Cantilevered mask for openings in additively manufactured parts

Abstract

A mask (100) for an additively manufactured part (102) is provided, the additively manufactured part including a plurality of openings (106, 204) in a surface (110) of the part (102). The mask (100) is manufactured together with the part (102) and includes an attachment tie (120, 220) configured to be integrally coupled to the part (102) adjacent to the plurality of openings (106, 204). A cover member (130, 140, 230) includes a proximal end (132, 142, 232) integrally coupled to the attachment tie (120, 220) and a distal end (134, 144, 234) extending at least partially above the plurality of openings (106, 204). A separation member (152, 252, 352) may optionally extend from an adjacent cover member (130, 140, 230). The attachment straps (120, 220) are the only connection to the part (102). The cross-section of the mask (100) may have an L-shape.

Description

Background Art

[0001] The present disclosure relates generally to post-manufacturing processing of parts, and more particularly to masks for protecting openings in the surface of additively manufactured parts.

[0002] Additive manufacturing (AM) includes a variety of processes that produce parts by successive layers of material rather than by the removal of material. As a result, AM can form complex geometries without the use of tools, molds, or fixtures of any kind, and with little or no waste of material. Rather than machining a part from a solid block of material (much of which is cut away and discarded), the only material used in AM is that required to form the component. As a result, many industrial parts, such as turbine rotor blades, are preferably made by AM.

[0003] After being formed by additive manufacturing, the part may be further processed. In one example, the part may be exposed to shot peening, in which the surface of the part is bombarded with a peening material, such as metal shot. In another example, the part may be coated with a protective layer to protect the material underneath from the harsh environment in which the part is used. For example, a thermal barrier coating (TBC) may be applied to the outer surface of a turbine rotor blade to protect the blade from high temperatures during use.

[0004] Some parts may include openings in their surfaces that need to be protected during post-manufacturing processing. For example, a turbine rotor blade may include various internal cooling circuits that lead to the outer surface of the part through cooling channels (i.e., openings in the surface of the part). Cooling channels may be provided to cool the internal structure in which they reside, and / or to create a cooling film across the outer surface of the part.

[0005] A variety of mechanisms are used to protect openings. In some cases, removable materials such as plugs may be provided in or above the openings to, for example, prevent them from being filled when a coating is applied over the openings. The removable material blocks the coating from entering the openings, but increases manufacturing time and complexity because the removable material and / or the coating over it must eventually be removed. For example, the blocking material must be removed for each opening, which may be time consuming. In addition, the coating is typically applied over the blocking material, but needs to be removed from over the blocking material to expose the blocking material and / or the opening. Because the coating bridges over the blocking material, the removal of the coating may result in a large amount of rupture of the remainder of the coating (e.g., TBC), which may make the part unusable or require a large amount of additional processing. In the case where the blocking material is stuck by the material of the part through the process, it may be particularly challenging to remove the blocking material after the hammering process. Other methods use permanent shielding features to protect the openings. In the latter case, the complexity of the part is increased, and the performance of the part may be sacrificed to accommodate the shielding. Summary of the invention

[0006] A first aspect of the present disclosure provides a mask for an additively manufactured part, the additively manufactured part comprising a plurality of openings spaced apart in a surface of the part, the mask comprising: an attachment strap configured to be integrally connected to the part in a cantilevered manner between the plurality of openings; a first cover member comprising a first proximal end integrally connected to the attachment strap and a first distal end extending at least partially over a first portion of the plurality of openings, the first distal end of the first cover member being separated from the part by a first spacing; a second cover member comprising a second proximal end integrally connected to the attachment strap and a second distal end extending at least partially over a second portion of the plurality of openings, the second distal end of the second cover member being separated from the part by a second spacing; and a separation member extending from adjacent first and second cover members, wherein the attachment strap is the only connection to the part.

[0007] A second aspect of the present disclosure provides an additive manufacturing (AM) structure comprising: a part comprising a plurality of openings spaced apart in a surface of the part; and a mask comprising: an attachment tether configured to be integrally coupled to the part in a cantilevered manner between a first plurality of openings and a second plurality of openings; a first cover member comprising a first proximal end integrally coupled to the attachment tether and a first distal end extending at least partially over a first portion of the plurality of openings, the first distal end of the first cover member being separated from the part by a first spacing; a second cover member comprising a second proximal end integrally coupled to the attachment tether and a second distal end extending at least partially over a second portion of the plurality of openings, the second distal end of the second cover member being separated from the part by a second spacing; and a separation member extending from adjacent first and second cover members, wherein the attachment tether is the only connection to the part, and wherein the part, the attachment tether, the first and second cover members, and the separation member comprise a plurality of integral material layers.

[0008] A third aspect of the present disclosure provides a mask for additively manufacturing a part, the part including a plurality of openings in a surface thereof, the mask comprising: an attachment tie configured to be integrally connected to the part in a cantilevered manner adjacent to a first plurality of openings; and a cover member comprising a proximal end integrally connected to the attachment tie and a distal end extending at least partially above the plurality of openings, the distal end of the cover member being separated from the part by a first spacing, wherein the attachment tie is the only connection to the part.

[0009] A fourth aspect of the present disclosure includes an additive manufacturing (AM) structure comprising: a part comprising a plurality of openings in a surface thereof; a mask comprising: an attachment tie configured to be integrally connected to the part in a cantilevered manner adjacent to a first plurality of openings; a cover member comprising a proximal end integrally connected to the attachment tie and a distal end extending at least partially above the plurality of openings, the distal end of the cover member being separated from the part by a first spacing; and a separation member extending from the cover member, wherein the attachment tie is the only connection to the part, and wherein the part, the attachment tie, the cover member, and the separation member comprise a plurality of integral material layers.

[0010] The exemplary aspects of the present disclosure are designed to solve the problems described herein and / or other problems not discussed. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] These and other features of the present disclosure will be more readily understood from the following detailed description of various aspects of the present disclosure taken in conjunction with the accompanying drawings which depict various embodiments of the present disclosure, wherein:

[0012] Figure 1 A perspective view of multiple masks for additive manufacturing a part is shown according to an embodiment of the present disclosure.

[0013] Figure 2 An enlarged cross-sectional view of a mask according to an embodiment of the present disclosure is shown.

[0014] Figure 3 An enlarged cross-sectional view of a mask having a coating thereon is shown according to an embodiment of the present disclosure.

[0015] Figure 4 An enlarged cross-sectional view of a mask having a coating and a space-filling material according to an embodiment of the present disclosure is shown.

[0016] Figure 5 An enlarged cross-sectional view of an alternative form of mask with attached ties according to an embodiment of the present disclosure is shown.

[0017] Figure 6 An enlarged cross-sectional view of another alternative form of mask having attached ties according to an embodiment of the present disclosure is shown.

[0018] Figure 7 Perspective views of multiple masks showing variations in attachment ties are shown according to embodiments of the present disclosure.

[0019] Figure 8 A perspective view of multiple masks showing segmented cover members and separation members is shown according to an embodiment of the present disclosure.

[0020] Fig. 9 Shown along Figure 8 Cross-sectional view along midline 9-9.

[0021] Fig.10 A cross-sectional view of a mask according to an alternative embodiment of the present disclosure is shown.

[0022] Fig.11 A cross-sectional view of a mask according to yet another alternative embodiment of the present disclosure is shown.

[0023] Fig.12 A cross-sectional view of a mask according to another embodiment of the present disclosure is shown.

[0024] Fig.13 A perspective view of multiple masks for additive manufacturing a part is shown according to an embodiment of the present disclosure.

[0025] Fig.14 The embodiment according to the present disclosure is shown Fig.13 An enlarged cross-sectional view of the mask in a relaxed position.

[0026] Fig.15 An enlarged cross-sectional view of a mask with a tool thereon is shown according to an embodiment of the present disclosure.

[0027] Fig.16 An enlarged cross-sectional view of a mask having a coating thereon is shown according to an embodiment of the present disclosure.

[0028] Fig.17 The embodiment according to the present disclosure is shown Fig.13 An enlarged cross-sectional view of the mask in a flexed position.

[0029] Fig.18 Perspective views of multiple masks showing variations in attachment ties are shown according to embodiments of the present disclosure.

[0030] Fig.19 A cross-sectional view of a mask including alternative features according to an embodiment of the present disclosure is shown.

[0031] Fig. 20 A cross-sectional view of a mask including alternative features according to an embodiment of the present disclosure is shown.

[0032] Fig.21 A cross-sectional view of a mask including alternative features according to an embodiment of the present disclosure is shown.

[0033] Fig. 22 A cross-sectional view of a mask including alternative features according to an embodiment of the present disclosure is shown.

[0034] Fig.23A cross-sectional view of a mask including alternative features according to an embodiment of the present disclosure is shown.

[0035] Fig.24 A cross-sectional view of a mask including alternative features according to an embodiment of the present disclosure is shown.

[0036] Fig.25 A cross-sectional view of a mask including alternative features according to an embodiment of the present disclosure is shown.

[0037] 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 present disclosure and therefore should not be considered to limit the scope of the present disclosure. In the drawings, like numbers represent like elements between drawings. DETAILED DESCRIPTION

[0038] As an initial matter, in order to clearly describe the present technology, it will be necessary to select certain terms when referring to and describing relevant machine parts. To the extent possible, common industry terms will be used and adopted in a manner consistent with the accepted meaning of the terms. Unless otherwise indicated, such terms should be given a broad interpretation consistent with the context of the present application and the scope of the appended claims. A person of ordinary skill in the art will understand that several different or overlapping terms may be used to refer to a particular component. An object that may be described as a single part in this article may include multiple parts and be referenced as consisting of multiple parts in another context. Alternatively, an object that may be described as comprising multiple parts in this article may be referred to as a single part elsewhere.

[0039] It is often necessary to describe parts that are arranged at different linear positions relative to a certain position. The term "distal" refers to a place or part of an object that is farther away than a "proximal" place or part of the same object. For example, the distal end of an object is farther away from the proximal end of the same object. Therefore, these terms provide a general positioning relative to each other. In addition, several descriptive terms may be used regularly in this article, as described below. The terms "first", "second", and "third" may be used interchangeably to distinguish one component from another, and are not intended to indicate the position or importance of individual components.

[0040] The terms used herein are only used for the purpose of describing specific embodiments and are not intended to limit the present disclosure. As used herein, the singular forms "one", "a kind of" and "the" are intended to also include plural forms, unless the context clearly states otherwise. It will be further understood that when used in the specification, the terms "include" and / or "comprising" specify the presence of stated features, integers, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, parts and / or their groups. "Optional" or "optionally" means that the event or situation described subsequently may or may not occur, and the description includes instances where the event occurs and instances where the event does not occur.

[0041] Where an element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it may be directly on, engaged to, connected to, or coupled to another element or layer, or there may be intervening elements or layers. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to," there may be no intervening elements or layers. Other words used to describe relationships between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0042] As described above, the present disclosure provides a mask for additive manufacturing a part, the part including a first plurality of openings and a second plurality of openings spaced apart in the surface of the part. The mask is manufactured together with the part and may include an attachment tether configured to be integrally connected to the part between the first plurality of openings and the second plurality of openings in a cantilevered manner. The mask can be removed from the part by breaking the attachment tether. In one embodiment, the first cover member and the second cover member include a proximal end integrally connected to the attachment tether and a distal end extending at least partially above the corresponding plurality of openings. In another embodiment, a single cover member is integrally connected to the attachment tether and extends at least partially above the plurality of openings. A separation member may be provided to certain embodiments to allow the mask to be easily removed from the part. In any case, the attachment tether is the only connection to the part. The cross section of the mask may be roughly umbrella-shaped or L-shaped.

[0043] See also Figures 1 to 12 , shows a mask 100 for additively manufacturing a part 102 according to certain embodiments of the present disclosure. Figure 1A perspective view of a mask 100 for additively manufacturing a part 102 (hereinafter referred to as "part 102") according to certain embodiments of the present disclosure is shown. Mask 100 and part 102 may be formed using any suitable additive manufacturing technique for the part material and may together form an additively manufactured (AM) structure 103 (only Figure 2 ). Additive manufacturing (AM) includes a variety of processes that produce parts by the continuous layering of material rather than the removal of material. Therefore, additive manufacturing can form complex geometries without the use of any kind of tools, molds or fixtures, and with little or no waste of material. Instead of machining a part from a solid material blank (much of which is cut away and discarded), the only material used in additive manufacturing is the material required to form the part. Additive manufacturing techniques generally include taking a three-dimensional computer-aided design (CAD) file of the part to be formed (e.g., part 102 and mask 100), electronically slicing the part into layers (e.g., 18 microns to 102 microns thick) and creating a file with a two-dimensional image (including vectors, images, or coordinates) of each layer. The file can then be loaded into a preparation software system that interprets the file so that the part (e.g., mask 100 and part 102) can be built by different types of additive manufacturing systems. In additive manufacturing in the form of 3D printing, rapid prototyping (RP) and direct digital manufacturing (DDM), layers of material (e.g., plastic or ceramic) are selectively distributed to form a part, for example, by laying down layer after layer of material. In contrast, in metal powder additive manufacturing techniques such as direct metal laser melting (DMLM), also known as selective laser melting (SLM), layers of metal powder are sequentially melted together to form the part. More specifically, layers of fine metal powder are sequentially melted after being evenly distributed on a bed of metal powder using an applicator. Each applicator includes an applicator element in the form of a die lip, brush, scraper or roller made of metal, plastic, material, carbon fiber or rubber, which spreads the metal powder evenly over the build platform. The metal powder bed can move in a vertical axis. The process occurs in a processing chamber with a precisely controlled atmosphere. Once each layer is formed, each two-dimensional slice of the component geometry can be fused by selectively melting the metal powder. The melting can be performed by a high power melting beam (such as a 100 watt ytterbium laser) to completely weld (melt) the metal powder to form a solid metal. The melting beam is moved in the XY direction using a scanning mirror and is strong enough to completely weld (melt) the metal powder to form a solid metal. The metal powder bed can be lowered for each subsequent two-dimensional layer and the process is repeated until the part is completely formed. In a non-limiting example, the mask 100 and the part 102 can be formed by DMLM or SLM for metal parts or 3D printing for ceramic parts.

[0044] exist Figure 1In an embodiment, part 102 includes a plurality of openings 106 in a surface 110 of part 102. The plurality of openings 106 may include any number of openings grouped generally in a line. Part 102 may include any industrial part now known or later developed. In one non-limiting example, part 102 may include a turbine rotor blade including various internal cooling circuits leading to an outer surface of the part (e.g., surface 110) through cooling channels. Cooling channels may be provided to cool internal structures in which they are present and / or to form a cooling film on surface 110 of part 102. Although not required in all cases, as Figure 1 In the example shown, the opening 106 may be positioned in a surface 110 of the part in a seat 112 extending from another surface 114 of the part.

[0045] The openings 106 may have any cross-sectional shape at the surface 110, such as circular, oval, polygonal (square, rectangular, trapezoidal, etc.), diffuser shape, etc., and may extend into the part 102 in any direction relative to the surface 110. A plurality of openings 106 are positioned across a distance (e.g., in a line) in the surface 110 of the part 102. The plurality of openings 106 may be positioned across the surface 110 in a spaced manner (e.g., equidistant or unequally spaced). Figure 1 Four groups of openings 106 are shown, each group having an associated mask 100. Any number of masks 100 may be used, such as less than four or more than four.

[0046] Figure 2 According to some embodiments of the present disclosure, Figure 1 1. The mask 100 includes an attachment tie 120 configured to be integrally coupled to the part 102 in a cantilevered manner between selected openings 106, i.e., it is a protruding member that is coupled to the part 102 at only one end thereof. The attachment tie 120 is the only connection to the part 102. As will be described, the attachment tie 120 couples the mask 100 to the part 102 in a manner that allows the mask 100 to be easily removed from the part 102. It should be noted that due to limitations of certain additive manufacturing techniques, the mask 100 and the part 102 may not necessarily be formed in the same orientation as shown.

[0047] The mask 100 also includes: a first cover member 130, the first cover member including a first proximal end 132 integrally coupled to the attachment tether 120 and a first distal end 134 extending at least partially over a first portion of the plurality of openings 106; and a second cover member 140, the second cover member including a second proximal end 142 integrally coupled to the attachment tether 120 and a second distal end 144 extending at least partially over a second portion of the plurality of openings 106. The first cover member 130 and the second cover member 140 extend at least partially over the plurality of openings 106 along the entire distance the openings extend, respectively. That is, all openings 106 are at least partially covered by the respective cover members 130, 140. "At least partially covered" means that some exposure of the openings 106 is allowed. For example, the first distal end 134 of the first cover member 130 is separated from the part 102 by a first spacing D1, and the second distal end 144 of the second cover member 140 is separated from the part 102 by a second spacing D2. Thus, some spacing D1 , D2 of the exposure opening 106 is provided by the cover members 130 , 140 .

[0048] The spacings D1 and D2 provide many advantages. In certain embodiments, such as Figure 2 As shown, the first spacing D1 and the second spacing D2 have dimensions configured to prevent hammering material 146 (e.g., metal shot, ice, pellets, sand, etc.) from passing therethrough. In this case, a diameter D3 of the hammering material 146 may be determined, and the dimensions of the spacings D1 and D2 may be designed to be sufficiently smaller than the diameter D3 to prevent the hammering material 146 from entering the spacings D1 and D2. In this manner, the cover members 130 and 140 may prevent damage to the opening 106 that may otherwise occur due to the impact of the hammering material 146. In certain embodiments, as Figure 3As shown, the first spacing D1 and the second spacing D2 have dimensions configured to prevent the coating 148 applied on the respective cover members 130, 140 from bridging from the respective cover members 130, 140 to the part 102. That is, a gap 149 exists in the coating 148. The spacings D1, D2 may be dimensioned based on factors such as the coating 148 material, coating format, expected thickness, and the like. As shown, although the coating 148 coats the part 102 and the mask 100, it fails to enter the spacings D1, D2, and thus does not coat or fill the opening 106. In addition, the coating 148 cannot connect across the spacings D1, D2, leaving the gap 149. In this way, when the mask 100 is removed, the coating 148 does not need to be broken to remove the mask, which may cause the coating 148 to break where it extends on the part 102. That is, there is no force applied to the coating 148 on the part 102, and therefore there is no possibility of the coating 148 on the part 102 breaking. While the size of the spacings D1, D2 may vary depending on the material 146 and / or coating 148 being hammered, in one non-limiting example, the first spacing D1 and the second spacing D2 may each be between 0.88 millimeters (mm) and 1.4 mm (0.035 inches to 0.055 inches). This size range will, for example, prevent a coating 148 having a thickness between 1.40 mm and 1.52 mm from bridging from the cover members 130, 140 to the part 102, and will prevent a 1.5 mm metal shot from being lodged in the spacings D1, D2 and striking the opening 106. Other sizes are possible.

[0049] like Figure 4 As shown, in some embodiments, a space filling material 150 may be positioned between at least one of the first cover member 130 and the second cover member 140 and the surface 110. The space filling material 150 may at least partially fill the space below the cover members 130, 140 and the spacings D1, D2. The space filling material 150 may include any material that can fill the space without unnecessarily overfilling the opening 106, and should be easy to remove. The space filling material 150 may include, but is not limited to, filaments that include a water-soluble polymer or other eutectic salt.

[0050] The mask 100 may also include a separation member 152 extending from the adjacent first cover member 130 and the second cover member 140. The separation member 152 may include any structure that can be engaged and manipulated to remove the mask 100 from the part 102 by breaking the attachment tie 120. The separation member 152 may include, for example, a square end that can be grasped by a tool (not shown) (e.g., channel lock pliers, adjustable wrench, etc.). In addition or alternatively, as Figure 7As shown, the separation member 152 may include a tool receiving feature 154 therein that is configured to receive a tool (not shown), such as, but not limited to, a pry bar, a screwdriver, a channel lock pliers, an adjustable wrench. The tool receiving feature 154 may have any shape and / or size to prevent the coating 148 ( Figure 3 ) fill it. In any case, the separation member 152 can be manipulated using a tool or manually to apply a force that breaks the attachment ties 120, thereby allowing the mask 100 to be removed. The separation member 152 can have any desired vertical height from the cover members 130, 140.

[0051] Further with respect to the attachment strap 120, as Figure 2 and Figure 3 As shown, the attachment tie 120 has a minimum width W that allows it to be easily separated from the part 102, and thus the mask 100, from the part. Figure 2 An attachment strap 120 is shown meeting the part 102 at a substantially perpendicular angle. Figure 2 In the embodiment of the present invention, the width W is generally uniform; however, this is not necessary in all cases, as it may be advantageous to tapered or narrow the attachment strap 120 to facilitate breaking. For example, Figure 3 An attachment tie 120 is shown having a lower portion 126 integrally coupled to the part 102 and having a first (smallest) width W1, and an upper portion 128 above the lower portion 126 and having a second width W2 that is wider than the first width W1. The smaller width W1 makes it easier to break the attachment tie 120 and leaves less residual portion on the part 102 that needs to be removed by machining. Figure 5 and Figure 6 An enlarged cross-sectional view of an attachment strap 120 having a varying width is shown according to other embodiments. Figure 5 and Figure 6 The cover members 130, 140 are shown to have their lower surfaces 156 shaped in any desired manner to produce a desired minimum width W of the attachment strap 120. In one non-limiting example, the attachment strap 120 can have a minimum width W in the range of 0.01 millimeters (mm) to 0.50 mm (0.01 inches to 0.02 inches). The minimum width W can vary depending on a number of factors, including but not limited to: part and mask materials, the size of the part 102, the size of the opening 106, the force required for removal, the intended tool to be used, the intended overall width Wc ( Figure 2 ) etc. Incidentally, in one non-limiting example, the total width Wc of the cover members 130 , 140 may be 3.81 mm to 4.32 mm (0.15 inch to 0.17 inch).

[0052] The attachment strap 120 may also be provided in a variety of configurations. Although shown as being generally perpendicular to the part 102, some non-perpendicular angles may be provided. In certain embodiments, such as Figure 1 As shown, the attachment strap 120 may extend over the entire length of the mask 100, which includes the single length cover members 130, 140. Alternatively, as shown Figure 7 As shown in various forms in FIG. 1 , the attachment ties 120 may be integrally coupled to the part 102 at spaced connection points along the distance covered by the cover members 130, 140. Any configuration of spaced attachment ties 120 may be employed. Figure 7 In a non-limiting example of: mask 100A has attachment ties 120 spaced approximately randomly at varying lengths; mask 100B also has attachment ties 120 spaced approximately randomly at varying lengths but spaced differently than mask 100A; mask 100C has attachment ties 120 equally spaced at uniform lengths except for end attachment ties 120E; and mask 100D has pairs of attachment ties 120 equally spaced at uniform lengths. In some embodiments, the attachment ties 120 are integrally coupled to part 102 along between 25% and 60% of the distance covered by cover members 130, 140. In another embodiment, the attachment ties 120 are integrally coupled to part 102 along between 25% and 35% of the distance covered by cover members 130, 140. Any desired attachment ties 120 spacing and length may be utilized to obtain a desired separation action (e.g., desired force, tool, etc.) and desired attachment ties 120 remaining on the part 120 after removal of the mask 100. Any remaining portions of the attachment ties 120 may be removed by machining (e.g., grinding).

[0053] See also Figure 8 and Fig. 9 In other embodiments, the first cover member 130 and the second cover member 140 and the separator member 152 may be segmented into a plurality of cover member and separator member segments 156 along the distance covered by the cover members 130 and 140. Here, the gap 158 ( Fig. 9 ) may be formed in the cover members 130, 140 and the separation member 152 along the length of the mask 100. Fig. 9 As shown, along Figure 8 9, the segments 156 may be connected at the lower ends of adjacent cover members 130, 140 to maintain support for the mask 100. Each of the plurality of cover member and separation member segments 156 may be individually separated from the part 102 by breaking a corresponding portion of the attachment ties 120. Segmentation allows for easier and selective removal of segments of the mask 100.

[0054] return Figure 2, the cover members 130, 140 have been shown as having a convex outer surface 164 facing away from the part 102 and a concave inner (lower) surface 156 facing the part 102. In this case, the cover members 130, 140 with the separation member 152 may have a mushroom-shaped cross-section. Figures 1 to 9 As shown, in these embodiments, the mask 100 has a somewhat umbrella-shaped cross-section. However, the cover members 130, 140 may have any desired shape to protect the opening 106 in a manner that can be additively manufactured with the part 102 as described herein. Figures 10 to 12 Cross-sectional views of several non-exhaustive examples of alternative shapes are shown. Fig.10 shows a closer fir-tree shaped mask, Fig.11 A more droopy umbrella or mushroom-shaped mask is shown, and Fig.12 A mask more like a cross is shown. Other shapes may also be possible and are considered to be within the scope of the present disclosure. The outer surface of mask 100 (e.g., surface 164 ( Figure 2 )) or the outer surface of the separation member 152 may be configured to be different from the coating 148 ( Figure 3 ) coupling, for example, with a rougher surface for better retention. Although the figures show cover members 130, 140 with identically shaped cover members on each side of the attachment strap 120 (i.e., as symmetrical), the differently shaped cover members shown herein may be used in an asymmetrical manner, for example, Figure 2 The cover member 130 and Fig.12 Any combination of the different shapes of cover members 130, 140 shown herein may be used in an asymmetrical manner.

[0055] The mask 100 may be made of the same material as the part 102. Thus, the material may depend on the application of the part. In one embodiment, the mask 100 and the part 102 may be made of a metal, which may include a pure metal or an alloy. For example, in the case where the part 102 is a turbine blade, the metal may include almost any non-reactive metal powder, i.e., a non-explosive or non-conductive powder, such as, but not limited to: cobalt-chromium-molybdenum (CoCrMo) alloy, stainless steel, austenitic nickel-chromium-based alloys such as nickel-chromium-molybdenum-niobium alloy (NiCrMoNb) (e.g., Inconel 625 or Inconel 718), nickel-chromium-iron-molybdenum alloy (NiCrFeMo) (e.g., available from Haynes International, Inc.) X) or nickel-chromium-cobalt-molybdenum alloy (NiCrCoMo) (e.g., Haynes 282 available from Haynes International, Inc.), etc. In another example, the metal may include almost any metal, such as, but not limited to: tool steel (e.g., H13), titanium alloy (e.g., Ti6Al4V), stainless steel (e.g., 316L), cobalt-chromium alloy (e.g., CoCrMo), and aluminum alloy (e.g., AlSi 10 Mg). Alternatively, part 102 and mask 100 may be made of, for example, plastic or ceramic. As noted, mask 100 and part 102 may be made by additive manufacturing (e.g., DMLM, SLM, 3D printing, etc.) techniques that will vary depending on the material. In any case, part 102, attachment ties 120, first and second cover members 130, 140, and separation member 152 will include multiple integral material layers resulting from additive manufacturing.

[0056] See also Figures 13 to 18 , shows a mask 200 for additively manufacturing a part 102 according to another embodiment of the present disclosure. The mask 200 and the part 102 can be formed using any suitable additive manufacturing technology for the part material, and can together form an AM structure 203 (only Fig.14 ). In this embodiment, the part 102 may include a (single) plurality of openings 204 in its surface 110. That is, while the mask 200 may cover a plurality of openings, in this embodiment, only a set of openings 204 in a single row is provided. The part 102 may include any industrial part now known or later developed. In one non-limiting example, the part 102 may include a turbine rotor blade including various internal cooling circuits leading to an outer surface of the part (e.g., surface 110) via cooling channels. The cooling channels may be provided to cool the internal structures in which they are present, and / or to form a cooling film on the surface 110 of the part 102. Although not required in all cases, as Fig.13 In the example shown, the openings 204 may be positioned in a base 112 in a surface 110 of a part extending from another surface 114 of the part. The openings 204 may have any cross-sectional shape at the surface 110, such as circular, oval, polygonal (square, rectangular, trapezoidal, etc.), diffuser shape, etc., and may extend into the part 102 in any direction relative to the surface 110. A plurality of openings 204 may be positioned in the surface 110 of the part 102 across a distance (e.g., approximately in a line). The openings 204 may be positioned across the surface 110 in a spaced manner (e.g., equidistant or unequally spaced). Although in Fig.13 Two masks 200 are shown in FIG. 1 , but any number of masks 200 may be employed, for example, less than two or more than two.

[0057] Fig.14 and Fig.15 An enlarged cross-sectional view of a mask 200 is shown according to certain embodiments of the present disclosure. Fig.14 is along Fig.13 The line 15-15 in FIG. 1 is taken, and Fig.15 is along Fig.13 16-16 in FIG. 16. The mask 200 includes an attachment tie 220 configured to be integrally coupled to the part 102 adjacent the plurality of openings 204 in a cantilevered manner, i.e., it is a protruding member that is coupled to the part 102 at only one end thereof. The attachment tie 220 is the only full-time connection to the part 102. As will be described, the attachment tie 220 couples the mask 200 to the part 102 in a manner that allows the mask 200 to be easily removed from the part 202.

[0058] The mask 200 also includes a cover member 230 including a proximal end 232 integrally coupled to the attachment tether 220 and a distal end 234 extending at least partially over the plurality of openings 204. The distal end 234 may have any cross-sectional shape, for example, a generally triangular shape as shown. The cover member 230 extends at least partially over the plurality of openings 204 along the entire distance that the plurality of openings extend. That is, all of the openings 204 are at least partially covered by the cover member 230. The cover member 230 and the attachment tether 220 provide the mask 200 with a slightly L-shaped or 7-shaped cross-section.

[0059] As previously mentioned, "at least partially covered" indicates that some exposure of the opening 204 is allowed. Fig.14 As shown, the distal end 234 of the cover member 230 is separated from the part 102 by a spacing D4. Therefore, some spacing D4 of the exposed opening 204 is provided by the cover member 230. The spacing D4 (similar to the spacings D1 and D2 in the previous figures) provides a number of advantages. In certain embodiments, such as Fig.14 As shown, the spacing D4 has a size configured to prevent the hammering material 246 (e.g., metal shot, ice, pellets, sand, etc.) from passing therethrough. In this case, the diameter D5 of the hammering material 246 can be determined, and the size of the spacing D4 is designed to be sufficiently smaller than the diameter D5 to prevent the hammering material 246 from entering the spacing D4. In this way, the cover member 230 can prevent damage to the opening 204 that may otherwise occur due to the impact of the hammering material 246. In some embodiments, such as Fig.16As shown, the spacing D4 has a dimension configured to prevent the coating 248 applied on the cover member 230 from bridging from the cover member 230 to the part 102 at the distal end 234. The spacing D4 can be designed based on factors such as the coating 248 material, the coating format, the expected thickness, etc. As shown, although the coating 248 coats the part 102 and the mask 200, the coating does not enter the spacing D4, and therefore does not coat or fill the opening 204. The cover member 230 prevents the coating 248 from reaching the opening 204, leaving a gap 249. In addition, the coating 248 cannot connect across the spacing D4. In this way, when the mask 200 is removed, the coating 248 on the part 102 is not affected. There is no force applied to the coating 248 on the part 102, so there is no possibility of cracking the coating 248 on the part 102. Although the size of the spacing D4 may vary depending on the material 246 and / or coating 248 being hammered, in one non-limiting example, the spacing D4 may be between 0.88 millimeters (mm) and 1.4 mm (0.035 inches to 0.055 inches). This size range will prevent, for example, a coating 248 having a thickness between 1.40 mm and 1.52 mm from bridging from the cover member 230 to the part 102, and will prevent a 1.5 mm metal shot from staying in the spacing D4 and striking the opening 204. Other sizes are also possible.

[0060] The mask 200 may also include a separation member 252 extending from the cover member 230. The separation member 252 may include any structure that can be engaged and manipulated to remove the mask 200 from the part 102 by breaking the attachment ties. The separation member 252 may include, for example, a square end that can be grasped by a tool (not shown) (e.g., channel lock pliers, an adjustable wrench, etc.). In addition or alternatively, as Fig.13 As shown, the separation member 252 may include a tool receiving feature 254 therein, which is configured to receive a tool 268 (only Fig.15 ), such as, but not limited to, a pry bar, a screwdriver, a channel lock pliers, an adjustable wrench. Tool receiving feature 254 may have any size and / or shape that prevents coating 248 from filling it. In certain embodiments, such as Fig.14 Best shown, with Figures 1 to 12 In contrast to the cover members 130 and 140 in FIG. 1 , the cover member 230 may further include a space D6 (only Fig.14 ) of the force receiving surface 270. The force F (upward or downward) applied by the tool 268 positioned in the tool receiving feature 254 of the separation member 252 applies a lever force LF (clockwise or counterclockwise, respectively) to separate the attachment ties 220 from the part 102. In any case, the separation member 252 is manipulable to apply a force that breaks the attachment ties 220, either by a tool or manually, thereby allowing the mask 200 to be removed. The separation member 252 can have any desired vertical height from the cover member 230. For example, Fig.14 As shown, the separation member 252 can be positioned above the proximal end 232 of the cover member 230, or as shown, for example Fig.15 As shown, the separation member can be spaced between the proximal end 232 and the distal end 234 of the cover member 230, such as closer to the proximal end 232 to allow for more direct application of force to the attachment tether 220 during removal.

[0061] like Fig.13 as well as Fig.14 As shown in the cross-section of FIG. 2 , the mask 200 may optionally include at least one pair of pivot limiting members 274 extending from the distal end 234 of the cover member 230. Fig.13 , three pivot limiting members 274 are shown extending from the distal end 234 of each mask 200; however, any number, including more than three, may be used. Fig.14 As shown, in the first relaxed position of the cover member 230, each pivot limiting member 274 extends from the distal end 234 to a distance D7 from the part 102 (i.e., the surface 110). That is, each pivot limiting member 274 can have its own distal end 276 spaced apart from the part 110 by a distance D7. The distance D7 between the pivot limiting member 274 and the part 102 is less than the distance D4 between the distal end 234 of the cover member 230 and the part 102. In one non-limiting example, the distance D7 can be approximately 0.1 millimeters (mm) (0.004 inches). Fig.17 As shown, due to the cantilever nature of the mask 200, in certain situations such as coating and / or hammering processes, the mask 200 can be pivoted. In this setting, the pivot limiting member 274 can be in the second pivot position (where the bending moment force BM ( Fig.17 ) is applied to at least one of the attachment strap 220, the cover member 230, and the separation member 252) to move closer to and / or contact the part 102. Thus, the pivot limiting member 274 resists any temporary force applied during processing that is not intended to remove the mask 200. Once the bending moment BM force is removed, the mask 200 can return to, for example, Fig.14 The relaxed position is shown, and the distance D7 is returned between the pivot limiting member 274 and the part 102. Fig.16 The mask 200 is shown without the pivot limiting member.

[0062] Further with respect to the attachment strap 220, as Fig.14 As shown, the attachment tie 220 has a minimum width W3 that allows it to be easily separated from the part 102, and therefore allows the mask 200 to be separated from the part. Fig.14 The attachment tether 220 is shown meeting the part 102 at a substantially perpendicular angle; other angles may be possible. The attachment tether 220 may be tapered or narrowed to facilitate breaking. For example, in Fig.14 , the attachment strap 220 may have a lower portion 226 integrally coupled to the part 102 having a first (smallest) width W3, and an upper portion 228 above the lower portion 226 having a second width W4 wider than the first width W3. The attachment strap 220 may also have a Figure 5 and Figure 6 The width of the change, or Figure 2 In one non-limiting example, the attachment strap 220 may have a minimum width W3 in the range of 0.01 millimeters (mm) to 0.50 mm (0.01 inches to 0.02 inches). The minimum width W3 may vary depending on a number of factors, including, but not limited to: the part and mask material, the size of the part 102, the size of the opening 204, the force required for removal, the intended tool to be used, the intended width Wcm (cm) of the cover member 230, and the desired width Wcm (cm) of the cover member 230. Fig.14 ) etc. Incidentally, in one non-limiting example, the cover member width Wcm of the cover member 230 may be 5.33 mm to 6.35 mm (0.21 inch to 0.25 inch).

[0063] The attachment strap 220 may also be in a variety of structural forms. In certain embodiments, such as Fig.13 As shown, the attachment strap 120 may extend over the entire length of the mask 200, which includes a single length of cover member 230. Alternatively, similar to Figure 7 As shown in various forms in FIG. 1 , the attachment ties 220 may be integrally coupled to the part 102 at spaced connection points along the distance covered by the cover member 230. Any configuration of spaced attachment ties 220 may be employed. Fig.18 In a non-limiting example of: mask 200A has attachment ties 220 spaced approximately randomly at varying lengths; mask 200B also has attachment ties 220 spaced approximately randomly at varying lengths but spaced differently than mask 200A; mask 200C has attachment ties 220 equally spaced at uniform lengths except for end attachment ties 220E; and mask 200D has pairs of attachment ties 220 equally spaced at uniform lengths. In some embodiments, the attachment ties 220 are integrally coupled to part 102 along between 25% and 60% of the distance covered by cover member 230. In another embodiment, the attachment ties 220 are integrally coupled to part 102 along between 25% and 35% of the distance covered by cover member 230. Any desired attachment ties 220 spacing and length may be utilized to obtain a desired separation action (e.g., desired force, tool, etc.) and desired attachment ties 220 remaining on the part 220 after removal of the mask 200. Any remaining portions of the attachment ties 220 may be removed by machining (e.g., grinding).

[0064] With further reference to the cover member 230, for example Fig.14 As shown, the cover member 230 may include a pair of square corners 280, 282. The square corners 280, 282 are located on opposite sides of the attachment ties 220. In this way, the mask 200 can be easily removed by breaking the attachment ties 220 when grasped by hand or by a tool such as pliers.

[0065] Figures 19 to 25 200 are cross-sectional views of various alternative embodiments similar to mask 200. In these embodiments, for example, Fig.19 As shown, the mask 300 includes an attachment strap 220 and a cover member 230. The proximal end 232 of the cover member 230 is coupled to the attachment strap 220. The cover member 230 and its distal end 234 extend above the opening 204, and the distal end 234 has a spacing D8 from the part 102 (i.e., the surface 110). The spacing D8 may be similar to the spacing D4 ( Fig.14 ). In each embodiment, an optional pivot limiting member 274 may extend from the distal end 234, but may not be shown for clarity.

[0066] Figures 19 to 21 Shown with mask 200 ( Figures 12 to 18 ) is a cross-sectional view of a similar mask 300 (including separation member 252 and various alternative structures). Fig.19 The mask 300 is shown having a distal end 234 having a generally polygonal (eg, rectangular) cross-sectional shape. Fig. 20 The mask 300 is shown having a distal end 234 including a flange 384 extending away from the attachment strap 220 . Fig.21 Shows something like Fig. 20 300, but includes a separation member 352 spaced between the proximal end 232 and the distal end 234 of the cover member 230, and includes a cutout 386 for receiving a tool (not shown).

[0067] Figure 22 to Figure 25 A cross-sectional view of the mask 300 is shown, wherein the separation member 352 ( Figures 19 to 21 ) has been omitted. Fig. 22 A mask 300 is shown in which a separation member 352 ( Figures 19 to 21 ) has been omitted and the attachment strap 220 is linear. Fig.23 Shows something like Fig. 22 However, the mask 300 includes a distal end 234 having a flange 384 extending away from the attachment strap 220 . Fig.24 and Fig.25A mask 300 is shown in which square corners 280, 282 ( Fig. 22 ) is omitted. Fig.24 In the embodiment, the cover member 230 is rounded and Fig.25 In FIG. 2 , the cover member 230 includes parallel sides 388, 390 for grasping by hand or by a tool (not shown) such as pliers. Fig.25 , the attachment strap 220 has a lower portion 326 integrally coupled to the part 102 having a first (minimum) width W5, and an upper portion 328 above the lower portion 326 and having a second width W6 wider than the first width W5. Fig.25 The distal end 234 in the embodiment has a tip 392 .

[0068] Figures 19 to 25 Any of the alternative features shown may be mixed and matched to form alternative embodiments within the scope of the present disclosure.

[0069] The masks 200, 300 may be made of the same material as the part 102. The masks 200, 300 and the part 102 may be made of any of the materials listed herein for the masks 100 and the part 102. The masks 200, 300 and the part 102 may be made by additive manufacturing (e.g., DMLM or SLM for metal parts, or 3D printing for ceramic parts). In this case, the part 102, the attachment ties 220, the cover member 230, and the separation member 252 (and any optional features described herein) will include multiple integral material layers.

[0070] Although embodiments of the present disclosure have been described as masks 100 , 200 , 300 being additively manufactured with part 102 , it will be readily appreciated that masks 100 , 200 , 300 may be formed separately by additive manufacturing or other techniques and coupled to part 102 , such as by welding.

[0071] Embodiments of the present disclosure provide masks for additively manufactured parts that provide protection for openings in the surface of the part during other processes, such as coating and hammering. The masks described herein can be additively manufactured with the part to eliminate the need for laborious manual masking of the openings, such as with tape or welded structures. The masks also better protect the openings from processes that can damage them, such as hammering, and eliminate the need for costly cleaning of the openings.

[0072] As used throughout the specification and claims, approximate language can be used to modify any quantitative representation that can be allowed to vary without causing a change in the basic function associated with it. Therefore, the values ​​modified by one or more terms (such as "about", "approximately" and "substantially") are not limited to the specified precise values. In at least some cases, approximate language can correspond to the precision of the instrument used to measure the value. Here and throughout the specification and claims, range limitations can be combined and / or interchangeable. Unless the context or language indicates otherwise, these ranges are identified and include all subranges contained therein. "Approximately" applied to a specific value of a range applies to both end values, and + / -10% of the value can be indicated unless otherwise dependent on the precision of the instrument for measuring the value.

[0073] The corresponding structures, materials, actions and equivalents of all means or steps plus function elements in the following claims are intended to include any structure, material or action for performing functions in conjunction with other claimed elements specifically claimed. A description of the present disclosure has been given for the purpose of illustration and description, but it is not intended to be exhaustive or to limit the present disclosure to the disclosed form. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and essence of the present disclosure. Embodiments have been selected and described in order to best explain the principles and practical applications of the present disclosure, and to enable other persons of ordinary skill in the art to understand the various embodiments of the present disclosure with various modifications suitable for the intended specific use.

Claims

1. A mask (100) for additively manufacturing a part (102), the part (102) comprising a plurality of openings (106, 204) in a surface (110) of the part, the mask (100) comprising: an attachment strap (120, 220) configured to be integrally coupled to the part (102) in a cantilevered manner adjacent to the plurality of openings (106, 204); and a cover member (130, 140, 230) comprising a proximal end (132, 142, 232) integrally coupled to the attachment strap (120, 220) and a distal end (134, 144, 234) extending at least partially over the plurality of openings (106, 204), the distal end (134, 144, 234) of the cover member (130, 140, 230) being separated from the part (102) by a first spacing, wherein the attachment strap (120, 220) is the only connection to the part (102), and The first spacing is sized to prevent a coating (148, 248) applied to the respective cover member (130, 140, 230) from bridging from the respective cover member (130, 140, 230) to the part (102) and to prevent hammer material (146, 246) from passing therethrough.

2. The mask (100) of claim 1, wherein the attachment strap (120, 220) has a minimum width in the range of 0.01 millimeters (mm) to 0.50 mm.

3. The mask (100) of claim 1, wherein the plurality of openings (106, 204) are positioned in the surface (110) of the part (102) across a distance, and wherein the cover member (130, 140, 230) extends at least partially over the plurality of openings (106, 204) along the entirety of the distance.

4. The mask (100) of claim 3, wherein the attachment ties (120, 220) are integrally coupled to the part (102) at spaced apart connection points along the distance.

5. The mask (100) of claim 4, wherein the attachment ties (120, 220) are integrally coupled to the part (102) along between 25% and 60% of the distance.

6. The mask (100) of claim 1, wherein the first pitch is between 0.88 millimeters (mm) and 1.4 mm (0.035 inches and 0.055 inches).

7. The mask (100) of claim 1, further comprising a separation member (152, 252, 352) extending from the cover member (130, 140, 230).

8. The mask (100) of claim 7, wherein the part (102), the attachment ties (120, 220), the cover member (130, 140, 230), and the separating member (152, 252, 352) comprise a plurality of integral material layers.

9. The mask (100) of claim 7, further comprising at least one pair of pivot limiting members (274) extending from the distal end (234) of the cover member (130, 140, 230), wherein in a first relaxed position of the cover member (130, 140, 230), each pivot limiting member (274) has a distal end (234) spaced apart from the part (102) by a second spacing less than the first spacing, and contacts the part (102) in a second position, wherein a bending moment force is applied to at least one of the attachment strap (120, 220), the cover member (130, 140, 230) and the separation member (152, 252, 352).

10. The mask (100) of claim 8, wherein the second pitch is approximately 0.1 millimeters (mm).

11. The mask (100) of claim 7, wherein the separating member (152, 252, 352) includes a tool (268) receiving feature therein, the tool receiving feature being configured to receive a tool (268), and the cover member (130, 140, 230) includes a force receiving surface (270) at a distance from the separating member (152, 252, 352), wherein a force applied by a tool (268) positioned in a tool (268) receiving feature of the separation member (152, 252, 352) applies a lever force to separate the attachment tie (120, 220) from the part (102).

12. The mask (100) of claim 1, wherein the cover member (130, 140, 230) includes a pair of square corners (280, 282), the square corners (280, 282) being located on opposite sides of the attachment strap (120, 220).

13. The mask (100) of claim 1, wherein the attachment strap (120, 220) comprises a lower portion (126, 226, 326) integrally coupled to the part (102) and having a first width, and an upper portion (128, 228, 328) located above the lower portion (126, 226, 326) and having a second width wider than the first width.

14. An additively manufactured (AM) structure comprising: A part (102) comprising a plurality of openings (106, 204) in a surface (110, 114, 156) thereof; A mask (100), comprising: an attachment strap (120, 220) configured to be integrally coupled to the part (102) in a cantilevered manner adjacent the first plurality of openings (106, 204); a cover member (130, 140, 230) comprising a proximal end (232) integrally coupled to the attachment strap (120, 220) and a distal end (234) extending at least partially over the plurality of openings (106, 204), the distal end (234) of the cover member (130, 140, 230) being separated from the part (102) by a first spacing; and a separation member (152, 252, 352) extending from the cover member (130, 140, 230), wherein the attachment strap (120, 220) is the only connection to the part (102), and wherein the part (102), the attachment straps (120, 220), the cover member (130, 140, 230) and the separating member (152, 252, 352) comprise a plurality of integral material layers.

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