Additive manufacturing method for making complex film holes

Patent metadata

Field	Value
Publication number	US-2017129014-A1
Application number	US-201514937325-A
Country	US
Kind code	A1
Filing date	Nov 10, 2015
Priority date	Nov 10, 2015
Publication date	May 11, 2017
Grant date	—

Abstract

A method of forming a cooling hole structure on a turbine component. The turbine component has a component wall with inner and outer surfaces. A bore passes through the component wall and fluidly connects the inner surface and the outer surface. The method includes the steps of: A) forming a recess communicating with the bore and the outer surface; and B) using an additive manufacturing process to form an exit region in the recess.

First claim

What is claimed is:

1 . A method of forming a cooling hole structure on a turbine component having a component wall with inner and outer surfaces, wherein a bore passes through the component wall and fluidly connects the inner surface and the outer surface, the method comprising:
forming a recess communicating with the bore and the outer surface; and using an additive manufacturing process to form an exit region in the recess.

2 . The method of claim 1 further comprising depositing powder on a first surface that defines the recess; and
fusing the powder in a pattern corresponding to a layer of the structure.

3 . The method of claim 2 further comprising repeating in a cycle the steps of depositing and fusing to build up the structure in a layer-by-layer fashion.

4 . The method of claim 3 wherein the repeating cycle of depositing and fusing results in the component including both fused and un-fused powder, the method further comprising removing the un-fused powder.

5 . The method of claim 2 wherein the powder is adhered to the first surface by:
applying an adhesive to the first surface; and
applying powder to the adhesive.

6 . The method of claim 5 further comprising removing excess powder after the powder is applied to the adhesive.

7 . The method of claim 2 further comprising forming a plug in the bore and depositing powder on the plug.

8 . The method of claim 7 further comprising fusing the powder such that the pattern leaves unfused powder over at least a portion of the plug.

9 . The method of claim 8 further comprising forming the diffusing section by fusing subsequent layers such that unfused powder of each subsequent layer overlaps unfused powder of the previous layer.

10 . The method of claim 1 wherein the component comprises a metal alloy.

11 . The method of claim 1 wherein the powder comprises a metal alloy.

12 . A method of forming a cooling hole structure on a turbine component having a component wall with inner and outer surfaces, wherein a bore passes through the component wall and fluidly connects the inner surface and the outer surface, the method comprising:
forming a recess communicating with the bore and the outer surface; and using an additive manufacturing process to form a section of a film hole that changes dimension with distance along the hole centerline.

13 . The method of claim 12 further comprising depositing powder on a first surface that defines the recess; and
fusing the powder in a pattern corresponding to a layer of the structure.

14 . The method of claim 13 further comprising repeating in a cycle the steps of depositing and fusing to build up the structure in a layer-by-layer fashion.

15 . The method of claim 14 wherein the repeating cycle of depositing and fusing results in the component including both fused and un-fused powder, the method further comprising removing the un-fused powder.

16 . The method of claim 13 wherein the powder is adhered to the first surface by:
applying an adhesive to the first surface; and
applying powder to the adhesive.

17 . The method of claim 16 further comprising removing excess powder after the powder is applied to the adhesive.

18 . The method of claim 13 further comprising forming a plug in the bore and depositing powder in a layer that at least partially overlaps the plug.

19 . The method of claim 18 further comprising fusing the powder in the layer such that the pattern leaves unfused powder over at least a portion of the plug.

20 . The method of claim 19 further comprising forming the exit section of the film hole by fusing subsequent layers such that unfused powder of each subsequent layer overlaps both unfused and fused powder of the previous layer.

Assignees

• Gen Electric

Inventors

• Bunker Ronald Scott

Classifications

• B23P2700/06

  Cooling passages of turbine components, e.g. unblocking or preventing blocking of cooling passages of turbine components · CPC title

• B22F10/28

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

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title

• B22F10/68

  Cleaning or washing · CPC title

• F01D5/186 Primary

  Film cooling (F01D5/187 takes precedence) · CPC title