Cantilevered mask for openings in additively manufactured part

Patent metadata

Field	Value
Publication number	US-11358335-B2
Application number	US-202016837089-A
Country	US
Kind code	B2
Filing date	Apr 1, 2020
Priority date	Apr 1, 2020
Publication date	Jun 14, 2022
Grant date	Jun 14, 2022

Abstract

A mask is provided for an additively manufactured part including a plurality of spaced openings in a surface of the part. The mask is made with the part and includes an attachment ligament configured to integrally couple to the part between the openings in a cantilever fashion. First and second cover members include a proximal ends integrally coupled to the attachment ligament and distal ends extending at least partially over a respective portions of the plurality of openings. A detachment member extends from each of the first and second cover members. The attachment ligament is the sole connection to the part. The mask may have an umbrella shape in cross-section.

First claim

What is claimed is:

1. A mask for an additively manufactured part including a plurality of openings spaced in a surface of the part, the mask comprising:
an attachment ligament configured to integrally couple to the part between the plurality of openings in a cantilever fashion;
a first cover member including a first proximal end integrally coupled to the attachment ligament and a first distal end extending at least partially over a first portion of the plurality of openings, the first distal end of the first cover member separated from the part by a first spacing;
a second cover member including a second proximal end integrally coupled to the attachment ligament and a second distal end extending at least partially over a second portion of the plurality of openings, the second distal end of the second cover member separated from the part by a second spacing; and
a detachment member extending from each of the first and second cover members,
wherein the attachment ligament is the only connection to the surface of the part.

2. The mask of claim 1 , wherein the attachment ligament has a minimum width ranging from 0.01 millimeters (mm) to 0.50 mm.

3. The mask of claim 1 , wherein the plurality of openings are positioned in the surface of the part across a distance, and wherein the first and second cover members extend at least partially over the first and second portions of the plurality of openings, respectively, along an entirety of the distance.

4. The mask of claim 3 , wherein the attachment ligament integrally couples to the part at spaced connection points along the distance.

5. The mask of claim 4 , wherein the attachment ligament integrally couples to the part along between 25% and 60% of the distance.

6. The mask of claim 3 , wherein the first and second cover members and the detachment member are segmented into a plurality of cover members and detachment member segments along the distance.

7. The mask of claim 6 , wherein each of the plurality of cover members and detachment member segments are individually separable from the part by breaking a respective portion of the attachment ligament.

8. The mask of claim 1 , wherein the first and second spacing is between 0.88 millimeters (mm) to 1.4 mm.

9. The mask of claim 1 , wherein the first and second spacing have a dimension configured to prevent a coating applied over each cover member from bridging from each cover member, respectively, to the part, and prevent a peening material from passing therethrough.

10. The mask of claim 1 , wherein the plurality of openings are positioned in a pedestal extending from another surface of the part.

11. The mask of claim 1 , further comprising a space filling material positioned between at least one of the first and second cover members and the surface of the part.

12. The mask of claim 1 , wherein the first and second cover members have a convex outer surface facing away from the part, and a concave inner surface facing the part.

13. The mask of claim 12 , wherein the first and second cover members have a mushroom-shaped cross-section.

14. The mask of claim 1 , wherein the detachment member includes a tool receiving feature therein configured to receive a tool.

15. The mask of claim 1 , wherein the part, the attachment ligament, the first and second cover members and the detachment member include a plurality of integral material layers.

16. The mask of claim 1 , wherein the attachment ligament includes a lower portion integrally coupled to the part and having a first width, and an upper portion above the lower portion and having a second minimum width that is wider than the first width.

17. An additively manufactured (AM) structure, comprising:
a part including a plurality of openings spaced in a surface of the part; and
a mask including:
an attachment ligament configured to integrally couple to the part between a first portion of the plurality of openings and a second portion of the plurality of openings in a cantilever fashion;
a first cover member including a first proximal end integrally coupled to the attachment ligament and a first distal end extending at least partially over the first portion of the plurality of openings, the first distal end of the first cover member separated from the part by a first spacing;
a second cover member including a second proximal end integrally coupled to the attachment ligament and a second distal end extending at least partially over the second portion of the plurality of openings, the second distal end of the second cover member separated from the part by a second spacing; and
a detachment member extending from each of the first and second cover members,

wherein the attachment ligament is the only connection to the surface of the part, and
wherein the part, the attachment ligament, the first and second cover members and the detachment member include a plurality of integral material layers.

18. The AM structure of claim 17 , wherein the plurality of openings are positioned in the surface of the part across a distance, and wherein the first and second cover members extend at least partially over the first and second portions of the plurality of openings, respectively, along an entirety of the distance, and the attachment ligament integrally couples to the part at spaced connection points along the distance.

19. The AM structure of claim 17 , wherein the first and second spacing have a dimension configured to prevent a coating applied over each cover member from bridging from each cover member, respectively, to the part, and prevent a peening material from passing therethrough.

20. The AM structure of claim 17 , wherein at least one of the first and second cover members has a convex outer surface facing away from the part, and a concave inner surface facing the part.

Assignees

• Gen Electric

Inventors

• Packer Travis J
• Vantassel Brad Wilson
• Porter Christopher Donald
• Lomas Jonathan Matthew
• Taxacher Glenn Curtis

Classifications

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title

• B22F10/20

  Direct sintering or melting · CPC title

• F05D2260/202

  by film cooling · CPC title

• F05D2230/22

  by sintering · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title