Fuse Plug System

Abstract

The present invention is titled "Sacrificial Plug System". Aspects of embodiments of the present invention illustrate a sacrificial plug (100) system that includes: a component having a surface (85) and at least one cooling hole (108) in the surface (85); a sacrificial plug (100) integrally formed with the component and integrally formed in the at least one cooling hole (108), wherein the sacrificial plug (100) includes a top portion (110); a cap portion (120); and a bottom portion that is integrally formed with, joined to, and connected to the at least one cooling hole. The sacrificial plug (100) system further includes at least one connecting member (144) integrally formed with the bottom portion of the sacrificial plug (100) and integral with the inner wall (109) of each corresponding at least one cooling hole (108); when a force is applied to the top portion (110), each at least one connecting member (144) is capable of being severed from the corresponding inner wall (109), thus allowing the sacrificial plug (100) to be removed from the at least one corresponding cooling hole (108).

Description

BACKGROUND OF THE DISCLOSURE

[0001] The present disclosure generally relates to sacrificial plug systems and, more particularly, to sacrificial plug systems for protecting the configuration of cooling holes during post-formation processing of components having cooling holes. SUMMARY OF THE DISCLOSURE

[0002] A first aspect of an embodiment recites a sacrificial plug system that includes a component having a surface and at least one cooling hole in the surface; a sacrificial plug integrally formed with the component and integrally formed within the at least one cooling hole. The sacrificial plug includes a top portion; a cap portion; and a bottom portion integrally formed with, engaged with, and connected to the at least one cooling hole. The sacrificial plug system further includes at least one connecting member integrally formed with the bottom portion of the sacrificial plug and integral with the inner wall of each corresponding at least one cooling hole; when a force is applied to the top portion, each at least one connecting member is capable of being severed from the corresponding inner wall, thereby allowing the sacrificial plug to be removed from the at least one corresponding cooling hole.

[0003] Exemplary aspects of the present disclosure are designed to address the problems described herein and / or other problems not discussed. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] 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 in conjunction with the accompanying drawings depicting embodiments of the present disclosure, where:

[0005] Figure 1 A schematic perspective view of a blade according to an embodiment of the present disclosure is shown;

[0006] Figure 2 A schematic perspective view of a sacrificial plug within a cooling hole of a blade according to an embodiment of the present disclosure is shown;

[0007] Figure 3 A schematic perspective view of a sacrificial plug according to an embodiment of the present disclosure is shown;

[0008] Figure 4 A schematic close-up view of a sacrificial plug within a cooling hole of a blade according to an embodiment of the present disclosure is shown;

[0009] Figure 5 A schematic close-up view of a sacrificial plug within a cooling hole and a cooling channel of a blade according to an embodiment of the present disclosure is shown;

[0010] Figure 6 A schematic view of a sacrificial plug according to an embodiment of the present disclosure taken along line 6-6( Figure 5Schematic perspective view of a connecting member of a cooling hole joining portion where cooling holes are joined;

[0011] Figure 7 Shows the in-line 6-6 of a sacrificial plug according to an embodiment of the present disclosure ( Figure 5 ) Schematic perspective view of another connecting member of a cooling hole joining portion where cooling holes are joined;

[0012] Figure 8 Shows the in-line 6-6 of a sacrificial plug according to an embodiment of the present disclosure ( Figure 5 ) Schematic perspective view of yet another connecting member of a cooling hole joining portion where cooling holes are joined;

[0013] Figure 9 Shows the in-line 6-6 of a sacrificial plug according to an embodiment of the present disclosure ( Figure 5 ) Schematic perspective view of yet another embodiment of a connecting member of a cooling hole joining portion where cooling holes are joined;

[0014] Figure 10 Shows the in-line 6-6 of a sacrificial plug according to an embodiment of the present disclosure ( Figure 5 ) Schematic perspective view of yet another additional embodiment of a connecting member of a cooling hole joining portion where cooling holes are joined;

[0015] Figure 11 Shows the in-line 6-6 of a sacrificial plug according to an embodiment of the present disclosure ( Figure 5 ) Schematic perspective view of yet another embodiment of a connecting member of a cooling hole joining portion where cooling holes are joined;

[0016] Figure 12 Shows the in-line 6-6 of a sacrificial plug according to an embodiment of the present disclosure ( Figure 5 ) Schematic perspective view of another embodiment of a connecting member of a cooling hole joining portion where cooling holes are joined;

[0017] Figure 13 Shows the in-line 6-6 of a sacrificial plug according to an embodiment of the present disclosure ( Figure 5 ) Schematic perspective view of yet another embodiment of a connecting member of a cooling hole joining portion where cooling holes are joined;

[0018] Figure 14 Shows the in-line 6-6 of a sacrificial plug according to an embodiment of the present disclosure ( Figure 5 ) Schematic perspective view of another and additional embodiment of a connecting member of a cooling hole joining portion where cooling holes are joined;

[0019] Figure 15 Schematic perspective view of a sacrificial plug having a mechanism for mechanically applying a rotational force according to an embodiment of the present disclosure;

[0020] Figure 16 shows a schematic perspective view of a mechanism for mechanically applying a rotational force to a sacrificial plug according to an embodiment of the present disclosure; and

[0021] Figure 17 shows a schematic perspective view of a sacrificial plug having an additional mechanism for mechanically applying a rotational force according to an embodiment of the present disclosure.

[0022] It should be noted that the drawings of the present disclosure are not drawn to scale. The drawings are intended to depict only typical aspects of the present disclosure and should not therefore be regarded as limiting the scope of the present disclosure. In the drawings, like numerals represent like elements between the drawings. Detailed Description

[0023] Initially, in order to clearly describe the current technology, it will become necessary to select certain terms when referring to and describing a sacrificial plug system for protecting cooling holes, particularly during any post-formation processing, in a component having cooling holes. To the extent possible, common industry terms will be used and adopted in a manner consistent with their accepted meanings. 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. Those of ordinary skill in the art will appreciate that several different or overlapping terms may typically be used to refer to a particular component. An object that may be described herein as a single part may include multiple components and be referred to in another context as being composed of multiple components. Alternatively, an object that may be described herein as including multiple components may elsewhere be referred to as a single part.

[0024] In addition, several descriptive terms may be regularly used herein, and it should prove helpful to define these terms at the beginning of this section. Unless otherwise indicated, these terms and their definitions are as follows. As used herein, "downstream" and "upstream" are terms indicating directions relative to the direction of fluid flow, such as the working fluid through a turbine engine, or for example, the air flow through a burner or the coolant through one of the component systems of a turbine. The term "downstream" corresponds to the direction of fluid flow, and the term "upstream" refers to the direction opposite to the flow. In the absence of any additional particularity, the terms "front" and "rear" refer to directions, where "front" refers to the front end or compressor end of the engine, and "rear" refers to the rear end or turbine end of the engine.

[0025] Parts disposed at different radial positions relative to a central axis are typically required to be described. The term "radial" refers to movement or position perpendicular to the axis. For example, if a first component is closer to the axis than a second component, it will be described herein that the first component is "radially inward" of or "inside" the second component. On the other hand, if a first component resides farther from the axis than a second component, it may be described herein that the first component is "radially outward" or "outside" of the second component. The term "axial" refers to movement or position parallel to the axis. Finally, the term "circumferential" refers to movement or position around the axis. It should be understood that such terms can be applied relative to the central axis of the turbine.

[0026] In addition, several descriptive terms may be regularly used herein as described below. The terms "first", "second", and "third" may be used interchangeably to distinguish one component from another and are not intended to denote the position or importance of individual components.

[0027] The terms used herein are for the purpose of describing particular embodiments only and are not intended to limit 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 dictates otherwise. It will be further understood that when used in the specification, the terms "comprises" and / or "comprising" 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" means that the subsequent described event or circumstance may or may not occur, and the description includes instances where the event occurs and instances where the event does not occur.

[0028] In cases where an element or layer is referred to as "on", "engaged to", "connected to", or "coupled to" another element or layer, it can be directly on, engaged to, connected to, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as "directly on another element or layer", "directly engaged to another element or layer", "directly connected to another element or layer", or "directly coupled to another element or layer", intervening elements or layers may not be present. Other words used to describe the relationship 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.

[0029] As noted above, the present disclosure relates to a sacrificial plug system. Specifically, the present disclosure relates to a sacrificial plug system for a component having cooling holes, which protects the configuration of the cooling holes to avoid subsequent post-forming processes (e.g., preventing coating sand plugging or clogging of the cooling holes in the component).

[0030] To facilitate understanding of embodiments of the present disclosure, the rate of change and improvement in the power generation, aviation, and other fields has been accompanied by extensive research into the components used in these fields. Conventional manufacturing of metal, plastic, or ceramic composite components generally involves first milling or cutting away regions from a material plate and then processing and modifying the cut-off material to produce a part, which can be simulated using a computer model, for example, in drafting software. Manufactured components that can be formed from metal can include, for example, airfoil components for installation in turbines (such as aircraft engines or power generation systems).

[0031] Additive manufacturing (AM) includes a variety of processes for producing components by the successive layering of materials rather than the removal of materials. Thus, additive manufacturing can form complex geometries without the use of any kind of tooling, dies, or fixtures and with little or no waste of material. Instead of machining a component from a solid material blank, where much of the material is cut away and discarded, the only material used in additive manufacturing is the material required to form the component.

[0032] Additive manufacturing techniques generally involve taking a three-dimensional computer-aided design (CAD) file of the component to be formed, electronically slicing the component into layers (e.g., 18 microns to 102 microns thick), and creating a file with two-dimensional images (including vectors, images, or coordinates) of each layer. The file can then be loaded into a preparation software system that interprets the file such that the component can be built by different types of additive manufacturing systems. In the 3D printing, rapid prototyping (RP), and direct digital manufacturing (DDM) forms of additive manufacturing, the material layers are selectively dispensed, sintered, formed, deposited, etc. to form the component.

[0033] 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 component. More specifically, after being evenly distributed over a metal powder bed using an applicator, a layer of fine metal powder is sequentially melted. Each applicator includes an applicator element in the form of a die lip, brush, squeegee, or roller made of metal, plastic, ceramic, carbon fiber, or rubber, which spreads the metal powder evenly above the build platform. The metal powder bed can be moved in a vertical axis. The process takes place in a processing chamber with an accurately 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) in order to fully weld (melt) the metal powder to form solid metal. The melting beam is moved in the X-Y direction using scanning mirrors, and its intensity is sufficient to fully weld (melt) the metal powder to form solid metal. The metal powder bed can be lowered for each subsequent two-dimensional layer, and the process is repeated until the component is fully formed.

[0034] In addition, turbine components such as, but not limited to, airfoils, turbine blades, and guide vanes (nozzles) of gas turbine engines typically require complex cooling schemes where cooling air flows through the airfoil and then exits through carefully constructed cooling holes. For example, but for illustrative purposes only of the present disclosure, the cooling holes of a component can include cooling holes at the trailing edge of the airfoil. Turbine blade performance is related to the ability to provide uniform cooling of the airfoil surface. Therefore, control of the cooling hole size and shape is important in turbine airfoil design because the size and shape of the openings can determine the flow rate exiting a given hole, the distribution of holes across the airfoil, and the overall flow distribution within the cooling circuit. Other factors (such as recirculation margins) are also affected by changes in the opening size. Therefore, protecting the intended configuration of the cooling holes (including after post-component processing such as coating) will enable the cooling holes to achieve their intended function.

[0035] In addition to conventional drilling techniques such as laser machining and electrical discharge machining (EDM), complex advanced casting practices can also be used to produce airfoils with correctly sized cooling hole openings so that the opening size can be controlled repeatably. Once cast, subsequent airfoil manufacturing operations must be performed such that the cooling hole openings cast to a certain size are not processed by operations that will change the size of some or all of the cooling hole openings.

[0036] However, as the air passage standards of some turbines become increasingly complex, additive manufacturing processes (discussed above) have been adopted to form turbine components. The additive manufacturing process enables the formation of intricate, serpentine, and complex cooling channels and cooling hole openings in a manner that is easier, more efficient, and less costly than some traditional forming methods.

[0037] Regardless of how they are formed, as the operating environments of turbine components become increasingly demanding, protective coatings are typically applied to these turbine components during their manufacture and possibly also during maintenance. Modern, high-efficiency combustion turbines have ignition temperatures in excess of approximately 1,000 degrees Celsius, and as the demand for even more efficient engines continues, even higher ignition temperatures are expected. Many components that form the "hot gas path" burner and turbine sections are directly exposed to erosive hot combustion gases, such components as burner liners, transition ducts between the combustion and turbine sections, and turbine stationary vanes and rotating blades and the surrounding annulus sections. In addition to thermal stresses, these components and other components are also exposed to mechanical stresses and loads, which cause further wear on the components.

[0038] By coating components with protective coatings, many iron, cobalt, and nickel-based superalloy materials that are traditionally used to fabricate most combustion turbine components used in the hot gas path sections of combustion turbine engines are isolated from the hot gas flow in order to withstand long-term operation in this erosive, high-temperature combustion environment. Protective coatings include, but are not limited to, thermal barrier coatings (TBCs), bond coats, environmental barrier coatings (EBCs), combinations thereof, and other coatings now known or developed hereinafter. Protective coatings can be prepared by a multi-step process that includes coating the surface in need of a protective coating, for example, with a bond coat and subsequent additional coatings, depending on the intended use of the turbine component and the environment associated with that use.

[0039] TBCs are highly advanced material systems. These coatings are used as protective coatings to isolate components from large and long-term heat loads by utilizing insulating materials that can maintain a measurable temperature difference between the load-bearing alloy and the coating surface. Doing so allows these coatings to have higher operating temperatures while limiting the thermal exposure of the structural components, thereby extending component life by reducing oxidation and thermal fatigue.

[0040] TBCs are applied to turbine components by various methods. Spraying is commonly used to apply TBCs (or other coatings). Exemplary spray coating processes include, but are not limited to, plasma spraying in both air and vacuum, cold spraying, electrostatic spraying, electron beam physical vapor deposition, chemical vapor deposition, thermal spraying, high velocity oxygen-fuel coating, physical vapor deposition, combinations thereof, and other spraying techniques now known or developed hereinafter.

[0041] One aspect of a spray-coated component such as blade 10 according to an embodiment of the present disclosure pertains to the control or lack of control of the spray around the cooling holes 108 of the blade 10. Control means that the spray avoids sand plugging around the cooling holes 108 and subsequent rework requirements. Of course, any coating or other post-treatment / forming component process must not prevent the airfoil from meeting the operating requirements, including the cooling air flow requirements through the airfoil and the discharge through the cooling holes at the airfoil surface.

[0042] One post-treatment / forming coating consequence to be avoided is "sand plugging", which is the consequence when the subsequent post-forming coating process covers and changes the spacing between the cooling holes and / or closes the cooling holes. Sand plugging can be caused by excessive post-forming coating process material between and possibly in the cooling holes, thereby reducing the cooling hole opening size. If there is excessive post-forming coating process material, one or more of the cooling holes may actually be completely covered or sand plugged. Of course, in order to maintain the intended function of the cooling holes, sand plugging should be kept under control and minimized as much as possible.

[0043] As will be discussed in detail below, sand plugging is due to the "shadowing" effect of the spray (e.g., but not intended to limit the embodiment, TBC) when deposited on the component (here the blade 10). The shadowing effect can be best visualized by placing an object in front of a light source and observing the shadow cast by the object. The light rays surrounding the object represent the deposited spray, and the shadow cast by the object represents the voids in the deposited spray. However, in the natural process called shadowing, holes (such as cooling holes 108) that are too small or too close to each other can cause sand plugging because the coating can build up on its own and "sand plug" the holes. At these holes, the coating may block the holes. Additionally, the coating material may not adhere or bond strictly to the component or substrate. Therefore, rework will be required to clear the "sand plugged" holes 108 (when the coating builds up over the target area and the holes) or to re-coat at certain locations where the coating does not adhere or bond strictly to the component or substrate, which may prolong the processing time, require additional resources, and may result in loss of opportunity cost, etc.

[0044] In view of the above, the present disclosure describes systems, methods, and structures for preventing coating deposition into the cooling holes. In addition to reducing or almost eliminating the change in the size and shape of the cooling holes due to the entry of coating material through sand plugging, the present disclosure can achieve additional benefits in preventing coating in the cooling holes in a manner that reduces the amount of coating material consumed in the coating operation.

[0045] As Figure 1As shown, the turbine blade 10 includes an airfoil 80. The airfoil 80 includes a leading edge 81 and a trailing edge 82, a pressure sidewall 83 and a suction sidewall 94. The pressure sidewall 83 is connected to the suction sidewall 84 at the leading edge 81 and the trailing edge 82. The airfoil 80 also includes a tip 40 and a root 30 connected at a fillet 41 by the pressure sidewall 83, the suction sidewall 84, the leading edge 81, and the trailing edge 82. The root 30 includes a platform 32 and a dovetail 31.

[0046] The turbine blade 10 includes at least one cooling cavity 88 between the pressure sidewall 83 and the suction sidewall 84 (for purposes of illustration and clarity, Figure 1 and Figure 5 only one cavity 88 is shown in ). Each cooling cavity 88 is in fluid communication with one or more cooling holes 108, 109. The plurality of cooling holes 108 include, but are not limited to, leading edge and trailing edge cooling holes 108 that extend along and through the leading edge 81 and the trailing edge 82. The trailing edge cooling holes 108 are substantially circular, however, it is noted that it is possible that their position on the curved trailing edge 82 is in a slightly elliptical or elongated configuration relative to those trailing edge cooling holes 108. As discussed herein, reference may be made to circular cooling holes, or cooling holes of other configurations are aspects of the present disclosure. Unless explicitly discussed, the use of a single “cooling hole” or multiple “cooling holes” is not intended to limit the embodiments of the present disclosure. The remainder of the specification will refer to the cooling holes 108.

[0047] The other cooling holes 109 are substantially circular and extend through the airfoil 80 at a body location such that desired cooling of the blade 10 of the internal cooling passage from at least one cooling cavity 88 can be achieved. The other cooling holes 109 may be provided at the tip 40 of the airfoil 80, and along portions of the body of the airfoil 80.

[0048] According to an aspect of the present disclosure, a sacrificial plug system including a sacrificial plug 100 or a cap (hereinafter referred to as “sacrificial plug”) may be integrally printed with a component of the blade 10 having additive manufacturing (i.e., printing) in one or more cooling holes 108. By integrally additive manufacturing the component and the sacrificial plug 100 and simultaneously additive manufacturing them as an integral and one-piece structure with the blade 10 and in the holes 108 of the component, alignment and proper positioning of the sacrificial plug 100 in the cooling holes 108 are achieved. Thus, the positioning of the sacrificial plug 100 reduces or eliminates sand plugging between the cooling holes in the component during a post-additive manufacturing coating process.

[0049] First, the structure of the sacrificial plug 100 will be discussed, and then its integral additive manufacturing formation with an exemplary turbine component and holes 108 will be described. As embodied in the present disclosure and as Figure 2 and Figure 3As shown, the sacrificial plug 100 includes a top portion 110, a capping portion 120, and a cooling hole engagement portion 130. The sacrificial plug 100 is formed as a single element and, as described herein, is formed during the additive manufacturing of a turbine component and is formed in and with the cooling hole 108. This simultaneous formation substantially ensures that the sacrificial plug 100 and the cooling hole 108 will properly correspond and pair, and, as discussed below, are aligned and positioned in an integrally connected form.

[0050] The top portion 110 extends upwardly from the turbine component in which the sacrificial plug 100 is formed. The top portion 110 has an elongated configuration that enables a user or the user's tool to grip the top portion 110. By gripping the top portion 110 and manipulating the sacrificial plug 100, the sacrificial plug 100 can be removed from the cooling hole 108, as described below. Accordingly, the top portion 110 facilitates gripping and includes at least one of, but is not limited to, the following: a knurled surface; a contoured surface for conforming to a finger, tool, or machine; a rounded surface; a prismatic surface; a knob surface; a hooked surface; a surface that facilitates engagement with a machine to provide a motive force for removal (see Figures 15 to 17 , as described below), or any other structure that facilitates gripping now known or developed below.

[0051] In addition, the top portion 110 can be circular, oval, polygonal, or any other shape that enables and facilitates the gripping and removal of the sacrificial plug 100. The top portion 110 of the sacrificial plug 100 can be formed as at least one of a solid portion, a hollow portion, formed in a grid structure, or any other configuration that provides sufficient stiffness for removal, as described herein.

[0052] The capping portion 120 overlies the surface of the component that surrounds the cooling hole 108 into which the sacrificial plug 100 is formed. The overlying aspect of the capping portion 120 occurs in conjunction with the additive manufacturing of the capping portion 120. The additive manufacturing process forms the capping portion 120 at a distance A above the surface 85 of the turbine blade 10 at the cooling hole 108 ( Figure 4 ). The distance A is large enough to allow a limited amount of coating to enter beneath the capping portion 120. The capping portion 120 is set at a distance above the surface 85 such that the coating can flow around and beneath it to the surface 85.

[0053] However, the configuration of the capping portion 120 limits the amount of coating that can access the coating below the capping portion 120. Considering the possible post-print coating process that may be required, distance A is a set of predetermined distances, and controlled additive manufacturing provides the capping portion 120 at a distance A above the surface 85. Thus, understanding the post-print coating process will enable setting distance A and allowing an acceptable amount of coating to access below the capping portion 120 to coat the surface 85 without sand plugging the holes 108. By purposefully and advantageously setting distance A and limiting the amount of coating below the capping portion 120, the sacrificial plug 100 prevents excessive coating material around the cooling holes 108 and prevents sand plugging between the cooling holes 108.

[0054] As shown, note that Figure 2 and Figure 3 , the capping portion 120 is in a generally hyperbolic paraboloid configuration but has no peripheral height rise on the x-axis. As an approximate hyperbolic paraboloid configuration, each capping portion 120 has an x-axis and a y-axis. The x-axis follows the vertex of the trailing edge 82 at the curved component surface 85. The capping portion profile of the capping portion 120 along the x-axis is generally a mirror image of the component profile of the curved component surface 85. Further, on the y-axis, the capping portion 120 follows the curvature of the curved component surface 85 at the trailing edge 82 when extending to both the pressure sidewall 83 and the suction sidewall 84.

[0055] Also as Figures 2 to 5 shown, the capping portion 120 is not coaxially symmetric with the top portion 110 or coaxial with the cooling holes 108. Instead, as Figure 3 seen, the x-axis and y-axis define the center C of the cooling holes 108 ( Figure 3 shown in dashed lines in

[0056] ). The capping portion 120 is set to be off-center from the center C and is aligned with the center axis TP of the top portion 110 at the midpoint C'. The midpoint C' is on the x-axis but is separated from the center C of the cooling holes 108 by a certain distance. As Figure 2 and Figure 4 shown, the positioning of the capping portion 120 with respect to the top portion 110 provides an overlying extension of the cooling holes 108 at the larger side regions 121 of the capping portion 120. The shorter side regions 122 still overlie and cover the cooling holes 108. The formation of the sacrificial plugs 100 in adjacent cooling holes 108 positions the capping portion 120 such that each larger side region 121 is adjacent to a corresponding shorter side region 122 (except for the first and last sacrificial plugs 100 in the sequence that do not have adjacent sacrificial plugs on both sides).

[0057] The cooling hole joint portion 130 is integrally formed during the additive manufacturing of the turbine component and is integrally connected to the peripheral inner surface 109 of the cooling hole 108. Thus, the sacrificial plug 100 is integrally formed and connected to the turbine component as a unit before being cut off and removed (as will be described below). The connection of the cooling hole joint portion 130 to the cooling hole 108 at the peripheral inner wall 109 of the cooling hole enables the sacrificial plug 100 to be stably set in the cooling hole 108 during additive manufacturing.

[0058] The cooling hole joint portion 130 is formed with the turbine component to enable the cuttable removal of the sacrificial plug 100 after post-printing processes / operations such as, but not limited to, coating. Thus, between the cooling hole joint portion 130 and the peripheral inner surface 109 of the cooling hole 108, the cooling hole joint portion 130 has at least one cuttable connection, and preferably more than one cuttable connection. This connection is formed as a unit during the integral additive manufacturing of the turbine component and the sacrificial plug 100. This connection defines a cuttable, fragile, detachable, breakable, or separable connection (hereinafter referred to as "separable connection") between them, as discussed herein. This separable connection is strong enough to keep the sacrificial plug 100 in place, but fragile or brittle enough to allow separation between the cooling hole joint portion 130 and the peripheral inner surface 109 of the cooling hole 108 when sufficient force is applied to the top portion 110.

[0059] For example, and without limiting the embodiments in any way, during the additive manufacturing of the turbine component and the sacrificial plug 100, a separable connection is formed between the cooling hole joint portion 130 and the peripheral inner surface 109 of the cooling hole 108. The separable connection 131 will be formed at the lowest point of the sacrificial plug 100 extending into the hole 108 according to the additive manufacturing process. The separable connection 131 may be formed as at least one separable connection member 131( Figure 5 ).

[0060] In Figure 5 , each separable connection member 131 includes at least one additively manufactured connection member 131 attached to both the cooling hole joint portion 130 and the peripheral inner surface 109 of the cooling hole 108. Thus, considering the cuttable nature of the connection member 131, when a force ( Figure 5 ) is applied to the top portion 110 in the direction Z to remove the sacrificial plug 100 from the cooling hole 108, each connection member 131 will be cut off. Thus, each connection member 131 can separate the cooling hole joint portion 130 from the peripheral inner surface 109 of the cooling hole 108. In addition to the force applied in the direction Z, a rotational force may also be applied (see Figure 5arrow D) to sever the connecting member 131 from the peripheral inner surface 109 of the cooling hole 108. Once severed from the wall 109 of the cooling hole 108, the sacrificial plug 100 can be removed from the cooling hole 108 in the direction Z.

[0061] The connecting member 131 maintains the sacrificial plug 100 in the cooling hole 108 until sufficient force is applied to separate the sacrificial plug 100 from the wall 109 of the cooling hole 108. The number of connecting members 131 and their positions, orientations, distributions, and structures relative to each other can vary according to aspects of the present disclosure. Additionally, the connecting member 131 can include one or more of the connecting members 131. The connecting member 131 is discussed herein individually or in combination with other connecting members 131. Further, at least one connecting member 131 can be disposed on any portion of the cooling hole engagement portion 130 at the peripheral inner surface 109 of the cooling hole 108, provided that at least one connecting member 131 is initiated at the lowest point 135 of the cooling hole engagement portion 130 during additive manufacturing.

[0062] Reference Figures 6 to 14 , shows various exemplary configurations of the connecting member 131 having a cooling hole engagement portion 130 at the peripheral inner surface 109 at line 6-6( Figure 5 ). Figure 6 Shows the connecting member 131 in the form of two finger-like connecting members 131 that connect the cooling hole engagement portion 130 to the peripheral inner surface 109. Figure 7 The connecting member 131 is shown as three finger-like connecting members 131 that connect the cooling hole engagement portion 130 to the peripheral inner surface 109 of the cooling hole 108. In Figure 7 , more than three connecting members 131 (see the dashed outer frame) can be formed during the additive manufacturing of the turbine component and the sacrificial plug 100. According to aspects of the present disclosure, the connecting members 131 formed during additive manufacturing can be spaced at regular intervals or at irregular, non-uniformly spaced intervals, provided that the connecting members 131 connect the cooling hole engagement portion 130 to the peripheral inner surface 109 of the cooling hole 108.

[0063] In Figure 8 , the connecting member 131 includes a triangular connecting member 131 that connects the cooling hole engagement portion 130 to the peripheral inner surface 109 of the cooling hole 108. In Figure 8 , the base of the triangular connecting member 131 can be additively manufactured on the cooling hole engagement portion 130 or the peripheral inner surface 109 of the cooling hole 108 with the turbine component and the sacrificial plug 100. Alternatively, the base of the inverted triangular connecting member 132 (only in Figure 8 ) can be formed on the peripheral inner surface 109 of the cooling hole 108 that is connected to the cooling hole engagement portion 130.

[0064] Figure 9 shows a circumferential array of triangular connection members 131 formed as a complete 360 on a cooling hole joint portion 130 connected to the inner circumferential surface 109 of the cooling hole 108 during the additive manufacturing of the turbine component and the sacrificial plug 100. ° The circumferential array of triangular connection members 131. Figure 10 shows another configuration of the connection member 131 positioned on the cooling hole joint portion 130 connected to the inner circumferential surface 109 of the cooling hole 108. In Figure 10 it, the connection member 131 is formed in a "threaded" configuration during additive manufacturing. One or more of the threads 133 of the connection member 131 may be formed on the cooling hole joint portion 130 that engages with the inner circumferential surface 109 of the cooling hole 108. Some of the threads 134 may be eliminated or formed to be spaced apart from the inner circumferential surface 109 of the cooling hole 108 in a stepped form. This stepped form can save material and facilitate cutting when a force is applied to the top portion 110 to remove the sacrificial plug 100.

[0065] Figure 11 shows an elongated connection member 131 on the cooling hole joint portion 130 that engages elastically with the inner circumferential surface 109 of the cooling hole 108. The connection member 131 can be formed in any and varying lengths when engaging with the inner circumferential surface 109 of the cooling hole 108 and is formed with the cooling hole joint portion 130. In addition, any number of connection members 131 can engage with the inner circumferential surface 109 of the cooling hole 108. Additionally, any combination of the connection members 131 as discussed herein can be used with each other. Further, considering the limitations of the 2-d illustration, Figure 11 the connection member 131 and other connection member 131 configurations within the scope of the present disclosure need not be "linear", but can have any shape and configuration in and out of the plane of the drawing, such as spiraling around the cooling hole joint portion 130.

[0066] In addition, according to aspects of the present disclosure, Figure 11 shows a connection member 131 that includes struts 135 interconnected by a web 134 of breakable members. In Figure 11 this configuration, when the struts 135 and the web 134 are cut, the connection member 131 is breakable when a force is applied to remove the sacrificial plug 100 from the cooling hole 108. Additionally, as Figure 11 shown, an additional configuration of the connection member 131 including a web 136 of breakable members without strut fingers is formed during the additive manufacturing of the turbine component and the sacrificial plug 100. In Figure 11 this aspect, when the web 136 is cut, the connection member 131 is breakable when a force is applied to remove the sacrificial plug 100 from the cooling hole 108.

[0067] Figure 12Describes additional aspects of the connection member 131 as embodied in the present disclosure. In Figure 12 , the connection member 131 formed during additive manufacturing includes at least one connection member 131 having a zone 137 formed with controlled mechanical properties of the additive printing / manufacturing. The zone 137 includes material properties controlled during additive manufacturing, which have reduced density, elasticity, and ductility, and increased stiffness and brittleness compared to the remaining zone 138 of the connection member 131. The zone 137 is the area where Figure 12 the connection member 131 will likely break off, and the remaining zone 138 remains intact on the cooling hole engagement portion 130. When the sacrificial plug 100 is removed from the cooling hole 108, the connection member 131 moves upward in the cooling hole 108 together with the remaining zone 138 above. Any material (regardless of its source) in the cooling hole 108 may get trapped on the remaining zone 138 of the connection member 131 and move with the connection member 131 in a manner similar to a manual pump piston. Additionally, if the remaining zone 138 is close to the wall 109 of the cooling hole 108, the connection member 131 can be used as a scraper to further remove material from the wall 109 of the cooling hole 108.

[0068] Another configuration of the cooling hole engagement portion 130 includes a connection member 131 and a capture member 141, as Figure 13 shown. The capture member 141 is formed during the additive manufacturing of the turbine component and the sacrificial plug 100 and includes a groove or recess 140. In a manner similar to that described above with respect to Figure 12 , the connecting piece 139 includes a material similar to that of the zone 137, so it breaks off at this perimeter, and the remaining part of the connection member 131 remains intact. The recess 140 serves as a collector and retainer for the material in the cooling hole 108. When the sacrificial plug 100 is removed from the cooling hole 108, the material (regardless of its source) in the cooling hole 108 may get trapped in the recess 140 and move with the recess 140 in a manner similar to a manual pump piston. Additionally, if the perimeter 139 remains close to the wall 109 of the cooling hole 108, the perimeter 139 can be used as a scraper to further remove material from the wall 109 of the cooling hole 108.

[0069] Figure 14Shows additional aspects of the connection member. In this aspect, the connection member 144 is formed with a cooling hole engagement portion 130 during the additive manufacturing of the turbine component and the sacrificial plug 100. The connection member 144 is additively manufactured to have an overall circular configuration with gear-shaped teeth including a hub 145 and teeth 146. At least one and preferably two or more of the teeth 146 are additively manufactured together with the wall 109 of the cooling hole 108. The hub 145 can be additively manufactured as a rotatable element on the cooling hole engagement portion 130, so that the gear-shaped connection member 144 rotates around the hub 145 when the sacrificial plug 100 is retracted. During rotation, the teeth 146 held on the gear-shaped connection member 144 can engage the wall 109. In a similar manner to the collector member 138, the gear-shaped connection member 144 can be used as a scraper to further remove material from the wall 109 of the cooling hole 108.

[0070] Alternatively, if the gear-shaped connection member 144 does not rotate around the hub 145, the teeth 146 of the gear-shaped connection member 144 can engage the wall 109. When the sacrificial plug 100 is removed from the cooling hole 108, the gear-shaped connection member 144 moves upward in the cooling hole 108. Any material (regardless of its source) in the cooling hole 108 may be trapped in and / or move with the teeth 146.

[0071] As embodied in the present disclosure and as described above, the removal of the sacrificial plug 100 can be accomplished by applying an upward force in the direction Z, which is sufficient to cut the additively manufactured connection between these connection members when the connection member 131 engages the peripheral inner surface 109 of the cooling hole 108. Additionally, as noted above, a rotational force in the direction of arrow D can also be applied to cut the connection member 131 from the peripheral inner surface 109 of the cooling hole 108. In a further aspect of the present disclosure, the top portion 110 of the sacrificial plug 100 can be provided with a structure that facilitates the application of a rotational force in the direction of arrow D. The structure that facilitates the application of a rotational force enables a firmer grip by an individual. This structure can enable engagement with a mechanism for mechanically applying a rotational force to it.

[0072] In Figure 15 the top portion 110 of the sacrificial plug 100 includes a gear structure 111 that is additively manufactured together with the top portion 110. The gear structure 111 includes teeth 112 that can engage a power device to impart a rotational motion to these power devices, thus enabling the rotation of the entire sacrificial plug 100. Therefore, the cutting of the connection member 131 from the peripheral inner surface 109 of the cooling hole 108 can be achieved. In one aspect of the present disclosure, a complementary gear 202 ( Figure 16 ) can engage the teeth 112 of the gear structure 111 to rotate the gear structure 111 and the entire sacrificial plug 100 (direction D). Therefore, the cutting of the connection member 131 from the peripheral inner surface 109 of the cooling hole 108 can be achieved.

[0073] Alternatively, as Figure 16 shown, the gear 111 may engage with a rack 200 including linear teeth 201. Thus, when the rack 200 is translated (arrow R), the engagement of teeth 112 and 201 causes rotation of the sacrificial plug 100 through rotation of the top portion 110. The sacrificial plug 100 rotates (direction D) through rotation of the top portion 110 to cut the connecting member 131 from the peripheral inner surface 109 of the cooling hole 108. Then, the sacrificial plug 100 can be removed from the cooling hole 108 in the direction Z ( Figure 5 ).

[0074] Figure 17 An alternative configuration for cutting the connecting member 131 from the peripheral inner surface 109 of the cooling hole 108 is shown. A strip or bonding tape 300 (hereinafter “tape” 300) mates with one or more gears 111 on the top portion 110 of the sacrificial plug 100. The mating of the tape 300 with the one or more gears 111 is a frictional engagement, so that the gears 111 rotate when the tape 300 is moved in a clockwise or counterclockwise direction ( Figure 17 arrow R in). The tape 300 frictionally engages the teeth 112 and causes them to rotate, causing the gears 111 to rotate, and thus causing the sacrificial plug 100 to rotate (direction D) through rotation of the top portion 110. By virtue of the rotation of the sacrificial plug 100, the connecting member 131 is cut from the peripheral inner surface 109 of the cooling hole 108. Then, the sacrificial plug 100 can be removed from the cooling hole 108 in the direction Z ( Figure 5 ).

[0075] Another aspect of the present disclosure provides that the top portion 110 of the sacrificial plug 100 is formed with an orifice or slot 115 at the end face 117 (specifically Figure 2 and Figure 15 ). The orifice or slot (hereinafter “slot”) 115 is configured to be engaged by a mechanical device to impart rotation to the top portion 110 and thus to the sacrificial plug 100. The rotation of the sacrificial plug 100 through rotation of the slot 115 cuts the connecting member 131 from the peripheral inner surface 109 of the cooling hole 108. The slot 115 may be a flat head slot, a Phillips slot, a cross slot, a square (Robertson) slot or other polygonal slot, a ratchet slot, or any other slot configuration now known or developed hereinafter. The slot 115 may be capable of engaging with a complementary tool such as a screwdriver, drill bit, ratchet, driver, socket, Allen wrench, or any other tool for rotation now known or developed in the future.

[0076] Additional aspects of the present disclosure include forming the top portion 110 of the sacrificial plug 100 into a polygonal shape. The polygonal shape of the top portion 110 can engage with a complementary tool, such as but not limited to, a ratchet, socket, wrench, pliers, or any other suitable device for imparting rotation. As Figure 2 and Figure 15 shown, the rightmost top portion 110 (for illustrative purposes in the figure) is additively manufactured with a polygonal shape 116 (illustrated as hexagonal for illustrative purposes only) together with an end face 117. Thus, the sacrificial plug 100 cuts the connecting member 131 from the inner surface 109 of the periphery of the cooling hole 108 by rotation of the polygonal 116 end face 117.

[0077] As used throughout the specification and claims, approximate language may be used to modify any quantitative representation that can permit variation without resulting in a change in the basic function associated therewith. Thus, a value modified by one or more terms, such as "about," "approximately," and "substantially," is not limited to the specified exact value. In at least some instances, the approximate language may correspond to the precision of the instrument used to measure the value. Here and throughout the specification and claims, range limitations may be combined and / or interchanged. Unless the context or language dictates otherwise, these ranges are recognized and include all subranges subsumed therein. "About" applied to a particular value of a range applies to both end values thereof and may indicate + / - 10% of the stated value, unless otherwise dependent on the precision of the instrument measuring the value.

[0078] All structural, material, acts, and equivalents of the means or step plus function elements in the following claims are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or to limit the 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 spirit of the disclosure. The embodiments were chosen and described in order to best explain the principles of the disclosure and its practical application, and to enable others of ordinary skill in the art to understand the disclosure in various embodiments with various modifications suited to the particular use contemplated.

Claims

1. A sacrificial plug (100) system, the sacrificial plug (100) system comprises: a component having a surface (85) and at least one cooling hole (108) in the surface (85); a sacrificial plug (100) integrally formed with the component and integrally formed in the at least one cooling hole (108), the sacrificial plug (100) comprising: a top portion (110); a cap portion (120); and a bottom portion integrally formed with, joined to, and connected to the at least one cooling hole; and at least one connecting member (144) integrally formed with the bottom portion of the sacrificial plug (100) and integral with the inner wall (109) of each respective at least one cooling hole (108); when a force is applied to the top portion (110), each at least one connecting member (144) is capable of being severed from the respective inner wall (109) of its respective at least one cooling hole (108), thereby allowing the sacrificial plug (100) to be removed from the at least one respective cooling hole (108).

2. The sacrificial plug (100) system according to claim 1, wherein the cap portion (120) is spaced a predetermined distance above the surface (85) and the respective at least one cooling hole (108).

3. The sacrificial plug (100) system according to claim 2, wherein the cap portion (120) includes a cap portion (120) profile and the component has a component profile, and the cap portion (120) profile is a mirror image of the component profile.

4. The sacrificial plug (100) system according to claim 2, wherein the sacrificial plug (100) system further comprises a coating applied to the integrally formed component, the sacrificial plug (100), and the at least one connecting member (144), and the predetermined distance allows the coating to enter below the cap portion (120) and prevents the coating from entering each respective at least one cooling hole (108), and wherein the predetermined distance prevents sand plugging between adjacent cooling holes of the at least one cooling hole (108).

5. The sacrificial plug (100) system according to claim 1, wherein the integrally formed component, the sacrificial plug (100), and the at least one connecting member (144) are integrally additively manufactured.

6. The sacrificial plug (100) system according to claim 1, wherein the component comprises a turbine blade (10), and the surface (85) includes a trailing edge (82) having a plurality of the at least one cooling hole (108), and wherein a plurality of the at least one connecting member (144) are formed in respective cooling holes (108) on the trailing edge (82) of the turbine blade (10).

7. The sacrificial plug (100) system according to claim 1, wherein the top portion (110) includes a configuration that enables rotation of the sacrificial plug (100) to sever each respective at least one connecting member (144) from the wall (109) of the respective at least one cooling hole (108).

8. The sacrificial plug (100) system according to claim 7, wherein the top portion (110) includes at least one of the following: a knurled surface; a contoured surface; a rounded surface; a prism surface; a knob surface; a hooked surface; a surface facilitating engagement to provide a removal motive force; and wherein the top portion (110) includes at least one of a solid portion, a hollow portion, and a grid portion.

9. The sacrificial plug (100) system according to claim 7, wherein the top portion (110) includes a gear structure (111) integral with the top portion (110), the gear structure (111) including teeth (112, 146) that engage at least one power device to rotate the gear structure (111) and thus rotate the sacrificial plug (100) to sever the at least one connecting member (144) of the sacrificial plug (100).

10. The sacrificial plug (100) system according to claim 9, wherein the at least one power device includes at least one of a complementary gear (202), a rack and pinion (200) having linear teeth (201), and an adhesive strip (300).

11. The sacrificial plug (100) system according to claim 9, wherein the at least one power device engages the gear structures (111) on a plurality of sacrificial plugs (100).

12. The sacrificial plug (100) system according to claim 9, wherein the top portion (110) includes an end face (117) having an orifice that engages a mechanical device to rotate the gear structure (111) and thus rotate the sacrificial plug (100) to sever the at least one connecting member (144) of the sacrificial plug (100).

13. The sacrificial plug (100) system according to claim 4, wherein the cap portion (120) is not coaxial with the axis of each respective at least one cooling hole (108).

14. The sacrificial plug (100) system according to claim 1, wherein the at least one connecting member (144) includes a plurality of connecting members.

15. The sacrificial plug (100) system according to claim 14, wherein the plurality of connecting members includes at least one of the following: finger-shaped connecting members (144); polygonal finger-shaped connecting members (144); threaded connecting members (144); webs of the connecting members (144); and webs surrounded by struts of the connecting members (144).

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