure includes, among other things, isolating a first chamber from a second chamber of the die casting system, melting a charge of material in the first chamber, sealing the second chamber relative to the first chamber, and simultaneously injecting the charge of material within the second chamber to cast the component and melting a second charge of material within the first chamber.
    Type: Application
    Filed: February 10, 2016
    Publication date: June 9, 2016
    Inventors: Mario P. BOCHIECHIO, John Joseph MARCIN, Carl R. VERNER, John F. BLONDIN, Mark F. BARTHOLOMEW, Raymond P. RISTAU, Kevin W. CHITTENDEN, Gary M. TAMISO, Robert C. RENAUD, Dennis M. KRAEMER, Robert E. LeBRUN, Paul R. ZAMJOHN, Charles A. ROOHR, Kerry KOZACZUK, Roy A. GARRISON, Steven J. BULLIED
  • Castings and Manufacture Methods
    Publication number: 20160158834
    Abstract: A method for casting an article comprises a first region and a second region. The method comprises casting an alloy in a shell, the shell having a casting core protruding from a first metal piece; and deshelling and decoring to remove the shell and core and leave the first region formed by the first piece and the second region formed by the casted alloy.
    Type: Application
    Filed: July 11, 2014
    Publication date: June 9, 2016
    Applicant: United Technologies Corporation
    Inventors: John Marcin J., Steven J. Bullied, Dilip M. Shah, Alan D. Cetel
  • Die casting system and cell
    Patent number: 9289823
    Abstract: A method of manufacturing a component in a die casting cell that includes a die casting system according to an exemplary aspect of the present disclosure includes, among other things, isolating a first chamber from a second chamber of the die casting system, melting a charge of material in the first chamber, sealing the second chamber relative to the first chamber, and simultaneously injecting the charge of material within the second chamber to cast the component and melting a second charge of material within the first chamber.
    Type: Grant
    Filed: November 10, 2014
    Date of Patent: March 22, 2016
    Assignee: United Technologies Corporation
    Inventors: Mario P. Bochiechio, John Joseph Marcin, Carl R. Verner, John F. Blondin, Mark F. Bartholomew, Raymond P. Ristau, Kevin W. Chittenden, Gary M. Tamiso, Robert C. Renaud, Dennis M. Kraemer, Robert E. LeBrun, Paul R. Zamjohn, Charles A. Roohr, Kerry Kozaczuk, Roy A. Garrison, Steven J. Bullied
  • DIE CASTING OF COMPONENT HAVING INTEGRAL SEAL
    Publication number: 20160074933
    Abstract: A method of die casting a component with an integral sea according to an exemplary aspect of the present disclosure includes, among other things, defining a first portion of a die cavity of a die to include an open cell structure and defining a second portion of the die cavity without the open cell structure. The first portion is located within an opening formed in a first die element of the die and the second portion is located within a void formed in a second die element of the die. The method further includes injecting molten metal into the die cavity and solidifying the molten metal within the die cavity to form the component with the integral seal.
    Type: Application
    Filed: November 11, 2015
    Publication date: March 17, 2016
    Inventors: Steven J. Bullied, Carl R. Verner, Gaurav M. Patel
  • Arcuate Directionally Solidified Components and Manufacture Methods
    Publication number: 20160031006
    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: Application
    Filed: June 5, 2015
    Publication date: February 4, 2016
    Applicant: 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
  • Cast Components and Manufacture and Use Methods
    Publication number: 20160008867
    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: Application
    Filed: June 24, 2015
    Publication date: January 14, 2016
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Dilip M. Shah, Alan D. Cetel, John J. Marcin, JR., Steven J. Bullied, Carl R. Verner
  • Multi-Shot Casting
    Publication number: 20150328681
    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: Application
    Filed: December 13, 2013
    Publication date: November 19, 2015
    Applicant: United Technologies Corporation
    Inventors: Steven J. Bullied, Dilip M. Shah, Alan D. Cetel, John J. Marcin
  • Casting Molds, Manufacture and Use Methods
    Publication number: 20150075745
    Abstract: A casting mold (260) comprises a shell (262) extending from a lower end (264) to an upper end (266) and having: an interior space (280) for casting metal; and an opening (268) for receiving metal to be cast. A plurality of thermocouples (900) are vertically-spaced from each other on the shell.
    Type: Application
    Filed: September 16, 2014
    Publication date: March 19, 2015
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: John J. Marcin, JR., Steven J. Bullied, Dilip M. Shah, Alan D. Cetel, Emily K. Kreek
  • DIE CASTING SYSTEM AND CELL
    Publication number: 20150060002
    Abstract: A method of manufacturing a component in a die casting cell that includes a die casting system according to an exemplary aspect of the present disclosure includes, among other things, isolating a first chamber from a second chamber of the die casting system, melting a charge of material in the first chamber, sealing the second chamber relative to the first chamber, and simultaneously injecting the charge of material within the second chamber to cast the component and melting a second charge of material within the first chamber.
    Type: Application
    Filed: November 10, 2014
    Publication date: March 5, 2015
    Inventors: Mario P. BOCHIECHIO, John Joseph MARCIN, Carl R. VERNER, John F. BLONDIN, Mark F. BARTHOLOMEW, Raymond P. RISTAU, Kevin W. CHITTENDEN, Gary M. TAMISO, Robert C. RENAUD, Dennis M. KRAEMER, Robert E. LeBRUN, Paul R. ZAMJOHN, Charles A. ROOHR, Kerry KOZACZUK, Roy A. GARRISON, Steven J. BULLIED
  • Die casting system and cell
    Patent number: 8919422
    Abstract: A die casting system includes a die, a shot tube, a melting system and a vacuum system. The die includes a plurality of die components that define a die cavity. The shot tube is in fluid communication with the die cavity and is operable to deliver a charge of material to the die cavity. The melting system is positioned adjacent to the die and includes an alloy loader, a melting unit and a crucible. The vacuum system defines a first chamber and a second chamber separated from the first chamber by an isolation valve. The melting system is disposed within the first chamber, and the die is disposed within the second chamber.
    Type: Grant
    Filed: February 18, 2011
    Date of Patent: December 30, 2014
    Assignee: United Technologies Corporation
    Inventors: Mario P. Bochiechio, John Joseph Marcin, Carl R. Verner, John F. Blondin, Mark F. Bartholomew, Raymond P. Ristau, Kevin W. Chittenden, Gary M. Tamiso, Robert C. Renaud, Dennis M. Kraemer, Robert E. LeBrun, Paul R. Zamjohn, Charles A. Roohr, Kerry Kozaczuk, Roy A. Garrison, Steven J. Bullied