ADDITIVE MANUFACTURING BAFFLES, COVERS, AND DIES

• US 20160023275A1
• Filed: 03/11/2014
• Published: 01/28/2016
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Rtx Corporation
• Original Assignee: United Technologies Corporation (Rtx Corporation)
• Inventors: Propheter-Hinckley, Tracy A., Donnell, Brandon S.
• Granted Patent: US 10,173,264 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 5/009 of turbine components other than turbine blades of turbine blades B22F5/04
• CPC Class Codes: B22F 5/04 of turbine blades
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: F01D 5/147 Construction, i.e. structural features, e.g. of weight-saving hollow blades F01D5/148, F01D5/16 and F01D5/20 take precedence; blade shape F01D5/141; blades with cooling or heating channels or cavities F01D5/18; heating, heat-insulating or cooling means on blades F01D5/18
• CPC Class Codes: F01D 5/188 with an insert in the blade cavity to guide the cooling fluid, e.g. forming a separation wall
• CPC Class Codes: F01D 5/189 the insert having a tubular cross-section, e.g. airfoil shape
• CPC Class Codes: F01D 9/041 using blades F01D5/148 takes precedence
• CPC Class Codes: F01D 9/065 Fluid supply or removal conduits traversing the working fluid flow, e.g. for lubrication-, cooling-, or sealing fluids see also F01D25/16, F01D25/24 and F01D25/26
• CPC Class Codes: F05D 2220/32 in gas turbines
• CPC Class Codes: F05D 2230/22 by sintering
• CPC Class Codes: F05D 2230/234 Laser welding
• CPC Class Codes: F05D 2230/50 Building or constructing in particular ways
• CPC Class Codes: F05D 2260/20 Heat transfer, e.g. cooling
• CPC Class Codes: F05D 2260/201 by impingement of a fluid
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

A method includes (a) depositing a layer of a powder material on a work stage, the layer having a thickness, (b) solidifying a portion of the layer based upon data that defines an insert with a body that is shaped to fit into a cavity in a gas turbine engine component, and (c) lowering the work stage by the thickness. Steps (a)-(c) can then be repeated until the insert is complete. The insert can then be removed from the work stage. An insert formed by the above process is also disclosed.

Claims

1. A method comprising:

(a) depositing a layer of a powder material on a work stage, the layer having a thickness;

(b) solidifying a portion of the layer based upon data that defines an insert with a body that is shaped to fit into a cavity in a gas turbine engine component;

(c) lowering the work stage by the thickness;

(d) repeating steps (a)-(c) until the insert is complete; and

(g) removing the insert from the work stage.

2. The method of claim 1, wherein holes are created in the body of the insert while solidifying portions of the layer of the powder material.

3. The method of claim 2, wherein there is a thickened wall portion surrounding the holes in the body of the insert.

4. The method of claim 1, wherein holes are tooled into the body of the insert after the insert has been removed from the work stage.

5. The method of claim 4, wherein there is a thickened wall portion surrounding the holes in the body of the insert.

6. The method of claim 1, wherein localized protrusions are created in the body of the insert while solidifying portions of the layer of powder material.

7. The method of claim 1, wherein localized divots are created in the body of the insert while solidifying portions of the layer of powder material.

8. The method of claim 1, wherein the powder material is solidified using a laser.

9. The method of claim 1, wherein the powder material is a nickel alloy.

10. The method of claim 1, wherein the powder material is deposited on the work stage by rolling it onto the work stage.

11. A method comprising:

(a) depositing a layer of a powder material on a work stage, the layer having a thickness;

(b) solidifying a portion of the layer based upon data that defines a die that can be used during a tooling process;

(c) lowering the work stage by the thickness;

(d) repeating steps (a)-(c) until the die is complete; and

(g) removing the die from the work stage.

12. The method of claim 11, wherein the die can be used to manufacture an insert that is shaped to fit in a cavity in a gas turbine engine component.

13. The method of claim 11, wherein the powder material is solidified using a laser.

14. The method of claim 11, wherein the powder material is a nickel alloy.

15. The method of claim 11, wherein the powder material is deposited on the work stage by rolling it onto the work stage.

16. An insert comprising:

a body formed by an additive manufacturing process and shaped to fit in a cavity in a gas turbine engine component, the body comprising;

a base portion that is substantially flat;

walls extending upwards from the base portion; and

flanges, for attachment to the gas turbine engine component, extending outwards from the walls;

a hole in the body of the insert; and

a localized build-up adjacent the hole to promote cooling of the component.

17. The insert of claim 16, wherein the insert is a baffle.

18. The insert of claim 17, and further comprising:

a plurality of holes in the walls.

19. The insert of claim 18, and further comprising:

a thickened wall portion surrounding the plurality of holes.

20. The insert of claim 16, wherein the insert is a cover.

21. The insert of claim 20, and further comprising:

a plurality of holes in the base portion.

22. The insert of claim 21, and further comprising:

a thickened wall portion surrounding the plurality of holes.

23. The insert of claim 16, and further comprising:

localized protrusions in the body of the insert.

24. The insert of claim 16, and further comprising:

localized divots in the body of the insert.

25. A gas turbine engine component with an insert, the component comprising:

a body with an airfoil running between an outer platform and an inner platform;

a cavity with an opening on at least one of the outer platform or the inner platform; and

an insert, formed by an additive manufacturing process, placed in the cavity with localized build-up in a pre-selected area to promote cooling of the component.

26. The component of claim 25, wherein the cavity runs through the airfoil and the insert is a baffle that is placed in the cavity.

27. The component of claim 25, wherein the cavity extends a defined distance into at least one of the outer platform or the inner platform and the insert is a cover that is placed in the cavity.