WO2014150490A1 - Additive manufacturing method for the addition of features within cooling holes - Google Patents
Additive manufacturing method for the addition of features within cooling holes Download PDFInfo
- Publication number
- WO2014150490A1 WO2014150490A1 PCT/US2014/023393 US2014023393W WO2014150490A1 WO 2014150490 A1 WO2014150490 A1 WO 2014150490A1 US 2014023393 W US2014023393 W US 2014023393W WO 2014150490 A1 WO2014150490 A1 WO 2014150490A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- substrate
- feature
- substrate surface
- metering section
- section
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K15/00—Electron-beam welding or cutting
- B23K15/0046—Welding
- B23K15/0086—Welding welding for purposes other than joining, e.g. built-up welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K15/00—Electron-beam welding or cutting
- B23K15/0046—Welding
- B23K15/0093—Welding characterised by the properties of the materials to be welded
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/0006—Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/34—Laser welding for purposes other than joining
- B23K26/342—Build-up welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/14—Form or construction
- F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
- F01D5/186—Film cooling
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D9/00—Stators
- F01D9/06—Fluid supply conduits to nozzles or the like
- F01D9/065—Fluid supply or removal conduits traversing the working fluid flow, e.g. for lubrication-, cooling-, or sealing fluids
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23R—GENERATING COMBUSTION PRODUCTS OF HIGH PRESSURE OR HIGH VELOCITY, e.g. GAS-TURBINE COMBUSTION CHAMBERS
- F23R3/00—Continuous combustion chambers using liquid or gaseous fuel
- F23R3/002—Wall structures
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/001—Turbines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/02—Iron or ferrous alloys
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
- B23K2103/52—Ceramics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/10—Manufacture by removing material
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/10—Manufacture by removing material
- F05D2230/12—Manufacture by removing material by spark erosion methods
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/10—Manufacture by removing material
- F05D2230/13—Manufacture by removing material using lasers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/10—Manufacture by removing material
- F05D2230/14—Micromachining
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/30—Manufacture with deposition of material
- F05D2230/31—Layer deposition
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2240/00—Components
- F05D2240/10—Stators
- F05D2240/11—Shroud seal segments
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2240/00—Components
- F05D2240/80—Platforms for stationary or moving blades
- F05D2240/81—Cooled platforms
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2260/00—Function
- F05D2260/20—Heat transfer, e.g. cooling
- F05D2260/202—Heat transfer, e.g. cooling by film cooling
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2260/00—Function
- F05D2260/20—Heat transfer, e.g. cooling
- F05D2260/221—Improvement of heat transfer
- F05D2260/2214—Improvement of heat transfer by increasing the heat transfer surface
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2260/00—Function
- F05D2260/20—Heat transfer, e.g. cooling
- F05D2260/221—Improvement of heat transfer
- F05D2260/2214—Improvement of heat transfer by increasing the heat transfer surface
- F05D2260/22141—Improvement of heat transfer by increasing the heat transfer surface using fins or ribs
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23R—GENERATING COMBUSTION PRODUCTS OF HIGH PRESSURE OR HIGH VELOCITY, e.g. GAS-TURBINE COMBUSTION CHAMBERS
- F23R2900/00—Special features of, or arrangements for continuous combustion chambers; Combustion processes therefor
- F23R2900/00018—Manufacturing combustion chamber liners or subparts
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23R—GENERATING COMBUSTION PRODUCTS OF HIGH PRESSURE OR HIGH VELOCITY, e.g. GAS-TURBINE COMBUSTION CHAMBERS
- F23R2900/00—Special features of, or arrangements for continuous combustion chambers; Combustion processes therefor
- F23R2900/03042—Film cooled combustion chamber walls or domes
Definitions
- This invention relates generally to turbomachinery, and specifically to turbine flow path components for gas turbine engines.
- the invention relates to cooling techniques for airfoils and other gas turbine engine components exposed to hot working fluid flow, including, but not limited to, rotor blades and stator vanes, platforms, blade outer air seals (BOAS), shrouds and compressor and turbine casings, combustor liners, turbine exhaust assemblies, thrust augmentors and exhaust nozzles.
- BOAS blade outer air seals
- Gas turbine engine performance depends on the balance between pressure ratios and core gas path temperatures and the related effects on service life and reliability due to stress and wear. This balance is particularly relevant to gas turbine engine components in the compressor, combustor, turbine and exhaust sections, where active cooling may be required to prevent damage due to high gas path temperatures.
- a method for forming a diffusion cooling hole in a substrate includes removing material from the substrate to form a metering section having an inlet on a first side of the substrate and removing material from the substrate to form a diffusing section that extends between the metering section and an outlet located on a second side of the substrate generally opposite the first side.
- the method also includes forming a feature on a substrate surface within one of the metering section and the diffusing section. Forming the feature includes depositing a material on the substrate surface and selectively heating the material to join the material with the substrate surface and form the feature.
- FIG. 1 is a view of a wall having diffusion cooling holes.
- FIG. 2 is a sectional view of the diffusion cooling hole of FIG. 1 taken along the line 2-2.
- FIG. 3 is a perspective view of a diffusion cooling hole before raised features have been added.
- FIG. 4 is a perspective view of one embodiment of a diffusion cooling hole with features formed by additive manufacturing.
- FIG. 5A is a cross section view of another embodiment of a diffusion cooling hole with features formed by additive manufacturing.
- FIG. 5B is a cross section view of the diffusion cooling hole of FIG. 5A taken along the line B-B.
- FIG. 6 is a perspective view of another embodiment of a diffusion cooling hole with features formed by additive manufacturing.
- FIG. 1 illustrates a view of a wall with cooling holes formed according to one embodiment of the present invention.
- Wall 10 is primarily metallic and includes opposite surfaces 12 and 14.
- surfaces 12 and 14 can include a coating layer such as a thermal barrier coating.
- Cooling holes 16 are oriented so that their inlets 18 are positioned along surface 12 of wall 10 and their outlets 20 are positioned along surface 14 of wall 10.
- surface 14 is in proximity to high temperature gases (e.g. , combustion gases, hot air). Cooling air is delivered along surface 12 of wall 10 where it enters inlets 18 of cooling holes 16, exits outlets 20 of cooling holes 16 and forms a cooling film on surface 14.
- a variety of components that require cooling can include cooling holes 16.
- Suitable components include, but are not limited to, turbine vanes and blades, combustors, blade outer air seals, and augmentors, etc.
- Cooling holes 16 can be utilized on the pressure side or suction side of vanes and blades. Cooling holes 16 can also be utilized on the blade tip or blade or vane platforms.
- FIG. 2 illustrates a sectional view of cooling hole 16 of FIG. 1 taken along the line 2-2.
- FIG. 2 illustrates cooling hole 16 before the fine features are formed along the surfaces that define cooling hole 16.
- Cooling hole 16 includes inlet 18, outlet 20, metering section 22 and diffusing section 24.
- Inlet 18 is an opening located on surface 12.
- Cooling air C enters cooling hole 16 through inlet 18 and passes through metering section 22 and diffusing section 24 before exiting cooling hole 16 at outlet 20 along surface 14.
- Metering section 22 is adjacent to and downstream from inlet 18 and controls (meters) the flow of air through cooling hole 16. As shown in FIGs. 2 and 3, metering section 22 is defined by continuous, generally circular surface 26. In some embodiments, metering section 22 has a substantially constant flow area generally from inlet 18 to diffusing section 24. Metering section 22 can have circular, oblong (oval or elliptical), racetrack (oval with two parallel sides having straight portions), crescent, cusp or dual- cusp shaped cross sections. In some embodiments, metering section 22 is inclined between surfaces 12 and 14 of wall 10 as illustrated in FIG. 2 (i.e. metering section 22 is not perpendicular to wall 10). Axis 27 extends through the center of metering section 22 as shown in FIG. 2.
- Diffusing section 24 is adjacent to and downstream from metering section 22. As shown in FIGs. 2 and 3, diffusing section 24 is defined by bottom surface 28, side surfaces 30 and 32 and top surface 34. As shown in FIG. 2, diffusing section 24 diverges longitudinally from axis 27 and metering section 22. Bottom surface 28 diverges longitudinally from axis 27 as it extends from surface 26 to outlet 20. As best shown in FIG. 3, diffusing section 24 also diverges laterally from metering section 22. Side surfaces 30 and 32 flare out as they extend from surface 26 to outlet 20. Cooling fluid traveling through cooling hole 16 diffuses and expands to fill diffusing section 24.
- FIG. 3 is a perspective view of cooling hole 16 before the fine features are formed along one or more of the surfaces that define the cooling hole.
- Surfaces 12 and 14 of wall 10 are not shown in FIG. 3 so that the features of the cooling hole can be better illustrated.
- bottom surface 28, side surfaces 30 and 32 and top surface 34 define diffusing section 24, and extend from surface 26 to outlet 20.
- Cooling holes 16 shown in FIGs. 2 and 3 are typically formed by traditional manufacturing techniques in which material is removed from wall 10 to form surfaces 26, 28, 30, 32 and 34 that define cooling hole 16. Suitable methods of material removal include, but are not limited to, drilling, laser drilling, machining, electrical discharge machining (EDM) and combinations thereof.
- metering section 22 of cooling hole 16 can be formed by drilling while diffusing section 24 of cooling hole 16 is formed by EDM. In some cases, cooling hole 16 can also be made using casting processes.
- FIG. 4 illustrates one embodiment of a cooling hole with fine features.
- FIG. 4 is a perspective view of cooling hole 16 having raised feature 36 on bottom surface 28.
- Raised feature 36 is formed within cooling hole 16 by adding material to bottom surface 28.
- feature 36 is a raised region of material located on bottom surface 28.
- metering section 22 and diffusing section 24 raised feature 36 cannot be easily formed by removing material from wall 10. Casting, drilling, laser drilling, machining and EDM techniques cannot typically form the geometry of raised feature 36 reliably and reproducibly or inexpensively.
- raised feature 36 is formed using additive manufacturing techniques.
- Suitable additive manufacturing techniques for forming raised feature 36 include, but are not limited to, selective laser melting, direct metal laser sintering, selective laser sintering and electron beam melting.
- the additive manufacturing technique chosen can depend on the type of material used to form raised feature 36.
- raised feature 36 is formed of a metal, alloy or superalloy. In these embodiments, any of the aforementioned techniques can be suitable.
- raised feature 36 is formed of a ceramic material.
- selective laser sintering is typically used to form ceramic raised feature 36.
- Each of these techniques involves heating a thin layer of material and melting it so that it joins with a substrate. The heating/melting and joining process can be repeated several times until the material has formed the desired raised feature 36.
- raised feature 36 is formed within cooling hole 16 by depositing a material on bottom surface 28 and selectively heating the material so that it melts and joins with bottom surface 28 following solidification. This process is repeated until the desired feature geometry and thickness has been formed. Joining the material with bottom surface 28 forms raised feature 36 as shown in FIG. 4.
- the material applied to bottom surface 28 can be a metal or ceramic powder that is sprayed or placed on bottom surface 28. Alternatively, thin layers of metal can be sequentially positioned along bottom surface 28 prior to each heating step. Metals and ceramic raw materials may also be formed into a slurry and brushed onto bottom surface 28.
- the material is selectively heated above it melting temperature so that it fuses and joins with bottom surface 28.
- the material is heated using a high powered laser or electron beam to deliver the energy necessary to melt the material.
- the entire part can be placed within a vacuum.
- the laser or electron beam energy may also melt part of bottom surface 28 in some cases, forming a strong bond between bottom surface 28 and raised feature 36.
- additional material is deposited and the heating process is carried out again. This series of steps (depositing, heating/melting, solidifying) is repeated until raised feature 36 contains the desired three-dimensional shape and thickness.
- the desired geometric characteristics of raised feature 36 are determined. These characteristics generally include the shape, thicknesses, curvature and other three-dimensional qualities of the desired feature.
- a computer generates a computer-aided design (CAD) file, additive manufacturing file format (AMF) file or other type of file that provides instructions to control the additive manufacturing operation.
- CAD computer-aided design
- AMF additive manufacturing file format
- This file contains information that controls the layer-by-layer depositing and melting process described above.
- an additive manufacturing machine or system deposits the material within cooling hole 16 and selectively melts the material to form raised feature 36.
- raised feature 36 is a pyramid-like three dimensional structure.
- a CAD, AMF or other file describing the geometry of raised feature 36 is generated by a computer. This file is used to control the layer-by-layer additive manufacturing process for creating raised feature 36.
- Raised feature 36 includes apex 38 and four relatively planar surfaces extending from apex 38 to bottom surface 28. Raised feature 36 diverts cooling air to the lateral edges of diffusing section 24, lobes 40 and 42 as shown and described in greater detail in FIG. 8 and the accompanying description in U.S. Patent Application No. 13/544.090, filed on July 9, 2012 and entitled "Multi-lobed cooling hole".
- raised feature 36 can be similarly formed on side surfaces 30 and 32 and top surface 34 or on surface 26. Raised feature 36 can also be flat or curved as necessary to divert cooling air through cooling hole 16.
- FIGs. 5A and 5B illustrate cross section views of a cooling hole and one example of raised feature 36A formed within metering section 22 of cooling hole 16A.
- raised feature 36A is formed near the downstream end of metering section 22 on surface 26.
- Raised feature 36A obstructs a portion of metering section 22 and creates a cusp-like opening as shown in FIG. 5B.
- Raised feature 36A obscures a line of sight between inlet 18 and outlet 20 of cooling hole 16A.
- Raised feature 36A cannot be easily formed by drilling or EDM methods.
- raised feature 36A is formed according to the additive manufacturing methods described above with respect to FIG. 4.
- FIG. 6 illustrates another embodiment of a cooling hole having raised features formed by additive manufacturing techniques.
- FIG. 6 is a perspective view of cooling hole 16B having raised features 36B along all the surfaces that extend from metering section 22 to the outlet 24 A (bottom surface 28, side surfaces 30 and 32 and top surface 34). Cooling hole 16B appears similar to cooling hole 16 shown in FIG. 4.
- the dashed lines near outlet 20A illustrate the location of outlet 20 in FIG. 4.
- additional material has been added to bottom surface 28, side surfaces 30 and 32 and top surface 34 along and near outlet 20A to provide a cooling hole with "sharper corners".
- a CAD, AMF or other file describing the geometry of raised feature 36B (the difference in distance between outlet 20 and outlet 20A) is generated by a computer. This file is used to control the layer-by-layer additive manufacturing process for creating raised feature 36B that reduces the sharp corners of outlet 20.
- Cooling holes can be fine tuned to contain wide corners, sharp corners, or a combination of both wide and sharp corners along the outlet to fit the specific needs based on the cooling hole location.
- the angle of the corner near the juncture of side surface 32 and bottom surface 28 shown before material was added to side surface 32 and bottom surface 28 (i.e. at outlet 20) ( ⁇ ) is greater than the angle of the corner near the juncture of side surface 32 and bottom surface 28 at outlet 20A ( ⁇ 2) ⁇
- the additional material added to the surfaces forms a sharper corner where side surface 32 and bottom surface 28 meet, reducing the chance of flow separation at that corner.
- FIG. 6 shows an embodiment in which all of the surfaces at outlet 20A include additional material, additional material can be added to as few as one of the surfaces in other embodiments.
- a method for forming a diffusion cooling hole in a substrate can include removing material from the substrate to form a metering section having an inlet on a first side of the substrate and removing material from the substrate to form a diffusing section that extends between the metering section and an outlet located on a second side of the substrate generally opposite the first side.
- the method can also include forming a feature on a substrate surface within one of the metering section and the diffusing section. Forming the feature can include depositing a material on the substrate surface and selectively heating the material to join the material with the substrate surface and form the feature.
- the method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:
- a further embodiment of the foregoing method can include that the steps of removing material from the substrate to form a metering section and removing material from the substrate to form a diffusing section are performed by a technique selected from the group consisting of casting, drilling, laser drilling, machining, electrical discharge machining and combinations thereof.
- a further embodiment of any of the foregoing methods can include that the substrate surface on which the feature is formed is located within the metering section.
- a further embodiment of any of the foregoing methods can include that the feature obscures a line of sight between the inlet and the outlet.
- a further embodiment of any of the foregoing methods can include that the feature obstructs a portion of the metering section to form a cusp-like opening.
- a further embodiment of any of the foregoing methods can include that the substrate surface on which the feature is formed is located within the diffusing section.
- a further embodiment of any of the foregoing methods can include that the feature includes an apex and a plurality of planar sides extending from the apex.
- a further embodiment of any of the foregoing methods can include that the feature is formed along a surface of the substrate adjacent the outlet.
- a further embodiment of any of the foregoing methods can include that the outlet before forming the feature includes a corner having a first angle, and wherein the feature forms a second corner having a second angle generally smaller than the first angle.
- a further embodiment of any of the foregoing methods can include that the feature is formed along substantially all of the substrate surfaces adjacent the outlet.
- a further embodiment of any of the foregoing methods can include that the material deposited on the substrate surface is a metal.
- a further embodiment of any of the foregoing methods can include that the material deposited on the substrate surface is a ceramic.
- a further embodiment of any of the foregoing methods can include that the material deposited on the substrate surface is selectively heated using a laser.
- a further embodiment of any of the foregoing methods can include that the material deposited on the substrate surface is selectively heated using an electron beam.
- a further embodiment of any of the foregoing methods can include that the material is deposited on the substrate surface by spraying.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- General Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Materials Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Optics & Photonics (AREA)
- Plasma & Fusion (AREA)
- Fluid Mechanics (AREA)
- Combustion & Propulsion (AREA)
- Ceramic Engineering (AREA)
- Composite Materials (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
- Welding Or Cutting Using Electron Beams (AREA)
- Laser Beam Processing (AREA)
- Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN201480015993.8A CN105189976B (en) | 2013-03-15 | 2014-03-11 | Addition manufacturing method for the supplementary features in cooling hole |
JP2016501224A JP6348965B2 (en) | 2013-03-15 | 2014-03-11 | Additive manufacturing method for adding structures in cooling holes |
US14/771,436 US10464135B2 (en) | 2013-03-15 | 2014-03-11 | Additive manufacturing method for the addition of features within cooling holes |
EP14767556.5A EP2971666B1 (en) | 2013-03-15 | 2014-03-11 | Method for forming a diffusion cooling hole |
US16/673,062 US20200070250A1 (en) | 2013-03-15 | 2019-11-04 | Additive manufacturing method for the addition of features within cooling holes |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201361790122P | 2013-03-15 | 2013-03-15 | |
US61/790,122 | 2013-03-15 |
Related Child Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/771,436 A-371-Of-International US10464135B2 (en) | 2013-03-15 | 2014-03-11 | Additive manufacturing method for the addition of features within cooling holes |
US16/673,062 Continuation US20200070250A1 (en) | 2013-03-15 | 2019-11-04 | Additive manufacturing method for the addition of features within cooling holes |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2014150490A1 true WO2014150490A1 (en) | 2014-09-25 |
Family
ID=51580771
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2014/023393 WO2014150490A1 (en) | 2013-03-15 | 2014-03-11 | Additive manufacturing method for the addition of features within cooling holes |
Country Status (5)
Country | Link |
---|---|
US (2) | US10464135B2 (en) |
EP (1) | EP2971666B1 (en) |
JP (1) | JP6348965B2 (en) |
CN (1) | CN105189976B (en) |
WO (1) | WO2014150490A1 (en) |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN105464723A (en) * | 2014-09-30 | 2016-04-06 | 通用电气公司 | Turbine component and turbine component coating process |
EP3156597A1 (en) * | 2015-10-12 | 2017-04-19 | United Technologies Corporation | Cooling holes of turbine |
JP2017089631A (en) * | 2015-11-09 | 2017-05-25 | ゼネラル・エレクトリック・カンパニイ | Additive manufacturing method for making overhanging tabs in cooling holes |
EP3167982A3 (en) * | 2015-11-10 | 2017-06-28 | General Electric Company | Additive manufacturing method for making complex film holes |
EP3315228A1 (en) * | 2016-10-27 | 2018-05-02 | United Technologies Corporation | Additively manufactured component for a gas powered turbine |
EP3461995A1 (en) * | 2017-09-27 | 2019-04-03 | Doosan Heavy Industries & Construction Co., Ltd | Gas turbine blade |
US10487677B2 (en) | 2015-11-10 | 2019-11-26 | General Electric Company | Turbine component having a seal slot and additive manufacturing process for making same |
US10487664B2 (en) | 2015-11-09 | 2019-11-26 | General Electric Company | Additive manufacturing method for making holes bounded by thin walls in turbine components |
Families Citing this family (17)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102013214487A1 (en) * | 2013-07-24 | 2015-01-29 | Rolls-Royce Deutschland Ltd & Co Kg | Combustor shingle of a gas turbine |
US9744614B2 (en) * | 2013-11-18 | 2017-08-29 | General Electric Company | Method for modifying an aperture and system for modifying flow through a component |
US20160201474A1 (en) * | 2014-10-17 | 2016-07-14 | United Technologies Corporation | Gas turbine engine component with film cooling hole feature |
CA2933884A1 (en) * | 2015-06-30 | 2016-12-30 | Rolls-Royce Corporation | Combustor tile |
US10260354B2 (en) | 2016-02-12 | 2019-04-16 | General Electric Company | Airfoil trailing edge cooling |
US10443396B2 (en) | 2016-06-13 | 2019-10-15 | General Electric Company | Turbine component cooling holes |
CN106870014B (en) * | 2016-12-30 | 2019-09-27 | 哈尔滨工程大学 | A kind of notching construction designed according to air film hole distribution of exit velocities |
US10563294B2 (en) * | 2017-03-07 | 2020-02-18 | General Electric Company | Component having active cooling and method of fabricating |
JP2018144403A (en) * | 2017-03-08 | 2018-09-20 | 株式会社Fts | Method for blow molding and blow pin |
US20190071977A1 (en) * | 2017-09-07 | 2019-03-07 | General Electric Company | Component for a turbine engine with a cooling hole |
CN109519969B (en) * | 2017-09-19 | 2020-08-04 | 中国航发商用航空发动机有限责任公司 | Cooling hole, engine combustion chamber and cooling hole machining method |
US10648342B2 (en) * | 2017-12-18 | 2020-05-12 | General Electric Company | Engine component with cooling hole |
US10612391B2 (en) | 2018-01-05 | 2020-04-07 | General Electric Company | Two portion cooling passage for airfoil |
US10933481B2 (en) | 2018-01-05 | 2021-03-02 | General Electric Company | Method of forming cooling passage for turbine component with cap element |
US11426818B2 (en) | 2018-08-10 | 2022-08-30 | The Research Foundation for the State University | Additive manufacturing processes and additively manufactured products |
WO2020246289A1 (en) * | 2019-06-07 | 2020-12-10 | 株式会社Ihi | Film cooling structure, and turbine blade for gas turbine engine |
US11225707B2 (en) | 2019-08-13 | 2022-01-18 | General Electric Company | Protective shields for improved coating of turbine component cooling features |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6210488B1 (en) * | 1998-12-30 | 2001-04-03 | General Electric Company | Method of removing a thermal barrier coating |
US6368060B1 (en) * | 2000-05-23 | 2002-04-09 | General Electric Company | Shaped cooling hole for an airfoil |
US20110143042A1 (en) * | 2009-03-24 | 2011-06-16 | Peretti Michael W | Methods for making near net shape airfoil leading edge protection |
US7997868B1 (en) * | 2008-11-18 | 2011-08-16 | Florida Turbine Technologies, Inc. | Film cooling hole for turbine airfoil |
US20110293423A1 (en) * | 2010-05-28 | 2011-12-01 | General Electric Company | Articles which include chevron film cooling holes, and related processes |
Family Cites Families (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2810023B2 (en) * | 1996-09-18 | 1998-10-15 | 株式会社東芝 | High temperature member cooling device |
DE10143153A1 (en) * | 2001-09-03 | 2003-03-20 | Rolls Royce Deutschland | Turbine blade for a gas turbine with at least one cooling recess |
US6984100B2 (en) * | 2003-06-30 | 2006-01-10 | General Electric Company | Component and turbine assembly with film cooling |
US6933052B2 (en) * | 2003-10-08 | 2005-08-23 | General Electric Company | Diffusion barrier and protective coating for turbine engine component and method for forming |
JP3997986B2 (en) * | 2003-12-19 | 2007-10-24 | 株式会社Ihi | Cooling turbine component and cooling turbine blade |
US7328580B2 (en) * | 2004-06-23 | 2008-02-12 | General Electric Company | Chevron film cooled wall |
JP4941891B2 (en) * | 2006-11-13 | 2012-05-30 | 株式会社Ihi | Film cooling structure |
US8672613B2 (en) * | 2010-08-31 | 2014-03-18 | General Electric Company | Components with conformal curved film holes and methods of manufacture |
US20120167389A1 (en) * | 2011-01-04 | 2012-07-05 | General Electric Company | Method for providing a film cooled article |
US20130045106A1 (en) * | 2011-08-15 | 2013-02-21 | General Electric Company | Angled trench diffuser |
US20130101761A1 (en) * | 2011-10-21 | 2013-04-25 | General Electric Company | Components with laser cladding and methods of manufacture |
-
2014
- 2014-03-11 US US14/771,436 patent/US10464135B2/en active Active
- 2014-03-11 CN CN201480015993.8A patent/CN105189976B/en active Active
- 2014-03-11 WO PCT/US2014/023393 patent/WO2014150490A1/en active Application Filing
- 2014-03-11 EP EP14767556.5A patent/EP2971666B1/en active Active
- 2014-03-11 JP JP2016501224A patent/JP6348965B2/en active Active
-
2019
- 2019-11-04 US US16/673,062 patent/US20200070250A1/en not_active Abandoned
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6210488B1 (en) * | 1998-12-30 | 2001-04-03 | General Electric Company | Method of removing a thermal barrier coating |
US6368060B1 (en) * | 2000-05-23 | 2002-04-09 | General Electric Company | Shaped cooling hole for an airfoil |
US7997868B1 (en) * | 2008-11-18 | 2011-08-16 | Florida Turbine Technologies, Inc. | Film cooling hole for turbine airfoil |
US20110143042A1 (en) * | 2009-03-24 | 2011-06-16 | Peretti Michael W | Methods for making near net shape airfoil leading edge protection |
US20110293423A1 (en) * | 2010-05-28 | 2011-12-01 | General Electric Company | Articles which include chevron film cooling holes, and related processes |
Non-Patent Citations (1)
Title |
---|
See also references of EP2971666A4 * |
Cited By (14)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN105464723A (en) * | 2014-09-30 | 2016-04-06 | 通用电气公司 | Turbine component and turbine component coating process |
EP3156597A1 (en) * | 2015-10-12 | 2017-04-19 | United Technologies Corporation | Cooling holes of turbine |
CN106944620B (en) * | 2015-11-09 | 2019-11-26 | 通用电气公司 | Addition manufacturing method for the production suspension lug in cooling hole |
CN106944620A (en) * | 2015-11-09 | 2017-07-14 | 通用电气公司 | Addition manufacture method for making suspension lug in Cooling Holes |
US10010937B2 (en) | 2015-11-09 | 2018-07-03 | General Electric Company | Additive manufacturing method for making overhanging tabs in cooling holes |
JP2017089631A (en) * | 2015-11-09 | 2017-05-25 | ゼネラル・エレクトリック・カンパニイ | Additive manufacturing method for making overhanging tabs in cooling holes |
US10487664B2 (en) | 2015-11-09 | 2019-11-26 | General Electric Company | Additive manufacturing method for making holes bounded by thin walls in turbine components |
US11713682B2 (en) | 2015-11-09 | 2023-08-01 | General Electric Company | Additive manufacturing method for making holes bounded by thin walls in turbine components |
EP3167982A3 (en) * | 2015-11-10 | 2017-06-28 | General Electric Company | Additive manufacturing method for making complex film holes |
US10350684B2 (en) | 2015-11-10 | 2019-07-16 | General Electric Company | Additive manufacturing method for making complex film holes |
US10487677B2 (en) | 2015-11-10 | 2019-11-26 | General Electric Company | Turbine component having a seal slot and additive manufacturing process for making same |
EP3315228A1 (en) * | 2016-10-27 | 2018-05-02 | United Technologies Corporation | Additively manufactured component for a gas powered turbine |
US10975703B2 (en) | 2016-10-27 | 2021-04-13 | Raytheon Technologies Corporation | Additively manufactured component for a gas powered turbine |
EP3461995A1 (en) * | 2017-09-27 | 2019-04-03 | Doosan Heavy Industries & Construction Co., Ltd | Gas turbine blade |
Also Published As
Publication number | Publication date |
---|---|
JP6348965B2 (en) | 2018-06-27 |
US10464135B2 (en) | 2019-11-05 |
CN105189976A (en) | 2015-12-23 |
US20200070250A1 (en) | 2020-03-05 |
JP2016519236A (en) | 2016-06-30 |
CN105189976B (en) | 2019-04-16 |
EP2971666A4 (en) | 2016-10-19 |
US20160008889A1 (en) | 2016-01-14 |
EP2971666B1 (en) | 2020-10-21 |
EP2971666A1 (en) | 2016-01-20 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US20200070250A1 (en) | Additive manufacturing method for the addition of features within cooling holes | |
US10500633B2 (en) | Gas turbine engine airfoil impingement cooling | |
EP3415718B1 (en) | Gas turbine engine components with air-cooling features, and related methods of manufacturing the same | |
EP2728119A1 (en) | Microchannel cooled turbine component and method of forming a microchannel cooled turbine component | |
EP2559855A2 (en) | Turbine blade with film cooling hole diffusers and method of its manufacture | |
US20120163984A1 (en) | Cooling channel systems for high-temperature components covered by coatings, and related processes | |
US20160003056A1 (en) | Gas turbine engine shaped film cooling hole | |
US20170368647A1 (en) | Methods for repairing film holes in a surface | |
JP4959718B2 (en) | Part to be placed in the flow path of a fluid machine and spray method for coating generation | |
CN104279006A (en) | Turbine component and methods of assembling the same | |
US10364683B2 (en) | Gas turbine engine component cooling passage turbulator | |
JP2017115861A (en) | Article and method of forming article | |
EP3475531B1 (en) | Method for repairing a gas turbine airfoil trailing edge | |
CN105804805A (en) | Engine component and methods for an engine component | |
US20170370221A1 (en) | Methods for repairing a damaged component of an engine | |
US10843271B2 (en) | Method for manufacturing a turbine shroud for a turbomachine | |
JP7317944B2 (en) | Method of forming a hot gas path component for a gas turbine engine | |
US20190195080A1 (en) | Ceramic coating system and method | |
CN112343665B (en) | Engine component with cooling holes | |
EP3495616B1 (en) | Airfoil with internal cooling passages |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
WWE | Wipo information: entry into national phase |
Ref document number: 201480015993.8 Country of ref document: CN |
|
121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 14767556 Country of ref document: EP Kind code of ref document: A1 |
|
WWE | Wipo information: entry into national phase |
Ref document number: 14771436 Country of ref document: US |
|
ENP | Entry into the national phase |
Ref document number: 2016501224 Country of ref document: JP Kind code of ref document: A |
|
NENP | Non-entry into the national phase |
Ref country code: DE |
|
WWE | Wipo information: entry into national phase |
Ref document number: 2014767556 Country of ref document: EP |