NASA Technical Reports Server (NTRS) 20170001250: Process for Forming a High Temperature Single Crystal Canted Spring

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(12) United States Patent (io) Patent No.: US 9,541,148 B1
DeMange et al. (45) Date of Patent: Jan. 10, 2017
(54) PROCESS FOR FORMING A HIGH (52) U.S. Cl.
TEMPERATURE SINGLE CRYSTAL CANTED CPC . F16F 1/00 (2013.01); B22C 9/04 (2013.01);
SPRING B23P 19/048 (2013.01); B29C 39/02
(2013.01); B22C 7102 (2013.01); B22D 19112
(71) Applicant: The United States of America as (2013.01); B22D 271045 (2013.01); F16F
represented by the Administrator of 11021 (2013.01); YIOT 29/49609 (2015.01);
NASA, Washington, DC (US) YIOT 29/49611 (2015.01); YIOT 29/49988
(2015.01)
(72) Inventors: Jeffrey J DeMange, Cleveland, OH (58) Field of Classification Search
(US); Frank J Ritzert, North CPC ............. F16F 1/00; F16F 1/021; B29C 39/02;
Ridgeville, OH (US); Michael V B29C 9/108; B29C 21/14; B29C
Nathal, Strongsville, OH (US); Patrick 9/04; B29C 9/043; B29C 7/00; B29C
H Dunlap, Strongsville, OH (US); 7/02; B22D 27/045; B22D 19/00; B22D
Bruce M Steinetz, Westlake, OH (US) 19/12; YlOT 29/49609; YIOT 29/49611;
YIOT 29/49988; YIOT 29/49989; B23P
(73) Assignee: The United States of America as
19/048
Represented by the Administrator of
See application file for complete search history.
National Aeronautics and Space
Administration, Washington, DC (US) (56) References Cited
(*) Notice: Subject to any disclaimer, the term of this U.S. PATENT DOCUMENTS
patent is extended or adjusted under 35
U.S.C. 154(b) by 337 days. 3,524,636 A * 8/1970 Duhl ....................... F16F 1/021
267/166
5,332,239 A 7/1994 Steinetz et al.
(21) Appl. No.: 13/968,000
6,039,325 A 3/2000 Steinetz et al.
(Continued)
(22) Filed: Aug. 15, 2013
Primary Examiner Sarang Afzali
Related U.S. Application Data (74) Attorney, Agent, or Firm Robert H. Earp, III
(60) Provisional application No. 61/694,372, filed on Aug.
(57) ABSTRACT
29, 2012.
A process for forming a high temperature single crystal
(51) Int. Cl. canted spring is provided. In one embodiment, the process
F16F 1/06 (2006.01) includes fabricating configurations of a rapid prototype
B22C 7/02 (2006.01) spring to fabricate a sacrificial mold pattern to create a
F16F 1/00 (2006.01) ceramic mold and casting a canted coiled spring to form at
B29C 39/02 (2006.01) least one canted coil spring configuration based on the
B22C 9/04 (2006.01) ceramic mold. The high temperature single crystal canted
B23P 19/04 (2006.01) spring is formed from a nickel-based alloy containing rhe-
B22D 27104 (2006.01) nium using the at least one coil spring configuration.
F16F 1102 (2006.01)
B22D 19112 (2006.01) 7 Claims, 13 Drawing Sheets
a00
US 9,541,148 BI
Page 2
(56) References Cited
U.S. PATENTDOCUMENTS
6,702,300 B1 3/2004 Steinetz et al.
7,451,989 B1 11/2008 Cornett et al.
7,464,940 B2 12/2008 Datta
7,497,443 B1 3/2009 Steinetz et al.
7,832,737 B2 11/2010 Chou et al.
7,938,407 B2 5/2011 Datta et al.
8,016,297 B2 9/2011 Heinemann et al.
8,016,549 B2 9/2011 Shah et al.
2003/0127807 Al 7/2003 More et al.
2004/0239053 Al 12/2004 Rowe et al.
2009/0311570 Al 12/2009 Chou et al.
2010/0139586 Al* 6/2010 Nakamura ......... B22C 9/10
123/90.6
2010/0289198 Al* 11/2010 Balsells ............. B21F 35/00
267/151
2011/0101619 Al 5/2011 Fairbourn et al.
2012/0126485 Al 5/2012 Fairbourn et al.
2012/0186769 Al* 7/2012 Hansen .............. B22C 7/00
164/45
2012/0235366 Al 9/2012 Walunj et al.
* cited by examiner
U.S. Patent Jan. 10, 2017 Sheet 1 of 13 US 9,541,148 B1
U.S. Patent Jan. 10, 2017 Sheet 2 of 13 US 9,541,148 B1
U.S. Patent Jan. 10, 2017 Sheet 3 of 13 US 9,541,148 B1
U.S. Patent
Jan. 10, 2017 Sheet 4 of 13 US 9,541,148 B1
FIG. 4
400
402
Design Coil Spring
Configuration
404
Create Rapid
Prototypes
406
Create Mold Tree
408
Remove Rapid
Prototype
410
Cast Single Crystal
Components
412
Extract
Components from
Mold
End
U.S. Patent
Jan. 10, 2017 Sheet 5 of 13 US 9,541,148 B1
FIG. 5
500
Start
502
Design Spring
Configuration
504
Cast Single Crystal
Slab
506
Insert Slab into
Goniometer
508
Optimize
Orientation of Slab
510
Machine Spring
Configuration
End
U.S. Patent Jan. 10, 2017 Sheet 6 of 13 US 9,541,148 B1
FIG,
802
'<iii`:.5~igf.:.:.:..;:....t.:~~:•R.i~iiRi~4i;giRi~4:' ~~:. .~~`.. :r..~f...: ,Y:.::~: ..:..~d.•~:.. :~.~.~:..~.. .~.~. .:.... :. .. .::::C:y:.~.,.:..:::.
3..
.. .......t..S.~.c .::::::i.~.[.} {..,~.[,t{r,t, ,..r..{. >.: .,.:{. :.:.`^:..
Compression Call
Spring 638
4 FIG.' 6
;`:• : '~`'•?..?,~.. ,'~'•.,^.`r a '... ''.:ti°:.'~..?:•n~ .nnvMt~'<.,. .~'7'?u .''a',k^r..i... ., ,. ..''3:w~:ct:'~4:t:~``t,.....
....M.,~J.'~•x'h:.'+`r.•tA'<s~'a~~`i+'~c\"'+:Y•`..'h.`.~~".'.~'~`i`.MA`b~'~c~h',w'',."+~y:ti^,'~}."`vi.'a.':~ati~e~:~'`i`~'+'•:+':%^~:.'~"i'.'a.~A.<ah'.0~'te~~"+~4h?;'is'%iSa~'N~':e~~~"+c~"'%?i"r.'ra.~'e`'n~fr~sl'Kew'Ku~~'V~'i"4'.`.'v"i.'a.'~a'n~de~re~'+te~'~~`~'bev..:.
€ anted Coil Spring
606 FIG. 6C
':iii..,..,.. ;•::.:::..¢:.;::'.:r..:...t .: :.....:.::.:.;.;.;:;.: .: ..:. :. .... ;...• .:.: ........... :,:;~.k.~c.;,...r~:.,,..:, $
...
<::svovavvo iaear rc c Si ~ z~ c.... .rirtoevvaaors~a~eaPdrfesexk k33 b33 ~
.::' .:
Mt#l~l Cc~Y1~AC~rs~7tfPl~,
U.S. Patent Jan.10, 2017 Sheet 7 of 13 US 9,541,148 B1
700
so
c
40
w
a
e
CL 30
N
O
V
m 20
CL
10
0 r-
0.00 0.05 0.10 0.15 0.20 0.25
Displacement, in.
FIG. 7
U.S. Patent Jan. 10, 2017 Sheet 8 of 13 US 9,541,148 B1
FIG. 8
800
100
t
a b
so
s
60
Z - EPM 102 -10 cycles It
53
.~ —~— EPM102- 20 cycles i
t
40 1
—eL— Rene 41- 20 cycles t
—0+— Si3N4 -10 cyies ;
20
t
0
0 S00 100D 1500 2000 2500 3000
'temperature," F