Additive manufacturing hybrid core

Patent metadata

Field	Value
Publication number	US-10035731-B2
Application number	US-201514672628-A
Country	US
Kind code	B2
Filing date	Mar 30, 2015
Priority date	Apr 5, 2012
Publication date	Jul 31, 2018
Grant date	Jul 31, 2018

Abstract

A hybrid core for manufacturing high temperature parts includes a non-refractory metal portion and a refractory metal portion wherein at least a portion of the non-refractory metal portion and the refractory metal portion are manufactured by using an additive manufacturing process.

First claim

What is claimed is:

1. A hybrid core for manufacturing high temperature parts, said hybrid core comprising:
a non-refractory metal portion; and
a refractory metal portion, wherein at least a portion of said non-refractory metal portion and said refractory metal portion are manufactured using an additive manufacturing process, wherein an interface between said non-refractory metal portion and said refractory metal portion is formed using an additive manufacturing process, and wherein one of said a non-refractory metal portion and said refractory metal portion is formed adjacent the other of said non-refractory metal portion and said refractory metal portion.

2. The hybrid core of claim 1 wherein at least a piece of said refractory metal portion is manufactured by using refractory metal powder during an additive manufacturing process.

3. The hybrid core of claim 1 wherein at least a portion of said non-refractory metal portion is manufactured by using non-refractory metal during an additive manufacturing process.

4. The hybrid core of claim 1 wherein at least a portion of said refractory metal portion is manufactured by using refractory metal powder during an additive manufacturing process and said non-refractory metal portion is manufactured by using non-refractory metal powder during an additive manufacturing process.

5. The hybrid core of claim 1 wherein one of said a non-refractory metal portion and said refractory metal portion is formed on top of the other of said non-refractory metal portion and said refractory metal portion.

6. The hybrid core of claim 1 wherein said non-refractory metal portion is a ceramic material.

7. The hybrid core of claim 1 , wherein said interface is formed as a laser fuses powder particles to one of said first portion and said second portion.

8. The hybrid core of claim 1 , wherein said non-refractory metal portion has a groove therein, and wherein a portion of said refractory metal portion is received in said groove.

9. The hybrid core of claim 1 , wherein said non-refractory metal portion includes an extension projecting from a surface thereof, and wherein a portion of said refractory metal portion is additively manufactured on a surface of said extension.

10. The hybrid core of claim 1 , wherein said non-refractory metal portion contacts said refractory metal portion via said interface.

11. A hybrid core for manufacturing high temperature parts, said hybrid core comprising:
a non-refractory metal portion; and
a refractory metal portion, wherein at least a portion of said non-refractory metal portion and said refractory metal portion are manufactured using an additive manufacturing process, and wherein an interface between said non-refractory metal portion and said refractory metal portion is formed using an additive manufacturing process;
wherein at least a portion of said refractory metal portion is manufactured by using refractory metal powder during an additive manufacturing process and said non-refractory metal portion is manufactured by using non-refractory metal powder during an additive manufacturing process;
wherein said at least a portion of said refractory metal portion and said non-refractory metal portion are attached to each other.

12. A hybrid core for manufacturing for turbine engine parts, said hybrid core comprising:
a first portion made of a non-refractory metal portion; and
a second portion made of a refractory metal portion or a non-refractory metal portion;
wherein at least one of said first portion or said second portion is manufactured using additive manufacturing process, and wherein an interface between said first portion and said second portion is formed using an additive manufacturing process, wherein one of said a first portion and said second portion is formed adjacent the other of said first portion and said second portion.

13. The hybrid core of claim 12 , wherein said interface is formed as a laser fuses powder particles to one of said first portion and said second portion.

Assignees

• United Technologies Corp

Inventors

• Xu Jinquan

Classifications

• C04B35/00 Primary

  Shaped ceramic products characterised by their composition {(porous ceramic products C04B38/00; ceramic articles characterised by particular shape, see the relevant classes, e.g. linings for casting ladles, tundishes, cups or the like B22D41/02; ceramic substrates for microelectronic semi-conductors H10W70/692)}; Ceramics compositions ({shaping of ceramics B28B;} containing free metal bonded to carbides, diamond, oxides, borides, nitrides, silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides or sulfides other than as macroscopic reinforcing agents C22C); Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products {(infiltration of sintered ceramic preforms with molten metal C04B41/51; chemical preparation of powders of inorganic compounds C01)} · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B22F7/06 Primary

  of composite workpieces or articles from parts, e.g. to form tipped tools {(B22F7/002 takes precedence)} · CPC title

• B22F2003/1058

  Operations & Transport · mapped topic

• B22F3/1055

  Operations & Transport · mapped topic