Flow devices and methods of making the same

Patent metadata

Field	Value
Publication number	US-2016376996-A1
Application number	US-201514749791-A
Country	US
Kind code	A1
Filing date	Jun 25, 2015
Priority date	Jun 25, 2015
Publication date	Dec 29, 2016
Grant date	—

Abstract

A method for producing a device having at least one internal feature includes manufacturing an internal volume of the internal features out of a first material, disposing the internal volume in a parent material that has a higher melting point than the first material, causing the internal volume to melt within the parent material, and allowing at least a portion of the first material to diffuse into the parent material, thereby leaving behind the at least one internal feature within the parent material.

First claim

What is claimed is:

1 . A method for producing a device having at least one internal feature, comprising:
manufacturing an internal volume of the internal features out of a first material; disposing the internal volume in a parent material that has a higher melting point than the first material; causing the internal volume to melt within the parent material; and allowing at least a portion of the first material to diffuse into the parent material, thereby leaving behind the at least one internal feature within the parent material.

2 . The method of claim 1 , wherein the internal feature is a flow channel, the internal volume is a flow volume, and the first material is a channel material.

3 . The method of claim 2 , wherein causing the flow volume to melt includes subjecting the channel material and the parent material to at least one of cold isostatic pressing or hot isostatic pressing.

4 . The method of claim 2 , wherein manufacturing the flow volume includes additively manufacturing the flow volume.

5 . The method of claim 4 , further comprising smoothing an exterior surface of the additively manufactured flow volume.

6 . The method of claim 2 , wherein the parent material includes a powder.

7 . The method of claim 6 , wherein the powder includes at least one of a metal powder, an alloy powder, a composite powder, or a ceramic powder.

8 . The method of claim 7 , further comprising fusing the powder together after or during melting the channel material within the powder.

9 . The method of claim 2 , wherein the parent material includes at least one of a metal, metal alloy, a composite material, or a ceramic.

10 . The method of claim 9 , wherein the channel material can include at least one of BNi-2, BNi-6, NB 30, NB 150, Bni-3, MBF-60, MBF-80, DF-3, Ni—Cr—B—Si, Haynes 230 doped with B, Al, Al+SiO 2 , B 2 O 3 , or Oxynitride glass.

11 . The method of claim 2 , wherein manufacturing the flow volume includes forming the flow volume such the flow channel defines at least part of a fuel flow circuit.

12 . The method of claim 11 , further comprising shaping the parent material into a fuel nozzle for a turbomachine.

13 . A flow device, comprising:
a parent material defining a flow channel; and a channel material diffused into the parent material through a wall that defines the flow channel.

14 . The flow device of claim 13 , wherein the channel material is only partially diffused into the parent material from the flow channel such that there is a portion of the parent material that includes the channel material and a portion of the parent material that does not include the channel material.

15 . The flow device of claim 13 , wherein a diffusion gradient exists such that an amount of channel material becomes greater closer to the wall that defines the flow channel.

16 . The flow device of claim 13 , wherein the flow device is a fuel nozzle and the flow channel is one or more fuel circuits.

17 . The flow device of claim 13 , wherein the parent material includes at least one of a metal, metal alloy, a composite material, or a ceramic.

18 . The flow device of claim 13 , wherein the channel material includes at least one of BNi-2, BNi-6, NB 30, NB 150, Bni-3, MBF-60, MBF-80, DF-3, Ni—Cr—B—Si, Haynes 230 doped with B, Al, Al+SiO 2 , B 2 O 3 , or Oxynitride glass.

19 . The flow device of claim 18 , wherein the wall that defines the flow channel includes a mirror finish.

20 . A method for creating a smooth finish in a flow channel of an additively manufactured fuel nozzle, comprising:
manufacturing a three dimensional flow volume of the flow channel out of a channel material such that the flow volume includes a smooth outer surface; disposing the flow volume in a parent material, wherein the parent material that has a higher melting point than the channel material; causing the flow volume to melt within the parent material; and allowing at least a portion of the channel material to diffuse into the parent material, thereby leaving behind the flow channel within the parent material, wherein the flow channel includes a wall having a smoothness substantially similar to the smooth outer surface of the flow volume.

Assignees

• Delavan Inc

Inventors

• Mironets Sergey
• Donovan Matthew

Classifications

• F05D2230/30

  with deposition of material · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B22D25/00 Primary

  Special casting characterised by the nature of the product (B22D15/02, B22D17/16, B22D19/00 take precedence; casting stereotype plates B41D3/00) · CPC title

• F05D2230/22

  by sintering · CPC title

• F02C7/22 Primary

  Fuel supply systems · CPC title