Work piece having self-supporting gusset and method related thereto

Patent metadata

Field	Value
Publication number	US-9486963-B2
Application number	US-201213729791-A
Country	US
Kind code	B2
Filing date	Dec 28, 2012
Priority date	Dec 28, 2012
Publication date	Nov 8, 2016
Grant date	Nov 8, 2016

Abstract

A powder-derived, non-finished work piece includes a first body section that has a wall that spans in a vertical direction. The wall has a relatively thin thickness with respect to a length and a width of the wall. A second body section is arranged next to, but spaced apart from, the first body section. A gusset connects the first body section and the second body section. The gusset extends obliquely from the wall of the first body section with respect to the vertical direction such that the gusset is self-supporting. The first body section has a geometry that corresponds to an end-use component exclusive of the gusset.

First claim

What is claimed is:

1. A method of making a powder-derived, vane structures, the method comprising:
depositing multiple layers of powdered material onto one another;
joining the layers to one another with reference to computer design data relating to a particular cross-section of a work piece that is to be produced, wherein the joining of the layers forms:
a first body section including a wall spanning in a vertical direction and having a relatively thin thickness with respect a length and a width of the wall,
a second body section next to, but spaced apart from, the first body section, and
a gusset connecting the first body section and the second body section, the gusset extending obliquely from the wall of the first body section with respect to the vertical direction such that the gusset is self-supporting, and the first body section having, exclusive of the gusset,

an airfoil;
subjecting the airfoil to a post-power processing process; and
after the post-power processing removing the gusset to produce a finished vane structure.

2. The method as recited in claim 1 , wherein the first body section and the second body section are airfoils.

3. The method as recited in claim 1 , wherein the gusset includes a first section and a second section oriented perpendicularly to the first section.

4. The method as recited in claim 1 , wherein the gusset includes a first section and a second section that are connected between each other at an angle of no greater than 140° maximum.

5. The method as recited in claim 1 , wherein the wall extends from a base end to a tip end, and the gusset extends from the tip end.

6. A method of controlling distortion in a powder-derived vane structure, the method comprising:
providing a work piece with a first body section including a wall spanning in a vertical direction and having a relatively thin thickness with respect a length and a width of the wall, a second body section next to, but spaced apart from, the first body section;
reinforcing the first body section to limit distortion thereof by providing a gusset connecting the first body section and the second body section together, the gusset extending obliquely from the wall of the first body section with respect to the vertical direction such that the gusset is self-supporting, the first body section having, exclusive of the gusset, an airfoil;
subjecting the airfoil to a post-power processing process; and
after the post-powder processing, removing the gusset to produce a finished vane structure.

7. The method as recited in claim 6 , wherein the post-powder processing process is selected from the group consisting of thermal stress relieving, hot isostatic processing, solution heat treating, aging heat treating, grit blasting and combinations thereof.

Assignees

• Mironets Sergey
• Dautova Lyutsia
• Ott Joseph
• O'Neill Christopher F
• Delisle Robert P
• Boyer Jesse R
• Klucha Agnes
• Porretti Louis
• United Technologies Corp

Inventors

• Mironets Sergey
• Dautova Lyutsia
• Ott Joseph
• O'Neill Christopher F
• Delisle Robert P
• Boyer Jesse R
• Klucha Agnes
• Porretti Louis

Classifications

• F16B5/00

  Joining sheets or plates {, e.g. panels,} to one another or to strips or bars parallel to them ({F16B17/00 takes precedence;} by sticking together F16B11/00; dowel connections F16B13/00; pins, including deformable elements F16B19/00; covering of walls E04F13/00; fastening signs, plates, panels or boards to a supporting structure, fastening readily-detachable elements, e.g. letters to signs, plates, panels, or boards, G09F7/00) · CPC title

• B29C64/40

  Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof · CPC title

• B33Y80/00 Primary

  Products made by additive manufacturing · CPC title

• F05D2230/31

  Layer deposition · CPC title

• F04D29/542

  Bladed diffusers (fixing blades to stators F01D9/042) · CPC title