Hybrid bearing forged flange

Patent metadata

Field	Value
Publication number	US-2024131588-A1
Application number	US-202318493470-A
Country	US
Kind code	A1
Filing date	Oct 23, 2023
Priority date	Oct 25, 2022
Publication date	Apr 25, 2024
Grant date	—

Abstract

A method of additive manufacturing of a component is provided. The method includes building up the component to have a first uppermost layer and a foundation to have a second uppermost layer below the first uppermost layer, evacuating powder from around the component and the foundation to expose the second uppermost layer, disposing, on the second uppermost layer, a forged flange having an upper surface coplanar with the first uppermost layer, backfilling powder about the component and the forged flange, applying a thin additive manufacturing layer to the upper surface and completing a building up of the component by building up on the thin additive manufacturing layer.

First claim

What is claimed is:

1 . A method of additive manufacturing of a component, the method comprising:
building up the component to have a first uppermost layer and a foundation to have a second uppermost layer below the first uppermost layer; evacuating powder from around the component and the foundation to expose the second uppermost layer; disposing, on the second uppermost layer, a forged flange having an upper surface coplanar with the first uppermost layer; backfilling powder about the component and the forged flange; applying a thin additive manufacturing layer to the upper surface; and completing a building up of the component by building up on the thin additive manufacturing layer.

2 . The method according to claim 1 , wherein the component comprises a bearing chamber of a gas turbine engine.

3 . The method according to claim 1 , wherein the forged flange comprises metallic material having substantially different properties of thermal expansion from materials of the component and the thin layer.

4 . The method according to claim 1 , further comprising chamfering the second uppermost layer prior to the disposing of the forged flange thereon.

5 . The method according to claim 1 , wherein the disposing of the forged flange on the second uppermost layer comprises mechanically attaching the forged flange to the second uppermost layer.

6 . The method according to claim 1 , wherein the thin additive manufacturing layer has a thickness which is less than thicknesses of each other layer of the component.

7 . The method according to claim 1 , wherein the thin additive manufacturing layer has a thickness of about 20 microns.

8 . The method according to claim 1 , wherein the completing of the building up of the component comprises:
restarting the building up of the component, comprising:
building up a main body of the component; and
building up a peripheral body of the component on the thin additive manufacturing layer; and
connecting the peripheral body to the main body.

9 . A method of additive manufacturing of a bearing chamber of a gas turbine engine, the method comprising:
building up a main body of the bearing chamber to have a first uppermost layer and a foundation to have a second uppermost layer below the first uppermost layer; evacuating powder from around the main body and the foundation to expose the second uppermost layer; disposing, on the second uppermost layer, a forged flange having an upper surface coplanar with the first uppermost layer; backfilling powder about the main body and the forged flange; applying a thin additive manufacturing layer to the upper surface; and completing the bearing chamber by continuing to build up the main body, building up a peripheral body of the bearing chamber on the thin additive manufacturing layer and connecting the peripheral body to the main body.

10 . The method according to claim 9 , wherein the forged flange comprises metallic material having substantially different properties of thermal expansion from materials of the main body and the peripheral body and the thin layer.

11 . The method according to claim 9 , further comprising chamfering the second uppermost layer prior to the disposing of the forged flange thereon.

12 . The method according to claim 9 , wherein the disposing of the forged flange on the second uppermost layer comprises mechanically attaching the forged flange to the second uppermost layer.

13 . The method according to claim 9 , wherein the thin additive manufacturing layer has a thickness which is less than thicknesses of each other layer of the main body and the peripheral body.

14 . The method according to claim 9 , wherein the thin additive manufacturing layer has a thickness of about 20 microns.

15 . An additively manufactured and hybridized component, comprising:
a main body built up of layers of additive manufacturing material; a forged flange formed of material having substantially different properties of thermal expansion from the additive manufacturing material; a thin layer of the additive manufacturing material applied to at least an uppermost surface of the forged flange; and a peripheral body built up of layers of the additive manufacturing material from the thin layer of the additive manufacturing material to connect with the main body.

16 . The additively manufactured and hybridized component according to claim 15 , wherein the thin layer of the additive manufacturing material has a thickness which is less than thicknesses of each of the layers of the main body and each of the layers of the peripheral body.

17 . The additively manufactured and hybridized component according to claim 15 , wherein the thin layer has a thickness of about 20 microns.

18 . The additively manufactured and hybridized component according to claim 15 , wherein the additively manufactured component comprises a bearing chamber of a gas turbine engine.

19 . The additively manufactured and hybridized component according to claim 15 , wherein the forged flange comprises metallic material having the substantially different properties of thermal expansion from the additive manufacturing material.

20 . The additively manufactured and hybridized component according to claim 15 , wherein a lower surface of the forged flange is substantially flat.

Assignees

• Rtx Corp

Inventors

• Binek Lawrence A
• Ramsey Christopher D
• Satoh Gen
• Gardell Benjamin G

Classifications

• B22F10/28 Primary

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

• B22F5/009 Primary

  of turbine components other than turbine blades (of turbine blades B22F5/04) · CPC title

• B22F10/37

  of powder bed aspects, e.g. density · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title