Additively manufactured components including integrally formed passages, channels, and conduits and methods of forming the same

Abstract

The invention is entitled "Additively Manufactured Components Including Integrally Formed Passages, Channels, and Conduits and Methods of Forming the Same." The invention provides additively manufactured components including unitary bodies. The components can include unitary bodies having component segments. The component segments can include at least one passage extending at least partially through the component segment. The unitary bodies can also include supplemental segments integrally formed with the component segments. The supplemental segments can be disposed on the passages of the component segments and can include channels extending at least partially through the supplemental segments. The channels can be in fluid communication with the passages of the component segments. Additionally, the unitary bodies can include transition conduits positioned within the component segments and the supplemental segments. The transition conduits can extend between the passages of the component segments and the channels of the supplemental segments to fluidly couple the passages and the channels.

Description

BACKGROUND

[0001] The present disclosure relates generally to additively manufactured components, and more particularly, to additively manufactured components including integrally formed passageways, channels, and conduits, and methods of forming the same.

[0002] Components or parts for various machines and mechanical systems can be built using an additive manufacturing system. Additive manufacturing systems can build such components by successively layering a powder material in a predetermined area and performing a material transformation process, such as sintering or melting, on the powder material. The material transformation process can change the physical state of the powder material from a granular composition to a solid material to build the component. Components built using additive manufacturing systems have nearly identical physical properties as conventional components that are typically made by performing a machining process (e.g., a material removal process) on a stock material. However, due to the advantageous processes, components formed using additive manufacturing can include unique features and / or complex geometries that are difficult or impossible to obtain and / or build using conventional machining processes.

[0003] However, the ability to readily form unique features and / or complex geometries results in new and / or additional manufacturing difficulties or issues. For example, when conduits or channels are exposed and / or formed to extend to a surface of a component, post-build machining performed on the additively manufactured component can create issues with the intended use of these conduits or channels. That is, when excess build material is removed and / or the surface of the component including the opening of the conduit or channel is resurfaced (e.g., polished / planed), undesirable burrs can form on the surface and / or can extend into the opening. Burrs formed during the post-build process can obstruct, block, or otherwise clog the conduit or channel formed in the component such that the feature cannot be used for its intended purpose. While a burr removal process can be performed on the component to remove the formed burrs, the tool used to remove the burrs can reshape, restructure, and / or otherwise damage a portion of the opening and / or conduit or channel. This is particularly common where the size or dimension of the opening or conduit is small, and / or where the conduit or channel does not extend directly perpendicular to (e.g., angled conduits) the surface including the opening. SUMMARY

[0004] A first aspect of the present disclosure provides a component comprising a unitary body comprising: a component segment comprising: at least one passageway extending at least partially through the component segment, the at least one passageway comprising an opening having a first dimension; a supplemental segment integrally formed with the component segment, the supplemental segment disposed on the at least one passageway of the component segment and comprising: a channel extending at least partially through the supplemental segment, the channel in fluid communication with the at least one passageway of the component segment; and a transition conduit positioned within the component segment and the supplemental segment, the transition conduit extending between the at least one passageway of the component segment and the channel of the supplemental segment to fluidly couple the at least one passageway and the channel.

[0005] A second aspect of the present disclosure provides a method comprising: additively manufacturing a unitary body of a component, the unitary body comprising: a component segment comprising at least one passageway extending at least partially through the component segment, the at least one passageway comprising an opening having a first dimension; a supplemental segment integrally formed with the component segment, the supplemental segment disposed on the at least one passageway of the component segment and comprising a channel extending at least partially through the supplemental segment, the channel in fluid communication with the at least one passageway of the component segment; and a transition conduit positioned within the component segment and the supplemental segment, the transition conduit extending between the at least one passageway of the component segment and the channel of the supplemental segment to fluidly couple the at least one passageway and the channel; performing at least one post-build process on the component comprising the unitary body; and removing the supplemental segment from the component segment of the unitary body to expose a portion of the transition conduit and the at least one passageway of the component segment.

[0006] Exemplary aspects of the present disclosure are designed to address the problems described herein and / or other problems not discussed. BRIEF DESCRIPTION OF DRAWINGS

[0007] These and other features of the present disclosure will be more readily understood from the following detailed description of the various aspects of the present disclosure, taken in conjunction with the accompanying drawings that illustrate various embodiments of the present disclosure, in which:

[0008] Figure 1 An exploded perspective view of a component comprising a component segment and a supplemental segment is shown in accordance with an embodiment of the present disclosure.

[0009] Figure 2 A front view of the component of Figure 1 comprising a component segment and a supplemental segment is shown in accordance with an embodiment of the present disclosure.

[0010] Figure 3 A front cross-sectional view of the component of Figure 2 taken along line CS-CS is shown in accordance with an embodiment of the present disclosure.

[0011] Figure 4 A front cross-sectional view of a component according to an embodiment of the disclosure is shown. Figure 2 A front cross-sectional view of a component according to an embodiment of the disclosure is shown.

[0012] Figure 5 A front cross-sectional view of a component according to an embodiment of the disclosure is shown. Figure 4 A close-up view of a portion of the component segment of

[0013] Figure 6 A front cross-sectional view of a component according to an embodiment of the disclosure is shown. Figure 4 A close-up view of a portion of the component segment of

[0014] Figure 7 A front cross-sectional view of a component according to an additional embodiment of the disclosure is shown.

[0015] Figure 8 A front cross-sectional view of a component according to an additional embodiment of the disclosure is shown. Figure 7 A front cross-sectional view of a component according to an additional embodiment of the disclosure is shown.

[0016] Figure 9 A front cross-sectional view of a component according to an additional embodiment of the disclosure is shown.

[0017] Figure 10 A front cross-sectional view of a component according to an additional embodiment of the disclosure is shown. Figure 9 A front cross-sectional view of a component according to an additional embodiment of the disclosure is shown.

[0018] Figure 11 and Figure 12 A front cross-sectional view of a component according to an embodiment of the disclosure is shown.

[0019] Figure 13 A front cross-sectional view of a component according to an embodiment of the disclosure is shown.

[0020] Figure 14 A front view of a component according to an embodiment of the disclosure is shown.

[0021] Figure 15 A flowchart of an exemplary process for forming an additively manufactured component including a component segment and a supplemental segment according to an embodiment of the disclosure is shown.

[0022] Figure 16A block diagram of an additive manufacturing system and process is shown, including a non-transitory computer readable storage medium storing code representing a part comprising part segments and supplemental segments, in accordance with an embodiment of the present disclosure.

[0023] It should be noted that the drawings of the present disclosure are not necessarily drawn to scale. The drawings are intended to depict only typical aspects of the disclosure, and therefore should not be considered as limiting the scope of the disclosure. In the drawings, like numbering depicts like elements throughout the several views. DETAILED DESCRIPTION

[0024] At the outset, in order to clearly and succinctly describe the present disclosure, it will be necessary to select and use certain terminology in describing the relevant machine components within the present disclosure. In doing so, if possible, generic industry terminology will be used and employed in a manner consistent with its accepted meaning. Unless otherwise indicated, such terminology should be given a broad interpretation consistent with the context and scope of the present application and the appended claims. One of ordinary skill in the art will appreciate that a number of different or overlapping terms can be used to reference a particular component. An object that can be described herein as a single part can include multiple components and be referenced elsewhere as being composed of multiple components. Alternatively, an object that can be described herein as including multiple components can be referred to elsewhere as a single part.

[0025] The following disclosure relates generally to additively manufactured parts, and more particularly, to additively manufactured parts including integrally formed passageways, channels, and conduits, and methods of forming the same.

[0026] Reference is made below to Figures 1 to 16 These and other embodiments are discussed. However, one skilled in the art will readily recognize from the following discussion that numerous other embodiments can be and are contemplated, each falling fairly within the scope of the present disclosure. Accordingly, the detailed description is not intended as limiting, but is merely presented as a illustrative description.

[0027] Figure 1 and Figure 2 Various views of a part 100 including a monolithic body 102 are shown. In particular, Figure 1 An exploded perspective view of a part 100 including a monolithic body 102 is shown, and Figure 2 A front view of a part 100 including a monolithic body 102 is shown. The part 100 including the monolithic body 102 can be considered an“intermediate” formed part and / or a part that can be at an intermediate stage of processing. Thus, and as discussed herein, the part 100 can undergo additional post-build processes that are performed before and / or after the final configuration of the part 100 (e.g., the part segments) can be used for its intended purpose.

[0028] In the non-limiting examples discussed herein, the component 100 may include and / or be formed as a unitary body 102 such that the component 100 is a single, continuous, and / or non-disjointed component or part. Figures 1 to 14 In the non-limiting example shown, because the component 100 includes a unitary body 102, the turbine shroud 100 may not require joining, coupling, and / or assembling various parts to fully form the component 100. Instead, once the single, continuous, and / or non-disjointed unitary body 102 of the component 100 is constructed, as discussed herein, the unitary body 102 of the component 100 may include all desired features therein that may be used in the final configuration of the component 100 (e.g., a component portion) for its intended purpose.

[0029] In a non-limiting example, the monolithic body 102 of the component 100 and the various components and / or features of the component 100 may be formed using any suitable additive manufacturing process and / or method. For example, the component 100 including the monolithic body 102 may be formed by direct metal laser melting (DMLM) (also known as selective laser melting (SLM)), direct metal laser sintering (DMLS), electron beam melting (EBM), stereolithography (SLA), binder jetting, or any other suitable additive manufacturing process. In this way, the monolithic body 102 of the component 100 and the various components and / or features integrally formed thereon and / or therein may be formed during a single additive manufacturing process and / or method. Additionally, the component 100, and more specifically the monolithic body 102, may be formed from any suitable material that may undergo an additive manufacturing process performed by an additive manufacturing system (AMS) (see Figure 15 ). In non-limiting examples, the unitary body 102 of the component 100 may be formed from thermoplastics, metals, metal alloys, ceramics, glass, and other suitable materials.

[0030] like Figure 1 and Figure 2 As shown, the unitary body 102 of the component 100 may include two different parts and / or segments. That is, although the unitary body 102 is formed as a single continuous component or part, the unitary body 102 of the component 100 may also be formed as two different segments. In the non-limiting example discussed herein, the unitary body 102 may include a component segment 104 and at least one supplemental segment 106, respectively. Figure 2 As shown, the component segment 104 and the supplemental segment 106 may be integrally formed to form the unitary body 102 of the component 100. The component segment 104 and the supplemental segment 106 may be integrally formed using a (single) additive manufacturing process and / or AMS (see Figure 15). As discussed herein, the component segment 104 and the supplemental segment 106 can be separable from one another after formation via the (single) additive manufacturing process, and the component segment 104 can be subsequently used for its intended purpose while the supplemental segment 106 can be discarded. As discussed herein, the component segment 104 of the component 100 can represent a“final” configuration, geometry, part, and / or assembly that can be used by the component, device, and / or system for its intended purpose, manufactured by AMS.

[0031] As a result of being formed from the monolithic body 102, and as discussed herein, the component 100 can include various integrally formed features, components, and / or segments that can provide desired functionality and / or operation for the final configuration of the component 100 (e.g., the component segment 104). That is, and because the component 100 includes the monolithic body 102 formed using any suitable (single) additive manufacturing process and / or method, the features, components, and / or segments of the component 100 can be integrally formed with the monolithic body 102. The term“integral feature” or“integrally formed feature” can refer to a feature formed on or in the monolithic body 102 during the (single) additive manufacturing process, formed from the same material as the monolithic body 102, and / or formed on or in the monolithic body 102 such that the feature is not manufactured using a different process and / or a separate and subsequent construction, joining, coupling, and / or assembly of a raw material component on or in the monolithic body 102 of the component 100. Additionally, the features formed in the monolithic body 102 of the component 100 can be specific to the operation and / or functionality of the component segment 104 of the component 100.

[0032] As shown in FIGS. 1-3, the component 100 can include at least one feature formed in the monolithic body 102. More specifically, the component 100 can include at least one feature formed at least partially in, on, and / or through the component segment 104 of the monolithic body 102. In non-limiting examples, the feature formed in the monolithic body 102 and more specifically the component segment 104 can be at least one passage 108. Figure 1 Figure 2 As shown in FIGS. 1-3, the component 100 can include at least one feature formed in the monolithic body 102. More specifically, the component 100 can include at least one feature formed at least partially in, on, and / or through the component segment 104 of the monolithic body 102. In non-limiting examples, the feature formed in the monolithic body 102 and more specifically the component segment 104 can be at least one passage 108. Figure 1 Figure 2 In non-limiting examples, the passage 108 can extend only partially through the component segment 104, and can be formed as a recess. In other non-limiting examples (see, e.g., FIGS. 4-6), the passage 108 can extend completely through the monolithic body 102 and / or the component segment 104, and can include two openings exposed and / or formed on a surface of the component segment 104 of the component 100. Figure 12 In non-limiting examples, the passage 108 can extend only partially through the component segment 104, and can be formed as a recess. In other non-limiting examples (see, e.g., FIGS. 4-6), the passage 108 can extend completely through the monolithic body 102 and / or the component segment 104, and can include two openings exposed and / or formed on a surface of the component segment 104 of the component 100.​​

[0033] As Figure 1 and Figure 2 shown, the passageway 108 can include an opening 110. That is, the passageway 108 can be at least partially defined by the opening 110, and / or the opening 110 can be in fluid communication with the passageway 108. The opening 110 can have a first predetermined dimension (D1). For example, in instances where the shape of the opening 110 is substantially circular, the opening 110 of the passageway 108 can include the first predetermined dimension (D1) corresponding to the circumference of the opening 110. As Figure 1 shown in the exploded view, and turning momentarily to Figure 4 , upon removal of the supplemental segment 106, the passageway 108 and / or the opening 110 can be exposed and / or formed adjacent to a “finished” surface 112 formed on the component segment 104, as discussed herein. Prior to removal of the supplemental segment 106, and as discussed herein, the “finished” surface 112 can be considered a reference, artificial, and / or intended surface of the component segment 104 of the component 100 that can be formed / disposed beneath and / or covered by the supplemental segment 106.

[0034] It should be appreciated that the shape and / or geometry of the passageway 108 and / or the opening 110 shown herein is exemplary. Thus, the passageway 108 and / or the opening 110 can include any geometry and / or dimension that can correspond to the intended function and / or operation of the component segment 104. Additionally, while shown to be in a shape that is consistent and / or substantially similar to the remainder of the passageway 108 extending at least partially within the component segment 104, it should be appreciated that the shape and / or dimension of the opening 110 can be different from the passageway 108. Moreover, the number of passageways 108 / openings 110 formed in the component segment 104 of the monolithic body 102 shown herein can also be exemplary, and the monolithic body 102 of the component 100 can include more or fewer passageways 108 and / or openings 110 than those shown and discussed herein.

[0035] As discussed herein, the monolithic body 102 of the component 100 can also include a supplemental segment 106. The supplemental segment 106 can be integrally formed with the component segment 104 of the monolithic body 102 of the component 100. That is, while shown in Figure 1 as exploded or separate from the component segment 104, the supplemental segment 106 can be integrally formed with, as part of, and / or integrated with the component segment 104 of the monolithic body 102 (see Figure 2 ). Figure 2 The dashed line (DL) shown can represent a location within the component 100 that separates or distinguishes the component segment 104 from the supplemental segment 106. In Figure 1 and Figure 2In the non-limiting example shown, the supplemental segment 106 can be integrally formed with at least a portion of the "finished" surface 112 of the component segment 104. Additionally, and as discussed herein, removal of the supplemental segment 106 from the component segment 104 of the unitary body 102 can substantially define and / or expose the "finished" surface 112, as well as the passageways 108 / openings 110 (e.g., features) formed in the component segment 104 of the unitary body 102. Although shown as being formed on and / or integrally formed with the "finished" surface 112 of the component segment 104, it should be understood that the supplemental segment 106 can be formed on other portions or surfaces of the component segment 104 (see Figure 12 ) and / or between the build surface 20 of the build plate 18 and the component segment 104 of the unitary body 102 (not shown), where the component 100 is directly built on the build plate of the additive manufacturing system.

[0036] In Figure 1 and Figure 2 the non-limiting example shown, the supplemental segment 106 can include a geometry similar to that of the component segment 104. That is, the supplemental segment 106 can include a geometry, shape, and / or dimension (e.g., width, depth) similar or substantially the same as a portion of the component segment 104 that includes the passageways 108 and / or openings 110. Accordingly, the supplemental segment 106 can cover and / or be disposed on the component segment 104 of the unitary body 102. More specifically, the supplemental segment 106 can be disposed on and / or can define the "finished" surface 112, and can substantially cover the passageways 108 / openings 110 (e.g., features) formed in the component segment 104, be positioned adjacent to and / or can be disposed on the passageways / openings. In another non-limiting example (not shown), the supplemental segment 106 can include a geometry, shape, and / or dimension (e.g., width, depth) substantially different from that of the component segment 104 of the unitary body 102. In this non-limiting example, the supplemental segment 106 can be sized and / or can include a geometry that can cover and / or be disposed on only a portion of the component segment 104 that includes the features (e.g., passageways 108 / openings 110) formed therein. Accordingly, a different portion of the component segment 104, and more specifically a portion of the "finished" surface 112 of the component segment 104, can not be covered by the supplemental segment 106, and can be fully exposed during post-build processing, as discussed herein.

[0037] As Figure 1 and Figure 2As shown, the supplemental segment 106 can also include at least one passage 118. More specifically, the passage 118 can be formed in the supplemental segment 106 and / or can extend at least partially through the supplemental segment. The passage 118 of the supplemental segment 106 can be in fluid communication with the passageway 108 / opening 110 (e.g., feature) formed in the component segment 104 of the monolithic body 102. The passage 118 can allow fluid (e.g., pressurized air) to flow through the passageway 108 formed in the component segment 104 of the monolithic body 102 in order to remove any unsintered powder material and / or particulate that can undesirably remain in the passageway 108 of the component segment 104 after the component 100 is formed. Additionally or alternatively, the passage 118 can allow a test fluid to flow through the passageway 108 formed in the component segment 104 to test operational parameters and / or characteristics of the passageway 108. For example, where the passageway 108 can be formed as a cooling passageway in the component 100, the passage 118 of the supplemental segment 106 can allow a test fluid to be provided to the passageway 108 to ensure that the test / actual flow rate and / or flow pressure meet desired operational flow rates and / or flow pressures.

[0038] In Figure 1 and Figure 2 In the non-limiting example shown, the passage 118 of the supplemental segment 106 can also include an opening 120. Specifically, the passage 118 extending at least partially through the supplemental segment 106 can include the opening 120 formed in, on, and / or through a surface 122 of the monolithic body 102. As a result of forming the opening 120 of the passage 118 on the surface 122 of the monolithic body 102, the passage 118 can be exposed in the component 100. Additionally, and because the passage 118 is in fluid communication with the passageway 108 / opening 110 extending at least partially through the component segment 104, forming the opening 120 of the passage 118 on the surface 122 of the monolithic body 102 can also expose the passageway 108 in the “intermediate” formed component (i.e., the component 100).

[0039] In Figure 1 and Figure 2 In the non-limiting example shown, the monolithic body 102 of the component 100 can also include a transition conduit 124. The transition conduit 124 can be positioned within the component segment 104 and the supplemental segment 106. More specifically, the transition conduit 124 can be positioned within, can be formed / constructed in, and / or can be disposed in at least a portion of both the component segment 104 and the supplemental segment 106 of the monolithic body 102. In the non-limiting example, the transition conduit 124 can extend between the transition between the component segment 104 and the supplemental segment 106, as indicated by the dashed line in FIG. 1. Figure 2defined by the dashed line (DL) shown and as discussed herein. The transition conduit 124 can be integrally formed within the monolithic body 102 using the (single) additive manufacturing process and / or AMS, and / or can be formed during the same additive manufacturing process and / or using the same AMS that can form features (e.g., the passage 108, the channel 118) within the monolithic body 102, as discussed herein. As Figure 1 and Figure 2 shown and as discussed herein, the transition conduit 124 can include a second dimension (D2) that is greater than a first dimension (D1) of the opening 110 of the passage 108 extending at least partially through the component segment 104.

[0040] Figure 3 a cross-sectional front view of a portion of the monolithic body 102 taken along the line CS-CS in Figure 2 is shown. As Figure 3 shown and with continued reference to Figure 1 and Figure 2 , the transition conduit 124 of the monolithic body 102 can also extend between the passage 108 of the component segment 104 and the channel 118 of the supplemental segment 106. Thus, the transition conduit 124 can fluidly couple the passage 108 extending through the component segment 104 with the channel 118 extending through the supplemental segment 106 of the monolithic body 102. In Figures 1 to 3 non-limiting example shown, the shape and / or geometry of the transition conduit 124 can also be frustoconical. More specifically, the transition conduit 124 can include a first end 126 (see Figure 3 ) positioned directly adjacent to and in direct fluid communication with the opening 110 of the passage 108 formed in the component segment 104, and a second end 128 (see Figure 3 ) positioned opposite the first end 126. The second end 128 can be positioned directly adjacent to and in direct fluid communication with the channel 118 positioned in the supplemental segment 106. In a non-limiting example, the first end 126 of the transition conduit 124 can be formed, constructed, and / or defined with the component segment 104 of the monolithic body 102, while the second end 128 of the transition conduit 124 can be formed, constructed, and / or defined with the supplemental segment 106 of the monolithic body 102. The first end 126 of the transition conduit 124 can include or can have a dimension (e.g., a third dimension) (D3) that can be (slightly) greater than the first dimension (D1) of the opening 110 of the passage 108. The second end 128 of the transition conduit 124 can include a second dimension (D2) that is greater than the first dimension (D1) of the opening 110 of the passage 108 and greater than the third dimension (D3) of the first end 126. Additionally, as Figure 3As shown, the second dimension (D2) may be substantially similar to the dimension of the passage 118 of the supplemental segment 106 of the monolithic body 102. Therefore, and based on the frusto-conical shape of the transition duct 124, the entire transition duct 124 may include larger dimensions (e.g., D2, D3) than the opening 110 of the passageway 108, and the difference in dimensions may increase as the distance between the opening 110 and the second end 128 of the transition duct 124 increases.

[0041] The formation and / or positioning of the transition duct 126 within the monolithic body 102 may prevent, eliminate, and / or reduce undesirable results and / or effects imposed on the component 100 after post-build processes are performed on the monolithic body 102, and are various segments / features. That is, once the component 100 is additively manufactured to include the component segment 104, the supplemental segment 106, and various features (e.g., passages 108, channels 118, etc.) therein, the monolithic body 102 of the component 100 may undergo various post-build processes. The post-build processes may include, for example, removing the supplemental segment 106 from the component segment 104 of the monolithic body 102. As discussed herein, the supplemental segment 106 may be removed from the component segment 104 such that the component segment 104 of the component 100 may represent a "final" configuration that may be used by the component, device, and / or system for its intended purpose. As Figure 3 and Figure 4 As shown, the supplemental segment 106 can be removed from the component segment 104 at the dashed line (DL), which is also identified as the separation line (SL) in the figure (see Figure 3 ).like Figure 3 As shown, a separation line (SL) may pass through a transition duct 124 that extends between and fluidly couples the passages 108 of the component segment 104 and the channels 118 of the supplemental component 106. Additionally, and as described herein with respect to Figure 2 As described, the reference dashed line / separation line (SL) can identify where the component segment 104 ends within the monolithic body 102 and / or where the supplemental segment 106 begins within the monolithic body 102. Therefore, and as discussed herein, the supplemental segment 106 can be completely removed from the component segment 104 along the separation line (SL) during a post-build removal process.

[0042] The supplemental segment 106 can be removed from the component segment 104 using any suitable material removal technique and / or process. For example, the monolithic body 102 of the component 100 can be machined (e.g., cut, milled, etc.) along the separation line (SL) to completely remove the supplemental segment 106 from the component segment 104. In another non-limiting example, the monolithic body 102 of the component 100 can undergo an electrical discharge machining process to remove the supplemental segment 106 from the component segment 104 along the separation line (SL). As a result of removing the supplemental segment 106 from the component segment 104, a“finished” surface 112 of the component segment 104 can be exposed, formed, and / or defined. Additionally, the remaining portion 130 of the transition conduit 124 (including the first end 126) as well as the passage 108 and the opening 110 of the component segment 104 can be exposed via the“finished” surface 112.

[0043] The supplemental segment 106 of the monolithic body 102 of the component 100 can be formed by the AMS to include predetermined build characteristics that are substantially similar to or different than those of the component segment 104 of the monolithic body 102. In non-limiting examples in which the predetermined build characteristics between the supplemental segment 106 and the component segment 104 are different, the material density or the material porosity of the supplemental segment 106 can be different than the material density or the material porosity of the component segment 104. More specifically, the material density or the material porosity of the supplemental segment 106 can be less than the material density or the material porosity of the component segment 104. The reduced material density or the material porosity of the supplemental segment 106 can enable the supplemental segment 106 to be more easily removed from the component segment 104. In the non-limiting examples discussed herein with respect to FIGS. 1-3, the supplemental segment 106 can be formed by the AMS to include predetermined build characteristics that are different than those of the component segment 104. Figures 1 to 4 In the non-limiting examples discussed, the supplemental segment 106 can be removed from the component segment 104 at a separation line (SL) that can also coincide with a dashed line (DL) that distinguishes the supplemental segment 106 and the component segment 104. As discussed herein, the component segment 104 can be free of the supplemental segment 106 and, thus, can not include any portion of the supplemental segment 106 having a reduced density or porosity. The AMS can build the supplemental segment 106 to include predetermined build characteristics that are different than those of the component segment 104 by, for example, adjusting the intensity or power output of the energy-emitting device used to form the supplemental segment 106 and the component segment 104 and / or the speed of the energy-emitting device used to form the supplemental segment 106 and the component segment 104.

[0044] In other non-limiting examples (see, e.g., FIG. 4), the supplemental segment 106 can be removed from the component segment 104 at a separation line (SL) that does not coincide with a dashed line (DL) that distinguishes the supplemental segment 106 and the component segment 104. As discussed herein, the component segment 104 can be free of the supplemental segment 106 and, thus, can not include any portion of the supplemental segment 106 having a reduced density or porosity. The AMS can build the supplemental segment 106 to include predetermined build characteristics that are different than those of the component segment 104 by, for example, adjusting the intensity or power output of the energy-emitting device used to form the supplemental segment 106 and the component segment 104 and / or the speed of the energy-emitting device used to form the supplemental segment 106 and the component segment 104. Figure 9 and Figure 10), where the separation line (SL) from which the supplemental segment 106 is removed from the component segment 104 can not coincide with the dashed line (DL) that distinguishes the supplemental segment 106 from the component segment 104. As such, a portion of the component segment 104 can be removed with the supplemental segment 106, and / or a portion of the supplemental segment 106 can be retained with the component segment 104. In these examples, the component segment 104 and the supplemental segment 106 can include similar predetermined build characteristics.

[0045] In non-limiting examples, the component segment 104 of the component 100, once the supplemental segment 106 is removed from the component segment 104, can be implemented, installed, and / or used for its intended purpose. That is, the component segment 104, including the remaining portion 130 of the transition conduit 124, the passageway 108, and the opening 110, can be considered a finished, final, and / or ready-to-use component that can be used for its intended purpose and / or used within an intended device without additional post-build processing.

[0046] Turning to Figure 5 , this figure illustrates an enlarged portion of the component segment 104 of the Figure 4 , after performing a machining process on the monolithic body 102 to remove the supplemental segment 106. In non-limiting examples, a burr 132 can be formed along the “finished” surface 112 and / or can extend into the transition conduit 124. That is, performing the machining process to remove the supplemental segment 106 from the component segment 104 can result in excess material or a burr 132 being formed, pushed inward, and / or extending into the transition conduit 124 from the “finished” surface 112. As shown in non-limiting examples, the burr 132 extending into the transition conduit 124 can not close, obstruct, and / or otherwise block the passageway 108 (e.g., allow fluid to flow in and / or out). That is, the passageway 108 of the component segment 104 can still be exposed and / or capable of receiving and / or expelling fluid through the opening 110 and / or the transition conduit 124 containing the burr 132, even with the inclusion of the burr 132. As the transition conduit 124, and more specifically the remaining portion 130 of the transition conduit 124 formed directly adjacent to the “finished” surface 112, has a greater dimension than the first dimension (D1) of the opening 110 and / or the passageway 108, the passageway 108 of the component segment 104 can not be obstructed by the burr 132. As such, the passageway 108 of the component segment 104 can be used for its intended purpose, where operational or performance parameters are not reduced or are reduced negligibly.

[0047] In another non-limiting example, the component segment 104 of the monolithic body 102, substantially free of the supplemental segment 106, can undergo additional post-build processing. For example, and with continued reference to Figure 5, it can be desirable to remove the burr 132 from the component segment 104. As such, a deburring process can be performed on the component segment 104 after the supplemental segment 106 is removed from the monolithic body 102 using a machining technique. Turning to Figure 6 The burr 132 (shown in dashed lines) can be removed via the deburring process and / or using any suitable technique and / or system that can be configured to remove the burr 132. The deburring process performed on the component segment 104 can also restore and / or reshape the remaining portion 130 of the transition conduit 124 to its original form, geometry, and / or shape prior to performing a removal process on the monolithic body 102 of the component 100 (see, e.g., Figure 3 The remaining portion 130 of the transition conduit 124 can be restored and / or reshaped to its original form, geometry, and / or shape when the deburring process is performed on the component segment 104. Additionally, the working tool and / or system performing the deburring process (e.g., a deburring tool) can only contact, restore, and / or reshape the remaining portion 130 of the transition conduit 124 while removing the burr 132 when the deburring process is performed on the component segment 104. As such, the configuration, geometry, and / or shape of the opening 110 and / or the passageway 108 of the component segment 104 can be unaltered, unchanged, and / or can retain a desired / constructed geometry. Removing the burr 132 that can extend into the transition conduit 124 can ensure that the passageway 108 / opening 110 of the component segment 104 can operate as intended and / or perform with desired operational parameters and characteristics when used for its intended purpose.

[0048] Figures 7 to 10 Additional non-limiting examples of the monolithic body 102 of the component 100 are illustrated. More specifically, Figures 7 to 10 A front cross-sectional view (e.g., taken along line A-A) of a portion of the monolithic body 102 including the integrally formed component segment 104 and supplemental segment 106 is illustrated (e.g., Figure 7 and Figure 9 ), and a cross-sectional view of the supplemental segment 106 removed from the component segment 104 (e.g., Figure 8 and Figure 10 ). It should be appreciated that similarly numbered and / or named components can function in substantially similar manners. Redundant explanations of these components have been omitted for the sake of clarity.

[0049] In the non-limiting examples illustrated in Figure 7 and Figure 8 , the shape of the transition conduit 124 can be substantially uniform and / or linear. That is, and in contrast to the different transition conduits 124 discussed herein with respect to Figures 1 to 6 , the shape of the transition conduit 124 can not be frustoconical and / or include varying / converging dimensions. Rather, Figure 7 and Figure 8The illustrated transition conduit 124 can be substantially linear and include a single uniform second dimension (D2) between the first end 126 and the second end 128. The uniform second dimension of the transition conduit 124 extending between and fluidly coupling the passageway 108 and the channel 118 can be greater than the first dimension (D1) of the opening 110 and / or the passageway 108. When the supplemental segment 106 is removed from the component segment 104, as Figure 8 As illustrated, the remaining portion 130 of the transition conduit 124 can include or maintain the uniform second dimension (D2), which can be greater than the first dimension (D1) of the opening 110. As discussed herein with respect to Figure 5 and Figure 6 Similarly discussed, the transition conduit 124, and more particularly the remaining portion 130 of the transition conduit 124 including the greater second dimension (D2), can prevent the burr 132 (see Figure 5 ) from obstructing the passageway 108 / opening 110. Additionally or alternatively thereto, the remaining portion 130 of the transition conduit 124 including the uniform second dimension (D2) can prevent the passageway 108 / opening 110 from being undesirably reshaped or reconfigured by a tool or system (e.g., a deburring tool) that can be used to remove the burr 132 extending into the transition conduit 124 after the supplemental segment 106 is removed.

[0050] Turning to Figure 9 and Figure 10 , the passageway 108 can extend through the component segment 104 at an angle (a). More particularly, the passageway 108 extends at least partially through the component segment 104 at a non-perpendicular angle relative to the “finished” surface 112 (see Figure 10 ) on the component segment 104 of the monolithic body 102. Similarly, as discussed herein, once the supplemental segment 106 is removed from the component segment 104, the “finished” surface 112 can expose the angled or non-perpendicular passageway 108 of the component segment 104.

[0051] Additionally, Figure 9 and Figure 10 non-limiting examples in which the supplemental segment 106 is not removed from the component segment 104 at the reference line (RL) and / or at the transition between the component segment 104 and the supplemental segment 106 is illustrated. That is, the supplemental segment 106 can be removed from the component segment 104 at a separation line (SL) that is different than the reference line (RL) indicating the transition between the two segments 104, 106 of the monolithic body 102. In non-limiting examples, the separation line (SL) can be positioned adjacent to and / or above the reference line (RL). As similarly discussed herein, the separation line (SL) can still be positioned by the transition conduit 124 formed, positioned, defined, and / or extending between the component segment 104 and the supplemental segment 106. However, unlike discussed herein with respect toFigures 1 to 8 The non-limiting examples discussed, Figure 9 The illustrated separation line (SL) can be positioned by only a portion of the transition conduit 124 that is positioned, defined, and / or extends within the supplemental segment 106 of the monolithic body 102.

[0052] Turning to Figure 10 In instances where the supplemental segment 106 is removed at the separation line (SL) positioned adjacent to the reference line (RL) and / or positioned above the reference line, a portion of the supplemental segment 106 can remain with the component segment 104. That is, the final configuration formed by the monolithic body 102 of the component 100 that is additively manufactured can include an unremoved portion or remaining portion 134 of the supplemental segment 106. In this non-limiting example, the “finished” surface 112 can be formed by the remaining portion 134 of the supplemental segment 106 of the monolithic body 102 that is not removed and / or remains integrally formed with the component segment 104. Exposing / defining the “finished” surface 112 formed by the remaining portion 134 of the supplemental segment 106 can also expose the remaining portion 130 of the transition conduit 124, the passageway 108, and the opening 110 of the component segment 104, as similarly discussed herein.

[0053] Figures 11 to 13 Additional non-limiting examples of the monolithic body 202 of the component 200 are illustrated. More specifically, Figures 11 to 13 A front cross-sectional view of the monolithic body 202 including a portion of the integrally formed component segment 204 and supplemental segment 206 is illustrated. In each of the non-limiting examples in the illustrated non-limiting examples, and as discussed herein, the component segment 204 can include a plurality of passageways 208A, 208B extending therein. It should be appreciated that the number of passageways 208 formed in the component segment 204 of the monolithic body 202 illustrated herein can be illustrative, and the monolithic body 202 of the component 200 can include more or fewer passageways 208 than those illustrated and discussed herein.

[0054] In Figure 11 In the illustrated non-limiting examples, the component segment 204 can include a first passageway 208A and a different second passageway 208B. The first passageway 208A can extend at least partially through the component segment 204 and can include a first opening 210A having a first dimension (D1). The first passageway 208A can be substantially similar to the passageway 108 discussed herein with respect to the component 100. Figures 1 to 6 The second passageway 208B of the monolithic body 102 can extend at least partially through the component segment 204 adjacent to the first passageway 208A. The second passageway 208B can also include a second opening 210B having a third dimension (D3).

[0055] As Figure 11As shown, the supplemental segment 206 can include a plurality of passages 218A, 218B, each passage corresponding to one of the plurality of passageways 208A, 208B formed in the component segment 204. That is, the supplemental segment 206 can be disposed, formed over, and / or can cover the first opening 210A of the first passageway 208A and the second opening 210B of the second passageway 208B, and can include a plurality of corresponding passages 2018A, 2018B extending therein. For example, the supplemental segment 206 can include a first passage 218A in fluid communication with the first passageway 208A. The first passage 218A can include a first opening 220A formed through the surface 222, and can be in fluid communication with the first passageway 208A via a first transition conduit 224A positioned between the first passage 218A and the first passageway 208A. As similarly discussed herein, the first transition conduit 224A can extend, be formed, defined, and / or positioned between the component segment 204 and the supplemental segment 206 to fluidly couple the first passage 218A and the first passageway 208A. As similarly discussed herein, the first transition conduit 224A can include a frustoconical shape, and the entire transition conduit 224A can have a dimension (e.g., D2) that is greater than a first dimension (D1) of the first opening 210A of the first passageway 208A. Additionally, the difference in dimensions can increase as the first transition conduit 224A transitions into the first passage 218A and / or away from the first opening 210A.

[0056] In Figure 11 In the non-limiting example shown, the supplemental segment 206 can also include a different second passage 218B. The second passage 218B can extend at least partially through the supplemental segment 206, and can be in fluid communication with the second passageway 208B. That is, the second passage 218B can extend at least partially through a portion of the supplemental segment 206 that is disposed over the second passageway 208B, and can include an opening 220B formed in the surface 222. The second passage 218B can also be in fluid communication with the second passageway 208 that extends at least partially through the component segment 204.

[0057] Additionally, and as Figure 11 As shown, the monolithic body 202 can include a second transition conduit 224B positioned within and / or extending between the component segment 204 and the supplemental segment 206. The segment transition conduit 224 can extend between the second passageway 208B of the component segment 204 and the second passage 218B of the supplemental segment 206 to fluidly couple the second passageway 208B and the second passage 218B. In Figure 11 In the non-limiting example shown, and as similarly discussed herein with respect to Figure 7 and Figure 8Similarly discussed, the second transition conduit 224B can have a substantially uniform fourth dimension (D4). The fourth dimension (D4) of the second transition conduit 224B can be greater than the third dimension (D3) of the second opening 210B of the second passageway 208B. Although shown as having a substantially uniform fourth dimension (D4), it should be appreciated that the second transition conduit 224B can alternatively be formed to include a frustoconical shape (see Figure 12 ), wherein the entire second transition conduit 224B can have a dimension (e.g., D4) that is greater than the third dimension (D3) of the second opening 210B of the second passageway 208B.

[0058] Turning to Figure 12 , the monolithic body 202 of the component 200 can include similar features (e.g., passageways 208A, 208B, openings 210A, 210B, and / or transition conduits 224A, 224B) such as those shown and discussed herein with respect to Figure 11 . It should be appreciated that similarly numbered and / or named components can function in substantially similar manners. Redundant explanations of these components have been omitted for the sake of clarity.

[0059] Unlike Figure 11 , Figure 12 the non-limiting example shown illustrates a supplemental segment 206 that includes a single channel 218 extending therein. More specifically, the supplemental segment 206 of the monolithic body 202 can include a single channel 218 that can include a single opening 220 formed in and / or through a surface 222. In the non-limiting example, the single channel 218 can be in fluid communication with each of the first passageway 208A and the second passageway 208B that extend at least partially through the component segment 204. The single channel 218 can also be in direct fluid communication with and / or fluidly coupled to each of the first transition conduit 224A and the second transition conduit 224B. Accordingly, the first transition conduit 224A can fluidly couple the first passageway 208A to the single channel 218, and the second transition conduit 224B can also fluidly couple the second passageway 208B to the single channel 218.

[0060] In Figure 13 the non-limiting example shown, the supplemental segment 206 can include a manifold 236 formed therein. The manifold 236 of the supplemental segment 206 can be in fluid communication with each of the first channel 218A and the second channel 218B that extend at least partially through the supplemental segment 206. As Figure 13As shown, the manifold 236 can include a single opening 238 formed in the surface 222 of the supplemental segment 206. The single opening 238 can be in fluid communication with a plurality of branches 240, 242 of the manifold 236. Each branch 240, 242 can correspond to and / or be fluidly coupled to a channel 218A, 2018B of the supplemental segment 206. For example, a first branch 240 of the manifold 236 can be fluidly coupled to the first channel 218A, and a second branch 242 can be fluidly coupled to the second channel 218B. As discussed herein, the manifold 236 of the supplemental segment 206 can also be a passageway through which fluid flows to and / or from the passageways 208A, 208B of the component segment 204 via the channels 218A, 218B.

[0061] Figure 14 A front view of a component 300 including a monolithic body 302 is shown. In non-limiting examples, the component segment 304 monolithic body 302 can include a first passageway 308A and a second passageway 308B extending therethrough and in fluid communication with and / or fluidly coupled to a cavity 344 formed therein. As shown, the second passageway 308B can extend at least partially through the component segment 304 at an angle (e.g., perpendicular) relative to the first passageway 308A. Accordingly, and unlike the non-limiting examples discussed herein with respect to the manifold 236 of the supplemental segment 206, the second passageway 308B can be exposed on a different “finished” surface (e.g., the “finished” surface 112) than the first passageway 308A when the component segment 304 is in a final form and / or configuration for use. Figures 11 to 13

[0062] Accordingly, the monolithic body 302 of the component 300 can include a first supplemental segment 306A and a different second supplemental segment 306B integrally formed with the component segment 304. That is, the first supplemental segment 306A can be integrally formed with the component segment 304 and can be disposed over and / or cover the first passageway 308A / first opening 310A. Figure 14 The monolithic body 302 shown can include a first channel 318A extending at least partially through the first supplemental segment 306A and in fluid communication with the first passageway 308A. As similarly discussed herein, the monolithic body 302 can also include a first transition conduit 324A extending between and / or positioned within the component segment 304 and the first supplemental segment 306A. The first transition conduit 324A can extend between the first passageway 308A of the component segment 304 and the first channel 318A of the first supplemental segment 306A to fluidly couple the first passageway 308A and the first channel 318A.

[0063] ​The second supplemental segment 306B can be integrally formed with a different portion of the component segment 304 of the monolithic body 302. That is, the second supplemental segment 306B can be integrally formed with the component segment 304 and can be disposed on and / or cover the second passageway 308B / second opening 310B. As Figure 14 shown, the second supplemental segment 306B of the monolithic body 302 can include a second channel 318B that extends at least partially through the second supplemental segment 306B. The second channel 318B can be in fluid communication with the second passageway 308B. In non-limiting examples, the monolithic body 302 can also include a second transition conduit 324B that extends between and / or is positioned within the component segment 304 and the second supplemental segment 306B. The second transition conduit 324B can extend between the second passageway 308B of the component segment 304 and the second channel 318B of the second supplemental segment 306B to fluidly couple the second passageway 308B and the second channel 318B. As similarly discussed herein, each of the first supplemental segment 306A and the second supplemental segment 306B can be removed along the respective separation line (SL1, SL2) to form the final configuration of the component 300 (e.g., the component segment 304) that can be used for its intended purpose.

[0064] While shown as two different supplemental segments 306A, 306B, it should be understood that, Figure 14 the non-limiting examples shown can include a single supplemental segment 306 that can be disposed on and / or cover both the first passageway 308A and the second passageway 308B. For example, a void 346 (shown in dashed lines) can be formed between the first supplemental segment 306A and the second supplemental segment 306B during the additive manufacturing build process to separate and / or distinguish the first supplemental segment 306A and the second supplemental segment 306B from the monolithic body 302. In another non-limiting example, Figure 14 the void 346 shown can include an additive manufactured material or build material that can bridge between, form, extend, and / or define the first supplemental segment 306A and the second supplemental segment 306B as a single integral supplemental segment of the monolithic body 302.

[0065] Figure 15 A non-limiting example process for forming a component using an additive manufacturing process and / or system is shown. Specifically, Figure 15 is a flow diagram showing an example process for forming a component that includes a component segment and a supplemental segment. In some cases, the process can be used to form the components 100, 200, 300 as discussed herein with respect to Figures 1 to 14 .

[0066] In process PI, an integral body of a component can be additively manufactured or built. That is, an additive manufacturing system (AMS) can perform a build process (e.g., direct metal laser melting) to build the body of the component as a whole. The integral body of the component can be built to include a respective segment and at least one feature formed therein. For example, the additively manufactured integral body can include a component segment that includes at least one passage extending at least partially through the component segment. The passage can include an opening having a first dimension. In a non-limiting example, the additively manufactured integral body can include the passage additively manufactured at a non-perpendicular angle relative to a finish surface of the integral body. The additively manufactured integral body can also include a supplemental segment integrally formed with the component segment. The supplemental segment can be disposed on the passage of the component segment and can include a passage extending at least partially through the supplemental segment. The passage of the supplemental segment can be in fluid communication with the passage of the component segment. Additionally, the additively manufactured integral body can include a transition conduit positioned within and / or extending between the component segment and the supplemental segment. The transition conduit can extend between the passage of the component segment and the passage of the supplemental segment to fluidly couple the passage and the passage.

[0067] The transition conduit can also be additively manufactured to have a second dimension that is greater than the first dimension of the opening of the passage of the component segment. In a non-limiting example, the second dimension of the transition conduit can be substantially uniform in shape and / or dimension. In another non-limiting example, the transition conduit can be additively manufactured to and / or include a frustoconical shape in process PI. The frustoconical transition conduit can be additively manufactured to include a first end positioned directly adjacent to and in direct fluid communication with the opening of the passage extending in the component segment. The first end of the frustoconical transition conduit can have a third dimension that is greater than the first dimension of the opening of the passage of the component segment. The frustoconical transition conduit can also be additively manufactured to include a second end positioned opposite the first end. The second end can be positioned directly adjacent to and in direct fluid communication with the passage positioned in the supplemental segment. The second end can also have a second dimension that is greater than the first dimension of the opening of the passage and the third dimension of the first end of the transition conduit.

[0068] In additional non-limiting examples, the integral body can include a plurality of passages. More specifically, the additive manufacturing performed in process PI can also include additively manufacturing a first passage extending at least partially through the component segment. The first passage can include a first opening having a first dimension. Additionally, process PI can also include additively manufacturing a second passage extending at least partially through the component segment adjacent to the first passage. The second passage can include a second opening having a third dimension.

[0069] As a result of forming the two (or more) passageways, the supplemental segment can include at least one channel and / or the monolithic body can include multiple transition conduits. Continuing the above example, process PI can include additively manufacturing a second channel that extends at least partially through the supplemental segment and is in fluid communication with the second passageway. The supplemental segment can be disposed over the first opening of the first passageway and the second opening of the second passageway. Additionally, process PI can further include additively manufacturing a second transition conduit positioned within the component segment and the supplemental segment. The second transition conduit can extend between the second passageway of the component segment and the second channel of the supplemental segment to fluidically couple the second passageway and the second channel. In this non-limiting example, the (first) channel of the supplemental segment is in fluid communication with the first passageway via the (first) transition conduit and the second channel of the supplemental segment is in fluid communication with the second passageway via the second transition conduit.

[0070] In another non-limiting example in which the component segment includes a first passageway and a second passageway, process PI can further include additively manufacturing a second supplemental segment that is integrally formed with the component segment and disposed over a second opening of the second passageway. The second supplemental segment can be distinct from the (first) supplemental segment and can include a second channel that extends at least partially through the second supplemental segment and is in fluid communication with the second passageway. Additionally, in the non-limiting example, additively manufacturing the monolithic body in process PI can include additively manufacturing a second transition conduit positioned within the component segment and the second supplemental segment. The second transition conduit can extend between the second passageway of the component segment and the second channel of the second supplemental segment to fluidically couple the second passageway and the second channel.

[0071] In any of the non-limiting examples in which the component segment includes a first passageway and a second passageway and the supplemental segment includes a first channel and a second channel, additively manufacturing the monolithic body in process PI can further include additively manufacturing a manifold in the supplemental segment. The manifold additively manufactured in the monolithic body of the component can be in direct fluid communication with the channels and the second channel of the supplemental segment.

[0072] In process P2 (shown in dashed lines as optional), at least one post-build process can be performed on the component including the monolithic body. Specifically, and after integrally forming and / or additively manufacturing (e.g., process PI) the component segment and the supplemental segment, one or more post-build processes can be performed on the monolithic body of the component including the integrally formed component segment and the supplemental segment. The post-build process(es) performed on the component including the monolithic body can prepare the monolithic body of the component for use by the component, device, and / or system for the intended purpose. Performing at least one post-build process on the component including the monolithic body can further include, for example, shot peening the monolithic body and / or recrystallizing the component including the monolithic body.

[0073] In process P3, the supplemental segment can be removed from the monolithic body. That is, the supplemental segment can be removed from the component segment of the monolithic body of the component. Removing the supplemental segment from the component segment of the monolithic body fabricated via additive manufacturing can substantially expose, define, and / or form a “finished” surface of the component segment of the monolithic body. Additionally, removing the supplemental segment from the component segment of the monolithic body can also expose at least a remaining portion of the transition conduit and the passageway of the component segment. The supplemental segment can be removed by performing any now known or later developed cutting process (e.g., electrical discharge machining (EDM), a cutting wheel, etc.). For example, removing the supplemental segment can include machining the supplemental segment through the transition conduit to define the finished surface of the monolithic body / component segment of the component. The finished surface can include the exposed / remaining portion of the transition conduit and the passageway of the component segment. By removing / machining the supplemental segment through the transition conduit, at least a portion of the transition conduit having a second dimension greater than a first dimension of the opening / passageway of the component segment can remain in and / or on the component segment of the component.

[0074] In process P4 (shown in dashed lines as optional), additional post-build processes can be performed on the monolithic body. Specifically, and after removing the supplemental segment from the component segment of the monolithic body, additional post-build processes can be performed on the component segment of the component to prepare the component segment and / or provide the component segment for its intended use. In the non-limiting example where the shot peening process is only performed in process P2, the component segment can undergo a recrystallization process without the supplemental segment. Additionally or alternatively, a burr removal process can be performed after removing the supplemental segment. For example, where the supplemental segment is removed from the component segment using a machining process, a burr can be formed on the “finished” surface. The burr can extend from the remaining portion of the transition conduit and can extend at least partially into and / or adjacent to the opening / passageway of the component segment. Accordingly, process P4 can include performing a burr removal process after removing the supplemental segment from the component segment of the monolithic body to remove at least one burr that extends into and / or from the remaining portion of the transition conduit.

[0075] The components 100, 200, 300 can be formed in a variety of ways. In one embodiment, the components 100, 200, 300 can be made by casting. However, as described herein, additive manufacturing is particularly well suited for making components 100, 200, 300 that include monolithic bodies. As used herein, additive manufacturing (AM) can include any process of producing objects by successively layering material rather than removing material (as in the case of conventional processes). Additive manufacturing can form complex geometries without the need to use any kind of tooling, molds, or fixtures, and with little or no waste of material. Rather than machining a component from a solid plastic or metal billet, of which much is cut away and discarded, the only material used in additive manufacturing is that which is needed to shape the part. Additive manufacturing processes can include, but are not limited to, 3D printing, rapid prototyping (RP), direct digital manufacturing (DDM), binder jetting, selective laser melting (SLM), and direct metal laser melting (DMLM). In the present setting, DMLM or SLM has been found to be advantageous.

[0076] To illustrate an example of an additive manufacturing process, Figure 16 An illustrative schematic / block diagram of an exemplary computerized additive manufacturing system 900 for generating an object 902 is shown. In this example, the system 900 is arranged for DMLM. It will be appreciated that the general teachings of the present disclosure are equally applicable to other forms of additive manufacturing. The object 902 is shown as a component 100, 200, 300 (see Figures 1 to 14 ). The AM system 900 generally includes a computerized additive manufacturing (AM) control system 904 and an AM printer 906. As will be described, the AM system 900 executes code 920, which includes a set of computer-executable instructions that define the component 100, 200, 300, to physically generate the object 902 using the AM printer 906. Each AM process can use different raw materials in the form of, for example, fine-grained powder, liquid (e.g., polymer), sheet, etc., of which a supply can be held in a chamber 910 of the AM printer 906. As shown, an applicator 912 can form a thin layer of the raw material 914 that spreads out as a blank canvas on a build plate 915 of the AM printer 906 from which each successive slice of the final object will be formed. In other cases, the applicator 912 can apply or print the next layer directly onto the previous layer as defined by the code 920, for example, in the case of using a metal binder jetting process. In the example shown, a laser or electron beam 916 melts the particles for each slice as defined by the code 920, although this can not be necessary in the case of using a fast-curing liquid plastic / polymer. Various parts of the AM printer 906 can move to accommodate the addition of each new layer, for example, after each layer, the build platform 918 can lower, and / or the chamber 910 and / or applicator 912 can raise.

[0077] The AM control system 904 is shown implemented as computer program code on a computer 930. To that extent, the computer 930 is shown to include a memory 932, a processor 934, input / output (I / O) interfaces 936, and a bus 938. Further, the computer 930 is shown in communication with external I / O devices / resources 940 and storage systems 942. Generally, the processor 934 executes instructions, codes, and / or data stored in the memory 932 and / or the storage systems 942 and / or received from the I / O devices 940 and / or AM printer 906 to operate the computer 930 in the manner described herein, such as the AM control system 904. When executing the computer program code, the processor 934 can read and / or write data used in the operation of the computer 930 from / to the memory 932, the storage systems 942, the I / O devices 940, and / or the AM printer 906. The bus 938 provides a communication link between each of the components in the computer 930 and the I / O devices 940 can include any device that enables a user to interact with the computer 940 (e.g., a keyboard, a pointing device, a display, etc.). The computer 930 represents a variety of possible combinations of hardware and software. For example, the processor 934 can include a single processing unit or one or more processing units distributed across one or more locations (e.g., on a client and server). Similarly, the memory 932 and / or the storage systems 942 can reside at one or more physical locations. The memory 932 and / or the storage systems 942 can include any combination of various types of non-transitory computer-readable storage media, including magnetic media, optical media, random access memory (RAM), read only memory (ROM), etc. The computer 930 can include any type of computing device, such as a network server, a desktop computer, a laptop computer, a handheld device, a mobile telephone, a pager, a personal digital assistant, etc.

[0078] The additive manufacturing process begins with a non-transitory computer- readable storage medium (e.g., the memory 932, the storage systems 942, etc.) storing code 920 representing the part 100, 200, 300. As noted, the code 920 includes a set of computer-executable instructions defining the external electrode, which can be used to physically generate the tip when the system 900 executes the code. For example, the code 920 can include a precise 3D model of the part 100, 200, 300 and can be generated by a wide variety of well-known computer-aided design (CAD) software systems, such as AutoCAD®, SolidWorks®, Pro / ENGINEER®, and the like. The code 920 can be stored on a non-transitory computer-readable storage medium, such as the memory 932, the storage systems 942, etc. The code 920 can be executed by the processor 934 to generate the part 100, 200, 300. Turbo The code 920 can be generated by any of a variety of computer-aided design (CAD) programs (e.g., Pro / ENGINEER®, SolidWorks®, AutoCAD®, DesignCAD 3D Max, etc.). In this regard, the code 920 can employ any now known or future developed file format. For example, the code 920 can be a standard tessellation language (STL) created by a stereolithography CAD program of 3D Systems, or an additive manufacturing file (AMF) as an American Society of Mechanical Engineers (ASME) standard, the latter being an extensible markup language (XML)-based format designed to allow any CAD software to describe the shape and composition of any three-dimensional object to be fabricated on any AM printer. The code 920 can be translated between different formats as needed, converted to a set of data signals, and transmitted, received, and converted to code, stored, etc. as a set of data signals. The code 920 can be an input to the system 900 and can come from a part designer, intellectual property (IP) provider, design firm, operator or owner of the system 900, or from other sources. In any case, the AM control system 904 executes the code 920 to divide the part 100, 200, 300 into a series of slices that are assembled using the AM printer 906 in successive layers of liquid, powder, sheet, or other material. In the DMLM example, each layer is fused into the precise geometry defined by the code 920 and fused to the previous layer. Subsequently, the part 100, 200, 300 can be exposed to any of a variety of finishing processes, such as those described herein for reshaping or other minor machining, sealing, polishing, etc.

[0079] Technical effects of the present disclosure include, for example, providing a part formed from a unitary body that includes a part segment, a supplemental segment, and a transition conduit extending between and fluidly coupling a passageway of the part segment and a channel of the supplemental segment. When a post-configuration process (e.g., burr removal) is performed on the part segment, the transition conduit positioned between the part segment and the supplemental segment of the unitary body allows the supplemental segment to be removed from the part segment without obstructing the passageway of the part segment and / or eliminating the risk of the passageway being undesirably modified.

[0080] The diagrams in the accompanying drawings are directed to possible architectural, functional and operational aspects of systems, methods and computer program products in accordance with various embodiments of the present disclosure. In that regard, each block in the flowcharts or block diagrams can represent a module, segment, or portion of code, which includes one or more executable instructions for implementing the specified logical function(s). It should also be noted that in some alternative implementations, the functions noted in the blocks can occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently or the blocks can sometimes be executed in the reverse order, depending on the functionality involved. It will also be noted that each block of the block diagrams and / or flowchart illustrations, and combinations thereof, can be implemented by special purpose hardware-based systems that perform the specified functions or operations, or combinations of special purpose hardware and computer instructions.

[0081] As discussed herein, various systems and components are described as “obtaining” data. It should be understood that any solution can be used to obtain the corresponding data. For example, the corresponding system / component can generate and / or be used to generate the data, retrieve the data from one or more data stores (e.g., databases), receive the data from another system / component, etc. When the data is not generated by the particular system / component, it should be understood that another system / component can be implemented in addition to the illustrated system / component that generates the data and provides it to the system / component and / or stores the data for access by the system / component.

[0082] The aforementioned diagrams illustrate some of the associated processes in accordance with several embodiments of the present disclosure. In that regard, each diagram or block within the flowcharts of the diagrams represents a process associated with an embodiment of the method. It should also be noted that in some alternative implementations, the actions mentioned in the diagrams or blocks can not occur in the order shown in the figures, or, for example, can actually be performed substantially concurrently or in reverse order, depending on the actions involved. Also, one of ordinary skill in the art will recognize that additional blocks describing this process can be added.

[0083] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and / or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. “Optional” or “optionally” mean that the subsequently described event or circumstance can or can not occur, and that the description includes instances where the event occurs and instances where it does not.

[0084] As used throughout the specification and claims, approximate language can be used to modify any quantitative representation that can allow for variation, without resulting in a change of the basic function to which it is related. Accordingly, a value modified by one or more terms such as “about,” “approximately,” and “substantially” is not limited to the precise value specified. In at least some instances, the approximate language can correspond to the precision of an instrument used to measure the value. In this and throughout the specification and claims, range limitations can be combined and / or interchanged, such ranges being identified and include all the sub-ranges contained therein, unless context or language indicates otherwise. “About” applied to numerical values means + / - 10% of the recited value, unless otherwise dependent on the precision of the instrument measuring the value.

[0085] All means or step-plus-function elements in the claims that follow the designation of an element preceded by the phrase “means for” or “step for” are intended to function as open-ended claims over a wide variety of elements that can serve an equivalent purpose to those specified in each instance of that term. A description of one or more embodiments of the disclosure has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise form disclosed. Many modifications and variations will be apparent to those skilled in the art. Embodiments were chosen and described in order to best explain the principles of the disclosure and its practical application, and to thereby enable others skilled in the art to best utilize the disclosure in various embodiments and with various modifications as are suited to the particular use contemplated.

Claims

1. An additively manufactured component (200), the component (200) comprising: A monolithic body (102, 202, 302), the monolithic body (102, 202, 302) comprising: A component segment (104, 204, 304), the component segment (104, 204, 304) comprising: at least one passageway (108) extending at least partially through the component segment (104, 204, 304), the at least one passageway (108) including an opening (110, 220B) having a first size; A supplementary segment (206) formed integrally with the component segment (104, 204, 304) and configured to be removable from the component segment (104, 204, 304), the supplementary segment (206) being disposed on the at least one passageway (108) of the component segment (104, 204, 304) and comprising: a channel (118, 218B, 218A) extending at least partially through the supplemental segment (206), the channel (118, 218B, 218A) being in fluid communication with the at least one passageway (108) of the component segment (104, 204, 304); and a transition duct (124, 224A) positioned within the component segment (104, 204, 304) and the supplemental segment (206), the transition duct (124, 224A) extending between the at least one passageway (108) of the component segment (104, 204, 304) and the passageway (118, 218B, 218A) of the supplemental segment (206) to fluidly couple the at least one passageway (108) and the passageway (118, 218B, 218A); wherein the transition duct (124, 224A) includes a second dimension that is larger than the first dimension of the opening (110, 220B) of the at least one passageway (108) of the component segment (104, 204, 304); and wherein the transition duct (124, 224A) includes a first end (126) positioned in the component segment (104, 204, 304) and a second end (128) positioned in the supplemental segment (206), the first end (126) having a third dimension greater than the first dimension and the second end (128) having the second dimension greater than the third dimension; and wherein the channel (118, 218B, 218A) of the supplemental segment (206) has a size that is greater than a size of the at least one passageway (108) of the component segment (104, 204, 304).

2. The component (200) of claim 1, wherein the at least one passageway (108) comprises: a first passageway (208A) extending at least partially through the component segment (104, 204, 304), the first passageway (208A) including a first opening (220A) having the first size, wherein said passage (118, 218B, 218A) of said supplemental segment (206) is in fluid communication with said first passageway (208A); and A second passage (208, 208B) extends at least partially through the component segment (104, 204, 304), the second passage (208, 208B) including a second opening (210B) having a third size.

3. The component (200) of claim 2, wherein the supplemental segment (206) is disposed above the second opening (210B) of the second passage (208, 208B), and further comprising: A second passage (218B, 318B) extends at least partially through the supplemental segment (206) and is in fluid communication with the second passageway (208, 208B).

4. The component (200) according to claim 3, further comprising: a second transition duct (224B, 324B) positioned within the component segment (104, 204, 304) and the supplemental segment (206), the second transition duct (224B, 324B) extending between the second passage (208, 208B) of the component segment (104, 204, 304) and the second channel (218B, 318B) of the supplemental segment (206) to fluidically couple the second passage (208, 208B) and the second channel (218B, 318B), wherein the second transition duct (224B, 324B) comprises a substantially uniform fourth dimension, the fourth dimension being greater than the third dimension of the second opening (210B) of the second passageway (208, 208B).

5. The component (200) of claim 3, wherein the supplemental segment (206) further comprises a manifold (236) in fluid communication with the passage (118, 218B, 218A) and the second passage (218B, 318B).

6. The component (200) according to claim 2, further comprising: a second supplementary segment (306B) formed integrally with the component segment (104, 204, 304) and disposed on the second opening (210B) of the second passage (208, 208B), the second supplementary segment (306B) comprising: A second passage (218B, 318B) extends at least partially through the second supplemental segment (306B) and is in fluid communication with the second passageway (208, 208B).

7. The component (200) according to claim 6, further comprising: A second transition duct (224B, 324B) is positioned within the component segment (104, 204, 304) and the second supplemental segment (306B), the second transition duct (224B, 324B) extending between the second passage (208, 208B) of the component segment (104, 204, 304) and the second channel (218B, 318B) of the second supplemental segment (306B) to fluidically couple the second passage (208, 208B) and the second channel (218B, 318B).

8. The component (200) of claim 1, wherein the transition duct (124, 224A) is frustoconical and comprises: the first end (126), the first end (126) being positioned directly adjacent to and in direct fluid communication with the opening (110, 220B) of the at least one passageway (108), and the second end (128), the second end (128), being positioned opposite the first end (126), the second end (128) being positioned directly adjacent to and in direct fluid communication with the passage (118, 218B, 218A) positioned in the supplemental segment (206), wherein the second end portion (128) has a second dimension that is greater than: The first dimension of the opening (110, 220B) of the at least one passageway (108).

9. The component (200) of claim 1, wherein the at least one passageway (108) extends at least partially through the component segment (104, 204, 304) at a non-perpendicular angle relative to a finished surface (20, 112, 122, 222) of the monolithic body (102, 202, 302), the finished surface (20, 112, 122, 222) of the monolithic body (102, 202, 302) exposing the at least one passageway (108).

10. A method for forming an additively manufactured part, comprising: A unitary body (102, 202, 302) of an additively manufactured component (200), the unitary body (102, 202, 302) comprising: a component segment (104, 204, 304), the component segment (104, 204, 304) comprising at least one passageway (108) extending at least partially through the component segment (104, 204, 304), the at least one passageway (108) comprising an opening (110, 220B) having a first size; a supplemental segment (206) formed integrally with the component segment (104, 204, 304) and configured to be removable from the component segment (104, 204, 304), the supplemental segment (206) being disposed on the at least one passageway (108) of the component segment (104, 204, 304) and including a passageway (118, 218B, 218A) extending at least partially through the supplemental segment (206), the passageway (118, 218B, 218A) being in fluid communication with the at least one passageway (108) of the component segment (200); and a transition duct (124, 224A) positioned within the component segment (104, 204, 304) and the supplemental segment (206), the transition duct (124, 224A) extending between the at least one passageway (108) of the component segment (104, 204, 304) and the passageway (118, 218B, 218A) of the supplemental segment (206) to fluidly couple the at least one passageway (108) and the passageway (118, 218B, 218A); performing at least one post-build process on the component (200) including the unitary body (102, 202, 302); and removing the supplemental segment (206) from the component segment (104, 204, 304) of the monolithic body (102, 202, 302) to expose a portion of the transition duct (124, 224A) and the at least one passageway (108) of the component segment (104, 204, 304); wherein the transition duct (124, 224A) comprises a second dimension that is larger than the first dimension of the opening (110, 220B) of the at least one passageway (108) of the component segment (104, 204, 304); wherein the transition duct (124, 224A) includes a first end (126) positioned in the component segment (104, 204, 304) and a second end (128) positioned in the supplemental segment (206), the first end (126) having a third dimension greater than the first dimension and the second end (128) having the second dimension greater than the third dimension; and wherein the channel (118, 218B, 218A) of the supplemental segment (206) has a size that is greater than a size of the at least one passageway (108) of the component segment (104, 204, 304).

11. The method of claim 10, wherein the transition duct (124, 224A) is frustoconical and comprises: the first end (126), the first end (126) being positioned directly adjacent to and in direct fluid communication with the opening (110, 220B) of the at least one passageway (108), and the second end (128), the second end (128), being positioned opposite the first end (126), the second end (128) being positioned directly adjacent to and in direct fluid communication with the passage (118, 218B, 218A) positioned in the supplemental segment (206), wherein the second end portion (128) has a second dimension that is greater than: The first dimension of the opening (110, 220B) of the at least one passageway (108).

12. The method of claim 10, wherein removing the supplemental segment (206) from the component segment (104, 204, 304) of the monolithic body (102, 202, 302) further comprises: The supplemental segment (206) is machined through the transition duct (124, 224A) to define a trim surface (20, 112, 122, 222) of the monolithic body (102, 202, 302) of the component (200), the trim surface (20, 112, 122, 222) including the portion of the exposed transition duct (124, 224A) and the at least one passageway (108) of the component segment (104, 204, 304).

13. The method of claim 12, wherein additively manufacturing the monolithic body (102, 202, 302) further comprises: The at least one passageway (108) is additively manufactured at a non-perpendicular angle relative to the finished surface (20, 112, 122, 222) of the monolithic body (102, 202, 302).

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