Article with internal structure

Patent metadata

Field	Value
Publication number	US-2016237828-A1
Application number	US-201415026155-A
Country	US
Kind code	A1
Filing date	Sep 24, 2014
Priority date	Oct 7, 2013
Publication date	Aug 18, 2016
Grant date	—

Abstract

A method includes building an article by a layer-by-layer additive manufacturing process. While the article is being built, a solid outer wall is formed. An inner structure of the article is integrally formed with the outer wall. The inner structure includes an internal permeable structure.

First claim

1 . A method comprising:
building an article by a layer-by-layer additive manufacturing process; forming, while building the article, a solid outer wall of the article; and integrally forming an inner structure of the article with the outer wall, wherein the inner structure comprises an internal permeable structure.

2 . The method of claim 1 , wherein:
the outer wall defines a passage within the article; and the inner structure is configured within the passage to allow transport of a fluid through the article.

3 . The method of claim 2 , wherein the article comprises a first end configured to allow the fluid to enter and/or exit the article.

4 . The method of claim 3 , wherein the article comprises a second end configured to allow the fluid to enter and/or exit the article.

5 . The method of claim 1 , wherein the outer wall includes cooling channels extending from the inner structure to an exterior environment outside of the article.

6 . The method of claim 1 , wherein the article comprises a component designed for use in a gas turbine engine.

7 . The method of claim 1 , wherein the internal structure is configured to perform at least one of vibration dampening, structural support, heat transfer, energy absorption, fluid flow, or piping.

8 . A component comprising:
an external structure, built by layer-by-layer additive manufacturing, and defining an external surface of the component; and an internal structure, built by the layer-by-layer additive manufacturing, and comprising a matrix structure, honeycomb structure, or lattice structure, the internal structure integrally formed to the external structure and positioned within the component to provide structural support, vibration dampening, heat transfer, energy absorption, fluid flow, or piping to the component.

9 . The component of claim 8 , wherein:
the external structure defines a passage within the component; and the inner structure is configured within the passage to allow transport of a fluid through the component.

10 . The component of claim 9 , wherein the article comprises a first end configured to allow the fluid to enter and/or exit the article.

11 . The component of claim 10 , wherein the article comprises a second end configured to allow the fluid to enter and/or exit the article.

12 . The component of claim 8 , wherein the outer wall includes cooling channels extending from the inner structure to an exterior environment outside of the article.

13 . The component of claim 9 , wherein the fluid comprises oil, fuel, gas, or air.

14 . The component of claim 8 , wherein the component comprises a part designed for use in a gas turbine engine.

15 . A method comprising:
designing a component having an external structure and an internal structure, wherein the internal structure performs at least one of vibration dampening, structural support, heat transfer, energy absorption, fluid flow, or piping, and wherein the internal structure includes at least one of a matrix structure, honeycomb structure, or lattice structure, the internal structure integrally formed to the external structure; creating digital files defining the component on a layer-by-layer basis; and producing the component by layer-by-layer additive manufacturing using the digital files.

16 . The method of claim 15 , wherein:
the external structure defines a passage within the component; and the inner structure is configured within the passage to allow transport of a fluid through the component.

17 . The method of claim 16 , wherein the fluid comprises oil, fuel, gas, or air.

18 . The method of claim 15 , wherein the component comprises a part designed for use in a gas turbine engine.

19 . The method of claim 16 , wherein the external structure comprises at least a first opening configured to allow the fluid to enter and/or exit the component.

20 . The method of claim 15 , wherein the external structures includes cooling channels extending from the inner structure to an exterior environment outside of the component.

Assignees

• United Technologies Corp

Inventors

• Burd Steven W

Classifications

• F01D5/187 Primary

  Convection cooling · CPC title

• F01D5/18 Primary

  Hollow blades, {i.e. blades with cooling or heating channels or cavities (structure of hollow blades in general F01D5/147)}; Heating, heat-insulating or cooling means on blades · CPC title

• B22F10/28

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

• B22F5/04

  of turbine blades · CPC title

• F05D2230/31

  Layer deposition · CPC title