Manufacture of component with cavity

Patent metadata

Field	Value
Publication number	US-2016356162-A1
Application number	US-201615151996-A
Country	US
Kind code	A1
Filing date	May 11, 2016
Priority date	Jun 3, 2015
Publication date	Dec 8, 2016
Grant date	—

Abstract

A method for the manufacture of a component having an internal cavity is described. The method comprises; defining an external geometry of the component, defining a core geometry of the component; and using an additive layer manufacturing (ALM) method, building the component from a plurality of layers laid on a first plane. The core geometry is advantageously designed to suit manufacture of the component using an ALM method which involves local melting of powder in a powder bed to form the layers, permitting easy removal of excess powder from the internal cavity.

First claim

1 . A method for the manufacture of a component having an internal cavity, the method comprising;
defining an external geometry of the component, defining a core geometry of the component; using an additive layer manufacturing (ALM) method, building the component from a plurality of layers laid on a first plane; wherein the core geometry includes a main core passage, a channel extending from a first end of the main core passage to an external surface of the component, the channel having an axis which is inclined at a first angle to an axis of the main core passage whereby to define an apex between walls of the channel and the main core passage which is obtuse, the channel axis further being inclined to the first plane; and the additive layer manufacturing method includes removing excess material from the main core passage via the channel.

2 . A method as claimed in claim 1 wherein the ALM method uses a powder bed and local melting to create the layers.

3 . A method as claimed in claim 1 wherein the step of removing the excess material involves upturning the component such that the channel faces downward, and agitating the component.

4 . A method as claimed in claim 1 wherein the obtuse angle of the apex is greater than 105 degrees.

5 . A method as claimed in claim 4 wherein the obtuse angle of the apex is in the range 120 to 165 degrees.

6 . A method as claimed in claim 1 wherein the channel is blended into the main core passage with a smoothly curved join.

7 . A method as claimed in claim 1 wherein the core passage is elongate.

8 . A method as claimed in claim 1 wherein the core passage is configured to define sloping shoulders extending from the first channel where the first channel meets the core passage.

9 . A method as claimed in claim 1 wherein the core passage includes a sloped surface at a second end, distal from and facing the first end.

10 . A method as claimed in claim 1 wherein the core includes a plurality of additional channels extending from an elongate side of the core passage.

11 . A method as claimed in claim 10 wherein the additional channels extend orthogonally to a longitudinal axis of the main core passage and/or in parallel with the first plane.

12 . A method as claimed in claim 11 wherein an additional channel is located adjacent to the second end of the main core passage.

13 . A method as claimed in claim 1 wherein the first plane is orthogonal to a longitudinal axis of the main core passage.

14 . A method as claimed in claim 1 wherein the layers are formed from a ferrous or non-ferrous alloy, or a ceramic.

15 . A component manufactured in accordance with the method of claim 1 .

16 . A component as claimed in claim 15 which is configured for use in a gas turbine engine.

17 . A component as claimed in claim 16 wherein one or more channels of the core geometry serve, in use, as cooling holes for cooling the component.

18 . A gas turbine engine comprising at least one component, the at least one component having the configuration as set out in any of claim 17 .

Assignees

• Rolls Royce Plc

Inventors

• Jones Simon
• Tucker Matthew

Classifications

• B28B1/001

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title

• B23K26/342

  Build-up welding · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B23K2103/26

  Alloys of Nickel and Cobalt and Chromium · 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