Pairing component and method and system thereof

Abstract

A method of forming a paired pair of components includes forming a first geometry on a first mating surface of a first component, and forming a complementary second geometry on a second mating surface of a second component. A first geometry and a second geometry may be determined from a geometric key associated with the component identifier, for example by inputting the geometric key into a mathematical algorithm or random number generator. When replacement of the second component is required, a component identifier may be obtained from the first component, a geometric key may be obtained using the component identifier, and then a second geometry may be determined using the geometric key. A second geometry may then be formed on the second component such that the second component may be suitably mated with the mating first component.

Description

[0001] This application is a divisional application of the invention patent application with application number 202011229256.1 filed on November 6, 2020 and invention name “Matching components, methods and systems thereof”. Technical Field

[0002] The present subject matter relates generally to methods for forming mating components and, more particularly, to systems and methods for forming components having unique mating geometries using geometric keys. Background Art

[0003] Original Equipment Manufacturers (OEMs) in every industry are interested in ensuring that replacement parts for use with their products or equipment are manufactured according to standards set and controlled by the OEM. Using the aviation industry as an example, manufacturers of gas turbine engines, as well as the airlines and passengers who rely on them, could be exposed to serious risks if knock-off or replica replacement parts were easily obtained and installed in the engines.

[0004] Such counterfeit parts can pose a serious risk to the integrity of the gas turbine engine or may otherwise cause a variety of problems for the OEM and end user. More specifically, OEM parts may require rigorous attention to detail to ensure reliable material properties and functionality for a specific application, as well as complex inspections to verify the performance of the part. The OEM cannot ensure the integrity or compatibility of counterfeit parts, which may result in hazardous engine operation and increase the risk of potential failures.

[0005] Furthermore, counterfeit parts undermine the OEM’s ability to control the quality of their products. For example, cheap copies and inferior parts on the market are a real threat to both the engines in which they are installed and the reputation of the OEM. Moreover, a gas turbine engine failure caused by a counterfeit replacement part could expose the OEM to legal liability for misrepresentation. Furthermore, by not being able to control the sales of OEM replacement parts, the OEM could lose a significant revenue stream.

[0006] Additive manufacturing technology is maturing rapidly. For example, very accurate additive manufacturing printers using a variety of materials, such as metals and polymers, are becoming available at reduced costs. In addition, improved scanning technology and modeling tools are now available. As a result, some OEMs are beginning to use this technology to produce both original and replacement parts. However, advances in additive manufacturing technology have also lowered barriers to entry into the additive manufacturing field. As a result, replacement parts may be more easily reverse engineered and copied, and there is an increased risk of a third party manufacturing and installing a knockoff part on an OEM device, such as a gas turbine engine, leading to the hazards described above.

[0007] Therefore, systems and methods for manufacturing components such that they can be identified as authentic and cannot be easily copied by unauthorized third parties and passed off as authentic OEM parts would be particularly beneficial. Summary of the invention

[0008] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0009] In an exemplary embodiment of the present disclosure, a method of forming a component pair is provided. The method includes obtaining a component identifier of a first component, the first component defining a first mating surface having a first geometric shape, and obtaining a geometric key associated with the component identifier. The method also includes determining a second geometric shape using the geometric key, the second geometric shape being complementary to the first geometric shape, and forming the second geometric shape on a second mating surface of a second component of the component pair.

[0010] In another exemplary aspect of the present disclosure, a component pair is provided, comprising: a first component comprising a first mating surface defining a first geometric shape associated with a geometric key; a second component comprising a second mating surface defining a second geometric shape, the second geometric shape being determined using the geometric key and being complementary to the first geometric shape, wherein the first component and the second component can be properly mated together only when the first geometric shape is received by the second geometric shape.

[0011] In yet another exemplary aspect of the present disclosure, a system for forming a component pair is provided. The system includes one or more processors and one or more memory devices, the one or more memory devices storing computer-readable instructions that, when executed by the one or more processors, cause the one or more processors to perform operations. The operations include obtaining a component identifier of a first component, the first component defining a first mating surface having a first geometric shape, and obtaining a geometric key associated with the component identifier. The operations also include determining a second geometric shape using the geometric key, the second geometric shape being complementary to the first geometric shape, and forming the second geometric shape on a second mating surface of a second component of the component pair.

[0012] These and other features, aspects and advantages of the present invention will be better understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] A full and enabling disclosure of the invention, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification, which refers to the accompanying drawings.

[0014] Figure 1 A schematic diagram of an additive manufacturing machine according to an exemplary embodiment of the present invention is shown.

[0015] Figure 2 An exemplary embodiment according to the present subject matter is shown. Figure 1 A close-up schematic of the build platform of an exemplary additive manufacturing machine.

[0016] Figure 3 Certain components of a controller according to an example embodiment of the present subject matter are depicted.

[0017] Figure 4 A method of forming a component pair according to an exemplary embodiment of the present subject matter is provided.

[0018] Figure 5 A method of forming a replacement portion of a component pair is provided according to an exemplary embodiment of the present subject matter.

[0019] Figure 6 is a schematic cross-sectional view of a mating component pair according to an exemplary embodiment of the present subject matter.

[0020] Figure 7 is a schematic cross-sectional view of a mating component pair according to another exemplary embodiment of the present subject matter.

[0021] Figure 8 A top view of a first component of a pair of components according to yet another exemplary embodiment of the present subject matter is shown.

[0022] Fig. 9 A schematic diagram of a component pair according to another exemplary embodiment of the present subject matter is shown.

[0023] Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention. DETAILED DESCRIPTION

[0024] Reference will now be made in detail to embodiments of the present invention, one or more examples of which are shown in the accompanying drawings. Each example is provided by way of illustration of the present invention rather than limitation thereof. Indeed, it will be apparent to those skilled in the art that various configurations, modifications and variations may be made in the present invention without departing from the scope of the present invention. For example, a feature shown or described as part of one embodiment may be used with another embodiment to produce yet another embodiment. Therefore, the present invention is intended to cover such modifications and variations that fall within the scope of the appended claims and their equivalents.

[0025] As used herein, the terms "first", "second", and "third" are used interchangeably to distinguish one component from another, and are not intended to indicate the position or importance of the respective components. In addition, as used herein, approximate terms such as "approximately", "substantially", or "approximately" refer to within a ten percent error range.

[0026] Aspects of the present subject matter relate to methods of forming a matching or mating component pair, the method comprising forming a first geometric shape on a first mating surface of a first component, and forming a complementary second geometric shape on a second mating surface of a second component. The first geometric shape and the second geometric shape can be determined from a geometric key associated with a component identifier, for example, by inputting the geometric key into a mathematical algorithm or a random number generator. When it is necessary to replace the second component, the component identifier can be obtained from the first component, the geometric key can be obtained using the component identifier, and then the geometric key can be used to determine the second geometric shape. The second geometric shape can then be formed on the second component so that the second component can be properly mated with the mating first component.

[0027] In general, the components described herein can be manufactured or formed using any suitable process. However, according to several aspects of the present subject matter, these components can be formed using an additive manufacturing process (e.g., a 3-D printing process). The use of such a process can allow the components to be formed integrally as a single monolithic component, or formed into any suitable number of sub-components. In particular, the manufacturing process can allow these components to be formed integrally and include a variety of features that are not possible when using existing manufacturing methods. For example, the additive manufacturing methods described herein enable the manufacture of components with various features, configurations, thicknesses, materials, densities, surface variations, and identifying features that are not possible using existing manufacturing methods. Some of these novel features are described herein.

[0028] As used herein, the term "additive manufacturing" or "additive manufacturing techniques or processes" generally refers to a manufacturing process in which successive layers of material are provided successively to one another to "build up" a three-dimensional component layer by layer. The successive layers are typically fused together to form a monolithic component having various integral subcomponents.

[0029] Although additive manufacturing techniques are described herein as enabling the manufacture of complex objects by typically building objects point by point, layer by layer in a vertical direction, other manufacturing methods are possible and within the scope of the present subject matter. For example, although the discussion herein relates to adding materials to form successive layers, those skilled in the art will appreciate that the methods and structures disclosed herein can be practiced with any additive manufacturing technique or manufacturing technology. For example, embodiments of the present invention can use layer-additive processing, layer-subtractive processing, or hybrid processing.

[0030] Suitable additive manufacturing techniques according to the present disclosure include, but are not limited to, fused deposition modeling (FDM), selective laser sintering (SLS), 3D printing such as by inkjet and laser inkjet, stereolithography (SLA), direct selective laser sintering (DSLS), electron beam sintering (EBS), electron beam melting (EBM), laser engineered net shaping (LENS), laser net shape manufacturing (LNSM), direct metal deposition (DMD), digital light processing (DLP), direct selective laser melting (DSLM), selective laser melting (SLM), direct metal laser melting (DMLM) and other known processes.

[0031] In addition to using a direct metal laser sintering (DMLS) or direct metal laser melting (DMLM) process (in which an energy source is used to selectively sinter or melt a portion of a powder layer), it should be understood that according to alternative embodiments, the additive manufacturing process can be a "binder jetting" process. In this regard, binder jetting involves continuously depositing layers of additive powder in a manner similar to that described above. However, instead of using an energy source to generate an energy beam to selectively melt or fuse the additive powder, binder jetting involves selectively depositing a liquid binder (e.g., a photocurable polymer or another liquid binder) onto each layer of powder. Other suitable additive manufacturing methods and variations are intended to fall within the scope of the present subject matter.

[0032] The additive manufacturing processes described herein can be used to form parts using any suitable material. For example, the material can be a plastic, a metal, concrete, a ceramic, a polymer, an epoxy resin, a photopolymer resin, or any other suitable material that can be in a solid, liquid, powder, sheet material, wire, or any other suitable form. More specifically, according to exemplary embodiments of the present subject matter, the additively manufactured parts described herein can be formed in part, in whole, or with some materials (including, but not limited to, pure metals, nickel alloys, chromium alloys, titanium, titanium alloys, magnesium, magnesium alloys, aluminum, aluminum alloys, iron, iron alloys, stainless steel, and nickel or cobalt-based superalloys (e.g., available from Special Metals Corporation under the name of These materials are examples of materials suitable for the additive manufacturing processes described herein and may generally be referred to as "additive materials."

[0033] In addition, those skilled in the art will appreciate that a variety of materials and methods for bonding these materials may be used, and these materials and methods are considered to be within the scope of the present disclosure. As used herein, reference to "melting" may refer to any suitable process for producing a bonding layer of any of the above materials. For example, if the object is made of a polymer, melting may refer to producing a thermosetting bond between the polymer materials. If the object is an epoxy resin, the bond may be formed by a cross-linking process. If the material is a ceramic, the bond may be formed by a sintering process. If the material is a powdered metal, the bond may be formed by a melting or sintering process. Those skilled in the art will appreciate that other methods of melting materials to manufacture parts by additive manufacturing are also feasible, and the subject matter currently disclosed may be practiced by those methods.

[0034] In addition, the additive manufacturing processes disclosed herein allow a single component to be formed from multiple materials. Therefore, the components described herein can be formed from any suitable mixture of the above materials. For example, a component may include multiple layers, segments, or portions formed using different materials, processes, and / or on different additive manufacturing machines. In this way, components with different materials and material properties can be constructed to meet the needs of any particular application. In addition, although the components described herein are entirely composed of additive manufacturing processes, it should be understood that in alternative embodiments, all or a portion of these components can be formed via casting, machining, and / or any other suitable manufacturing process. In fact, any suitable combination of materials and manufacturing methods can be used to form these components.

[0035] An exemplary additive manufacturing process will now be described. An additive manufacturing process uses three-dimensional (3D) information (e.g., a three-dimensional computer model of a component) to manufacture a component. Thus, a three-dimensional design model of a component may be defined prior to manufacturing. In this regard, a model or prototype of a component may be scanned to determine the three-dimensional information of the component. As another example, a model of a component may be constructed using an appropriate computer-aided design (CAD) program to define a three-dimensional design model of the component.

[0036] The design model can include 3D digital coordinates of the entire construction of the component, including the exterior and interior surfaces of the component. For example, the design model can define the body, surfaces and / or internal passages (e.g., openings), support structures, etc. In an exemplary embodiment, for example, along the central (e.g., vertical) axis of the component or any other suitable axis, the three-dimensional design model is converted into multiple slices or segments. Each slice can define a thin cross-section of the component for a predetermined height of the slice. Multiple consecutive cross-sectional slices together form the 3D component. The component is then "built" piece by piece or layer by layer until it is completed.

[0037] In this manner, additive processing can be used to manufacture the components described herein, or more specifically, to successively form each layer by melting material (e.g., by using laser energy or heat to polymerize plastics, or by sintering or melting metal powders). For example, a particular type of additive manufacturing process can use an energy beam (e.g., an electron beam) or electromagnetic radiation (e.g., a laser beam) to sinter or melt powdered materials. Any suitable laser and laser parameters can be used, including considerations regarding power, laser beam spot size, and scanning speed. The build material can be formed from any suitable powder or material selected for enhanced strength, durability, and service life (particularly at high temperatures).

[0038] According to alternative embodiments, each successive layer may be, for example, between about 10 μm and 200 μm, although the thickness may be selected based on any number of parameters and may have any suitable dimensions. Thus, utilizing the above-described additive forming methods, the components described herein may have a cross-section as thin as the thickness of the associated powder layer used during the additive forming process (e.g., 10 μm).

[0039] Additionally, using additive processing, the surface finish and features of the component can be varied as desired depending on the application. For example, the surface finish can be adjusted (e.g., made smoother or rougher) by selecting appropriate laser scanning parameters (e.g., laser power, scanning speed, laser focus size, etc.) during the additive process, particularly at the periphery of the cross-sectional layer corresponding to the part surface. For example, a rougher finish can be achieved by increasing the laser scanning speed or reducing the size of the formed molten pool, while a smoother finish can be achieved by reducing the laser scanning speed or increasing the size of the formed molten pool. The scanning pattern and / or laser power can also be changed to change the surface finish of the selected area.

[0040] After the fabrication of a component is complete, various post-processing procedures may be applied to the component. For example, a post-processing procedure may include the removal of excess powder by, for example, purging or vacuuming. Other post-processing procedures may include stress relief treatments. Additionally, parts may be finished using thermal, mechanical, and / or chemical post-processing procedures to achieve desired strength, surface finish, and other component attributes or features.

[0041] It is noteworthy that in exemplary embodiments, several aspects and features of the present subject matter were not previously possible due to manufacturing limitations. However, the inventors have advantageously utilized recent advances in additive manufacturing technology to improve various components and methods of additively manufacturing such components. Although the present disclosure is generally not limited to the use of additive manufacturing to form these components, additive manufacturing does provide a variety of manufacturing advantages, including ease of manufacturing, reduced costs, greater accuracy, etc.

[0042] Furthermore, the additive manufacturing methods described above enable more complex and elaborate shapes and contours of the components described herein to be formed with very high levels of precision. For example, such components may include thin additively manufactured layers, cross-sectional features, and component contours. Additionally, the additive manufacturing process enables the manufacture of a single component with different materials, such that different portions of the component may exhibit different performance characteristics. The continuous, additive nature of the manufacturing process enables these novel features to be constructed. As a result, components formed using the methods described herein may exhibit improved performance and reliability.

[0043] Reference now Figure 1 , an exemplary laser powder bed fusion system, such as a DMLS or DMLM system 100, will be described in accordance with exemplary embodiments. Specifically, the AM system 100 is described herein as being used to build all or a portion of one or more parts. It should be understood that the parts described herein are merely exemplary parts to be built and are primarily used to facilitate description of the operation of the AM machine 100. In this regard, the subject matter is not intended to be limited to the formation of the described parts, but rather the AM machine 100 may be used to print any suitable number, type, and configuration of parts or features of parts.

[0044] As shown, the AM system 100 generally defines a vertical direction V or Z direction, a lateral direction L or X direction, and a transverse direction T or Y direction ( Figure 1 ), each direction is perpendicular to each other, thus generally defining an orthogonal coordinate system. As shown, the system 100 includes a fixed housing or build area 102 that provides a contamination-free and controlled environment for performing additive manufacturing processes. In this regard, for example, the housing 102 is used to isolate and protect other components of the system 100. In addition, the housing 102 can be provided with a suitable protective gas flow, such as nitrogen, argon, or another suitable gas or gas mixture. In this regard, the housing 102 can define an inlet 104 and an exhaust port 106 for receiving a gas flow to produce a static pressurized volume or a dynamic gas flow.

[0045] The housing 102 may generally contain some or all of the components of the AM system 100. According to an exemplary embodiment, the AM system 100 generally includes a workbench 110, a powder supply 112, a scraper or recoater mechanism 114, an overflow container or reservoir 116, and a build platform 118 located within the housing 102. In addition, an energy source 120 generates an energy beam 122, and a beam steering device 124 directs the energy beam 122 to facilitate the AM process, as described in more detail below. Each of these components will be described in more detail below.

[0046] According to the illustrated embodiment, workbench 110 is a rigid structure defining a planar build surface 130. In addition, planar build surface 130 defines a build opening 132 through which a build chamber 134 can be accessed. More specifically, according to the illustrated embodiment, build chamber 134 is at least partially defined by vertical walls 136 and build platform 118. Notably, build platform 118 can be moved relative to build surface 130 along a build direction 138. More specifically, build direction 138 can correspond to a vertical direction V, such that moving build platform 118 downward increases the height of the part being printed and build chamber 134. In addition, build surface 130 defines a supply opening 140 through which additive powder 142 can be supplied from powder supply 112, and a reservoir opening 144 through which excess additive powder 142 can enter overflow reservoir 116. The collected additive powder can be selectively processed to screen out loose, agglomerated particles before reuse.

[0047] The powder supply 112 generally includes an additive powder supply container 150, which generally contains a certain amount of additive powder 142, sufficient for some or all of the additive manufacturing process of a particular part. In addition, the powder supply 112 includes a supply platform 152, which is a plate-like structure that can move in a vertical direction within the powder supply container 150. More specifically, a supply actuator 154 vertically supports the supply platform 152 and selectively moves the supply platform 152 up and down during the additive manufacturing process.

[0048] The AM system 100 also includes a recoater mechanism 114, which is a rigid, laterally elongated structure located near the build surface 130. For example, the recoater mechanism 114 can be a hard scraper, a soft scraper, or a roller. The recoater mechanism 114 is operably connected to a recoater actuator 160, which is operable to selectively move the recoater mechanism 114 along the build surface 130. In addition, a platform actuator 164 is operably connected to the build platform 118 and is generally operable to move the build platform 118 in a vertical direction during the build process. Although actuators 154, 160, and 164 are shown as hydraulic actuators, it should be understood that according to alternative embodiments, any other type and configuration of actuators, such as pneumatic actuators, hydraulic actuators, ball screw linear electric actuators, or any other suitable vertical support devices, can be used. Other configurations are also possible and within the scope of the present subject matter.

[0049] As used herein, "energy source" may be used to refer to any device or system of devices configured to direct an energy beam having appropriate power and other operating characteristics toward an additive powder layer to sinter, melt, or otherwise fuse a portion of the additive powder layer during a build process. For example, the energy source 120 may be a laser or any other suitable radiation emitting directing device or radiation device. In this regard, the radiation or laser source may initiate radiation of a photon or laser beam directed by a radiation emitting directing device or a beam steering device.

[0050] According to an exemplary embodiment, the beam steering device 124 includes one or more mirrors, prisms, lenses and / or electromagnets operably coupled to suitable actuators and arranged to direct and focus the energy beam 122. In this regard, for example, the beam steering device 124 can be a galvanometer scanner that moves or scans the focus of the laser beam 122 emitted by the energy source 120 across the build surface 130 during the laser melting and sintering process. In this regard, the energy beam 122 can be focused to a desired spot size and steered to a desired position in a plane that coincides with the build surface 130. The galvanometer scanners in powder bed fusion technology are typically in a fixed position, but the movable mirrors / lenses contained therein allow various characteristics of the laser beam to be controlled and adjusted. According to an exemplary embodiment, the beam steering device can further include one or more of the following: an optical lens, a deflector, a mirror, a beam splitter, a telecentric lens, etc.

[0051] It should be understood that other types of energy sources 120 may be used, which may use alternative beam steering devices 124. For example, an electron beam gun or other electron source may be used to generate an electron beam (e.g., an "e-beam"). The electron beam may be directed by any suitable radiation emission directing device, preferably in a vacuum. When the radiation source is an electron source, the radiation emission directing device may be, for example, an electronic control unit, which may include, for example, deflection coils, focusing coils, or similar elements. According to other embodiments, the energy source 120 may include one or more of a laser, an electron beam, a plasma arc, an electric arc, etc.

[0052] Prior to the additive manufacturing process, recoater actuator 160 may be lowered to supply powder 142 of a desired composition (e.g., metal, ceramic, and / or organic powder) into supply container 150. Additionally, platform actuator 164 may move build platform 118 to an initial high position, e.g., such that build platform 118 is substantially flush or coplanar with build surface 130. Build platform 118 is then lowered below build surface 130 by a selected layer increment. The layer increment affects the speed of the additive manufacturing process and the resolution of the manufactured part or component. As an example, the layer increment may be approximately 10 to 100 microns (0.0004 to 0.004 inches).

[0053] The additive powder is then deposited on build platform 118 before being melted by energy source 120. Specifically, supply actuator 154 can raise supply platform 152 to push powder through supply opening 140, thereby exposing the powder above build surface 130. Recoater mechanism 114 can then be moved across build surface 130 by recoater actuator 160 to horizontally distribute the raised additive powder 142 on build platform 118 (e.g., in selected layer increments or thicknesses). As recoater mechanism 114 passes from left to right (e.g., Figure 1 ), any excess additive powder 142 falls through the reservoir opening 144 into the overflow reservoir 116. Subsequently, the recoater mechanism 114 can be moved back to the starting position.

[0054] Therefore, as explained in this article and Figure 1 As shown, the recoater mechanism 114, the recoater actuator 160, the supply platform 152 and the supply actuator 154 can generally be operated to continuously deposit layers of additive powder 142 or other additive material to facilitate the printing process. As such, these components may be collectively referred to herein as powder dispensing devices, systems, or assemblies. The flattened additive powder 142 may be referred to as a "build layer" 172 (see Figure 2 ), and its exposed upper surface may be referred to as build surface 130. When build platform 118 is lowered into build chamber 134 during a build process, build chamber 134 and build platform 118 together surround and support a volume of additive powder 142 and any part being built. This volume of powder is often referred to as a "powder bed," and this particular type of additive manufacturing process may be referred to as a "powder bed process."

[0055] During the additive manufacturing process, a directed energy source 120 is used to melt a two-dimensional cross-section or layer of the part being built. More specifically, an energy beam 122 is emitted from the energy source 120, and a beam steering device 124 is used to steer a focal point 174 of the energy beam 122 over the exposed powder surface in a suitable pattern (referred to herein as a "tool path"). A small exposed layer of the additive powder 142 (referred to herein as a "weld pool" or "molten pool" or "heat affected zone" 176 (in the Figure 2 The molten pool 176 is heated by the energy beam 122 to a temperature that allows it to sinter or melt, flow, and solidify. As an example, the width of the molten pool 176 can be 100 microns (0.004 inches). This step can be referred to as melting the additive powder 142.

[0056] The build platform 118 is moved vertically downward by layer increments, and another layer of additive powder 142 is applied at a similar thickness. The directed energy source 120 again emits the energy beam 122, and the beam steering device 124 is used to steer the focus 174 of the energy beam 122 over the exposed powder surface in a suitable pattern. The exposed layer of additive powder 142 is heated by the energy beam 122 to a temperature that allows it to sinter or melt, flow, and consolidate within the top layer and the previously solidified layers below. The cycle of moving the build platform 118, applying the additive powder 142, and then directing the energy beam 122 to melt the additive powder 142 is repeated until the entire part is completed.

[0057] Reference again Figure 1 , the AM system 100 may include a system controller 180 that may be operably coupled to some or all portions of the AM system 100 or an external control system to facilitate system operation. For example, the system controller 180 may be operably coupled to a user interface panel 182 to allow an operator to communicate with the AM system 100, e.g., to input commands, upload a print tool path or CAD model, initiate an operating cycle, or otherwise control the operation of various components of the AM machine 100. Generally, the controller 180 may be operably coupled to all systems and subsystems within the AM system 100 to allow communication and data transfer therebetween. In this manner, the controller 180 may generally be configured to operate the AM system 100 and / or perform one or more of the methods described herein.

[0058] Figure 3 Certain components of a controller 180 according to an example embodiment of the present disclosure are depicted. The controller 180 may include one or more computing devices 180A that may be used to implement the methods described herein. The computing device 180A may include one or more processors 180B and one or more memory devices 180C. The one or more processors 180B may include any suitable processing device, such as a microprocessor, a microcontroller, an integrated circuit, an application specific integrated circuit (ASIC), a digital signal processor (DSP), a field programmable gate array (FPGA), a logic device, one or more central processing units (CPUs), a graphics processing unit (GPU) (e.g., dedicated to efficiently rendering images), a processing unit that performs other special-purpose calculations, etc. The memory device 180C may include one or more non-transitory computer-readable storage media, such as RAM, ROM, EEPROM, EPROM, flash memory devices, magnetic disks, etc., and / or combinations thereof.

[0059] The storage device 180C may include one or more computer-readable media and may store information accessible by one or more processors 180B, including instructions 180D that may be executed by one or more processors 180B. For example, the storage device 180C may store instructions 180D for running one or more software applications, displaying a user interface, receiving user input, processing user input, etc. In some embodiments, the instructions 180D may be executed by one or more processors 180B to cause one or more processors 180B to perform operations such as one or more parts of the methods described herein. The instructions 180D may be software written in any suitable programming language or that may be implemented in hardware. Additionally and / or alternatively, the instructions 180D may be executed in a logically and / or virtually separate thread on the processor 180B.

[0060] One or more memory devices 180C may also store data 180E that may be retrieved, manipulated, created, or stored by one or more processors 180B. Data 180E may include, for example, data that facilitates the execution of the methods described herein. Data 180E may be stored in one or more databases. One or more databases may be connected to the controller 180 via a high-bandwidth LAN or WAN, or may also be connected to the controller via one or more networks (not shown). One or more databases may be split so that they are located in multiple locations. In some embodiments, data 180E may be received from another device.

[0061] The computing device 180A may also include a communication module or interface 180F for communicating over a network with the controller 180 or one or more other components of the additive manufacturing machine 100. The communication interface 180F may include any suitable components for interfacing with one or more networks, including, for example, a transmitter, a receiver, a port, a controller, an antenna, or other suitable components.

[0062] Now that the structure and construction of the AM system 100 have been described according to an exemplary embodiment of the present subject matter, exemplary methods 200 and 300 for forming matching or paired component pairs or replacement components will be described according to exemplary embodiments of the present subject matter. Methods 200, 300 can be used to form components using the AM machine 100, or to form any other suitable component using any other suitable additive manufacturing machine or system. In this regard, for example, the controller 180 can be configured to implement some or all of the steps of methods 200, 300. In addition, it should be understood that exemplary methods 200, 300 are only discussed herein to describe exemplary aspects of the present subject matter, and are not intended to be limiting.

[0063] Method 200 generally provides a method for forming a component pair. In this regard, the term "component pair" is generally used herein to refer to any two or more components having mating surfaces that have unique geometries that are intended to engage, receive, or otherwise mate with each other. For example, each component within a component pair may define a mating surface that can appropriately mate or engage with surfaces from other components that are part of the component pair. In this regard, the component pairs described herein define mating surfaces having geometries that are complementary to each other and are substantially unique and preferably difficult to copy or replicate using conventional scanning and manufacturing techniques. It should be understood that, according to exemplary embodiments, the term "mating surfaces" may refer to features that do not necessarily contact each other, but can otherwise engage with each other or be accommodated within each other.

[0064] In this way, a manufacturer can form a pair of components for any particular system or machine, and when one of the components in the pair needs to be replaced, for example due to wear, degradation, etc., the replacement part will not be a knock-off part, so that the operator or end-user of the component pair can be assured that the replacement part is genuine hardware, specifically designed for ideal operation of its complementary component. In addition, the end-user may be confident that the replacement part is designed for the operating environment, thereby ensuring safe operation after the original equipment is purchased from the original equipment manufacturer (OEM). Additionally, aspects of the present subject matter may be applied when a component requires repair, is damaged, or is lost altogether. This is because the OEM may hold a specific geometric key associated with the unique geometric surface of the component pair to unlock the genuine replacement part. Thus, the geometric key unlocks the ability to form a genuine replacement part with complementary surface geometry to mate with the other component in the component pair.

[0065] It is worth noting that the description herein relates to a component pair having a first component and a second component. However, it should be understood that, according to alternative embodiments, a component pair need not be limited to two components, but may include any suitable number of components having any suitable number of surfaces for engaging other components that are part of the component pair. In addition, the terms "first" and "second" are not intended to refer to primary and alternative components, nor to indicate any other importance or relative importance of the components.

[0066] Reference now Figure 4, method 200 includes, at step 210, assigning at least one part identifier and a geometric key to the part pair. Typically, the part identifier may be an easily recognizable serial number, bar code, or other part identifier that a user of the part pair may recognize in order to determine what replacement part is needed. For example, if the part pair includes a first part and a second part that are paired together, and the user identifies the second part as needing replacement, the user may locate the part identifier on one or both of the first part and the second part. The part identifier may then be communicated to an OEM, an authorized replacement part manufacturer, or other recognized authentic parts seller having a geometric key associated with the part identifier to order a replacement part.

[0067] According to an exemplary embodiment, each component of a component pair may be identified using the same component identifier (i.e., identifying the pair) as well as a component specific identifier. For example, the component identifier may include a primary serial number (associated with the component pair) and a sub-component identifier (e.g., A, B, C, etc. identifying each component in the component pair). Alternatively, each component may have a unique component identifier, and an external database may be used to identify the component identifiers for each component within the component pair. An authorized replacement part manufacturer may enter the component identifier into a database or system to generate or retrieve a specific geometry key associated with that particular component pair. According to an exemplary embodiment, the step of "looking up in a database" may be as simple as, for example, using a serial number or geometry key to find the correct part drawing or physical part file for the corresponding geometry.

[0068] Step 210 may also include assigning a geometric key to the component pair that is associated with a first geometry and a second geometry that is complementary to the first geometry. As used herein, the term "geometric key" is intended to mean any physical device, software, code, password, or other tangible or intangible key or access tool that is constructed to unlock a unique geometry defined on a mating surface of each component of the component pair. In this regard, for example, the geometric key may define a physical profile of each mating surface that is unique to the component pair or a set of component pairs. Note that, according to an exemplary embodiment, only approved sellers or authorized replacement part manufacturers may hold geometric keys.

[0069] According to an exemplary embodiment, the geometric key is encrypted or otherwise maintained in a secure location to prevent others from easily duplicating a replacement component having a target mating surface geometry. According to an exemplary embodiment, the geometric key and the associated component identifier can be stored in a secure database for later retrieval. In addition, the geometric key can be used to obtain the surface geometry of the first component and the second component of the component pair in any suitable manner. For example, the first geometry of the first component and the second geometry of the second component can be obtained by inputting the geometric key into a mathematical algorithm that generates data indicating such geometry.

[0070] According to alternative embodiments, any other suitable means or methods for converting a geometric key into a usable surface geometry may be used while still within the scope of the present subject matter. According to an exemplary embodiment, any suitable "geometry creation algorithm" may be used to generate the first geometry and the second geometry. For example, the geometric key may be passed to a geometry creation algorithm, such as a random number generator that generates the target surface geometry. According to another embodiment, a Merkle tree may be used to securely generate the first geometry and the second geometry using a geometric key. In this regard, a Merkle tree is a structure that allows content to be efficiently and securely verified by creating a digital fingerprint or geometry associated with a specific geometric key. For example, a Merkle tree is a subject of cryptography and, as an example, may be used as part of a cryptocurrency verification process. It should be understood that the methods described herein for converting a geometric key into a useful surface geometry are exemplary only and are not intended to limit the scope of the present subject matter.

[0071] Step 220 includes determining a first geometric shape using a geometric key, and step 230 includes forming the first geometric shape on a first mating surface of a first component of the component pair. In this regard, once the unique first geometric shape is obtained using the geometric key, the first component can be formed using any suitable manufacturing process or technique. Similarly, step 240 includes determining a second geometric shape using the geometric key, and step 250 includes forming the second geometric shape on a second mating surface of a second component of the component pair.

[0072] According to an exemplary embodiment, the step of forming the first or second geometry may be performed by additive manufacturing, for example, using the AM system 100. However, it should be understood that according to alternative embodiments, any other suitable manufacturing method may be used to form the first component, the second component, and / or their mating surfaces and geometries. For example, all or part of the first component and the second component may be formed by casting, forging, machining, drilling, molding, etc.

[0073] Notably, by using a geometric key associated with a unique mating surface geometry of the pair of components, the first component and the second component can be formed such that they are uniquely compatible with each other and can be joined only when the first geometry of the first mating surface engages or is otherwise received by the second geometry of the second mating surface. Specifically, step 260 can include mating the first component and the second component by combining the second geometry of the second mating surface with the first geometry of the first mating surface.

[0074] Thus, the method 200 is generally configured to form a component group or component pair including a plurality of components that are intended to mate only with other components associated with the component group or component pair. The mating geometry is "locked" in a geometric key that can only be stored or maintained by the original equipment manufacturer or an authorized replacement component manufacturer. Thus, when any component in the component pair needs to be replaced in the future, only those entities in possession of the geometric key can "unlock" the unique geometry of the component mating surfaces to quickly and easily form a true replacement component.

[0075] Method 300 generally relates to the process of obtaining a replacement part. Figure 5 , method 300 includes obtaining a component identifier of a first component at step 310. As described above, the first component may define a first mating surface having a first geometry that is unique to a particular component in a particular component pair. Using the component identifier from the first component or the second component (e.g., a replacement component), a geometric key associated with the component pair may be obtained by a replacement part manufacturer.

[0076] Specifically, step 320 includes obtaining a geometric key associated with the component identifier. It is noteworthy that, as described above, the geometric key can only be obtained by the original component manufacturer or an authorized replacement component manufacturer. In practice, a user of the component pair can identify that the component should be replaced, obtain the component identifier (e.g., a serial number), and transmit the serial number when placing an order for a replacement component (e.g., referred to herein as the second part).

[0077] After receiving the component identifier and the geometric key, step 330 may include determining a second geometric shape using the geometric key. The second geometric shape may be uniquely compatible or complementary to the first geometric shape of the first component to establish a component pair. For example, as described above, the second geometric shape may be obtained by inputting the geometric key into a mathematical algorithm, a random number generator, a Merkle tree, or any other suitable software program or device that generates a unique second geometric shape from the geometric key. Step 340 includes forming the second geometric shape on a second mating surface of the second component of the component pair. Step 350 may include mating the first component with the second component by combining the second geometric shape of the second mating surface with the first geometric shape of the first mating surface.

[0078] Figure 4 and 5 An exemplary control method is depicted having steps performed in a specific order for illustration and discussion. One of ordinary skill in the art using the disclosure provided herein will appreciate that the steps of any method discussed herein may be adapted, rearranged, expanded, omitted, or modified in various ways without departing from the scope of the present disclosure. Furthermore, while aspects of the method are described using the AM machine 100 as an example, it should be understood that the methods may be applied to forming components using any other suitable manufacturing process or system.

[0079] Now roughly refer to Figures 6 to 9 , an exemplary component pair 400 will be described according to an exemplary embodiment of the present subject matter. Due to the similarity between the embodiments described in these figures, the same reference numerals may be used to refer to the same or similar features. In addition, the component pairs 400 can be formed using methods 200 and 300 using any suitable manufacturing method or process (e.g., additive manufacturing, machining, etc.). The components shown are exemplary only and are intended to illustrate aspects of the present subject matter without limiting its scope.

[0080] Specifically refer to Figure 6 , a schematic diagram of the mating surfaces of a first component 402 and a second component 404 will be described according to an exemplary embodiment. This embodiment is intended as a simplified illustration of how any surface of a component can be mated with a complementary surface of another component of a component pair or component group. As shown, the first component 402 defines a first mating surface 406, and the second component 404 defines a second mating surface 408. According to this illustrated embodiment, only a portion of the mating surfaces 406, 408 have unique complementary geometries. This area is referred to herein as a keyed area 410.

[0081] As shown, within the encryption region 410, a first geometric shape 412 is defined on the first mating surface 406. Similarly, within the encryption region 410, a second geometric shape 414 is defined on the second mating surface 408. Thus, the first component 402 and the second component 404 can only be joined if the second geometric shape 414 is received within or engages the first geometric shape 412. In this manner, the component pair 400 can be designed such that the first component 402 and the second component 404 are properly mated or engaged only when the first component 402 and the second component 404 are truly and correctly aligned (e.g., such that the encryption region 410 is aligned and the first geometric shape 412 is received within the second geometric shape 414).

[0082] Although the first geometric shape 412 and the second geometric shape 414 are illustrated and described above as being formed on exposed or otherwise visible surfaces of the first component 402 and the second component 404, it should be understood that the present subject matter is not limited to visible or "line of sight" features. In this regard, for example, the first geometric shape 412 and / or the second geometric shape 414 can be at least partially defined on a surface within their respective components 402, 404. Alternatively, the components 402, 404 can define additional features that hide or obscure the first geometric shape 412 and / or the second geometric shape 414. Furthermore, according to an exemplary embodiment, one or both of the first geometric shape 412 and / or the second geometric shape 414 can be hidden from or not directly in line of sight from the exterior of the components 402, 404. The first geometric shape 412 and / or the second geometric shape 414 can alternatively be positioned at any suitable location on the first component 402 and / or the second component 404 that is inaccessible or otherwise difficult to detect or interrogate.

[0083] Reference now Figure 7, the component pair 400 may include a tray 420 that receives a plurality of airfoils 422, such as for a gas turbine engine. In this regard, the tray 420 may be the first component 402 and may define a first geometry 412 in the form of a slot 424 defined in the tray 420. The second component 404 may include one or more airfoils 422 that define a second geometry 414 in the form of a dovetail 426 that is complementary to the slot 424. Notably, in a manner similar to that described above, the slot 424 in the tray 420 and the dovetail 426 of each airfoil 422 are associated with a geometric key held by the original equipment manufacturer or an authorized replacement part manufacturer. Thus, when an end user wants to replace the airfoil 422, they must obtain a part identifier (e.g., identified herein by reference numeral 428 on the tray 420, the airfoil 422, or both), provide the part identifier 428 to the replacement part manufacturer to order a replacement airfoil 422. As described above, part identifier 428 may be used to obtain a geometric key that may unlock the geometry of dovetail 426 necessary to be compatible with slot 424 of tray 420 .

[0084] It should be understood that any other suitable complementary geometric shapes may be defined or associated with the components of component pair 400 while remaining within the scope of the present subject matter. For example, component pair 400 may include a first tube that is intended to be pressed into or otherwise received within a second tube. A geometric key may define a non-circular diameter of each of the first tube and the second tube so that only the first tube can be received within the second tube. Additionally, any other suitable unique size or geometry may be used to ensure that the first tube and the second tube form a unique component pair as described herein. Other variations and modifications are possible within the scope of the present subject matter.

[0085] Reference now Figure 8 and 9 , the first part and the second part may be flanges formed to engage and be fixed only with complementary flanges. For example, Figure 8A flange 440 (e.g., equivalent to the first component 402) is shown that defines a radial direction R and a circumferential direction C. As shown, the flange 440 defines a plurality of bolt holes 442 spaced apart in the circumferential direction C to receive a complementary flange (e.g., equivalent to the second component 404) of bolts or studs (not shown) having similar spacing and size. It is noteworthy that the plurality of bolt holes 442 are spaced apart in an uneven pattern around the first mating surface 406, and the complementary bolt studs (not shown) are similarly spaced. Specifically, the bolt hole spacing (e.g., identified by reference numeral 444) can vary in an uneven manner around the circumference of the flange 440. In addition, the bolt holes 442 can be positioned at varying radial positions or can have varying sizes. All of these features can define or be associated with a geometric key held by the manufacturer.

[0086] Similarly, according to alternative embodiments, the first geometric shape 412 and the second geometric shape 414 may include any suitable interlocking features. For example, the first geometric shape 412 may be a male or convex portion or feature, and the second geometric shape 414 may be a female or concave portion or feature that interlock with each other such that the male portion cannot be disengaged from the female portion after receipt, thereby forming an interlocking assembly.

[0087] For example, Fig. 9 A first flange 450 is shown, the first flange 450 defining a plurality of dovetail pins 452 (e.g., a concave portion) and a second flange 454 defining a plurality of tails 456 (e.g., a convex portion) that are received within the dovetail pins 452. Similar to the manner described above, the size and spacing of the dovetail pins 452 and tails 456 can vary in a non-uniform manner and can be encoded into the geometric key. In this manner, in order to obtain a replacement part (e.g., the second flange 454), the end user must obtain the part identifier 428 and provide the part identifier 428 to the authorized manufacturer to order the replacement part.

[0088] According to other embodiments, the geometric key can include an effective deterrent to replacing parts with imitations or replicas. In this regard, rather than simply relying on the inability to pair the surfaces of incompatible parts, the component pairs can include active triggers that must be engaged for the components or systems to function properly. Alternatively, these active triggers can deactivate or disable mechanical systems, provide warning indications or notifications to users, etc. Thus, for example, when the first component 402 and the second component 404 are properly paired, the trigger can be engaged and some action can be performed in response. For example, if the appropriate, authentic airfoil 422 does not have a feature on the trigger disk 420, the gas turbine engine can be disabled.

[0089] For example, refer again to Figure 7, the disk 420 may define a trigger feature 460 positioned near the first mating surface 406 or within the slot 424 of the disk 420, and the dovetail 426 of the airfoil 422 may define a physical trigger 462. When the physical dovetail 426 engages the slot 424, the physical trigger 462 may depress the trigger feature 460. The gas turbine may also be configured to shut down or provide a warning if the trigger feature 460 is not triggered. It should be understood that any other suitable active trigger, switch, electrical contact or other feature may be uniquely defined by the component pair 400 to perform any other suitable action or function, while still within the scope of the present subject matter, according to alternative embodiments.

[0090] This written description uses examples to disclose the invention, including the best mode, and also enables those skilled in the art to practice the invention, including making and using any device or system and performing any combined method. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. If such other examples include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims, then these other examples are intended to fall within the scope of the claims.

[0091] Further aspects of the invention are provided by the subject matter of the following clauses:

[0092] 1. A method for forming a component pair, the method comprising: obtaining a geometric key associated with a component identifier of a first component, the first component defining a first mating surface having a first geometric shape; determining a second geometric shape using the geometric key, the second geometric shape being complementary to the first geometric shape; and forming the second geometric shape on a second mating surface of a second component of the component pair.

[0093] 2. The method according to any preceding clause, further comprising: mating the first component and the second component by combining the second geometry of the second mating surface with the first geometry of the first mating surface.

[0094] 3. A method according to any preceding clause, wherein determining the second geometry using the geometry key comprises: using the geometry key and a mathematical algorithm to generate data indicative of the second geometry.

[0095] 4. A method according to any preceding clause, wherein determining the second geometric shape using the geometric key comprises: using the geometric key and a geometry creation algorithm to generate data indicative of the second geometric shape.

[0096] 5. A method according to any preceding clause, wherein the geometric key is encrypted.

[0097] 6. The method according to any preceding clause, wherein forming the second geometry comprises additive manufacturing at least a portion of the second component.

[0098] 7. The method according to any of the preceding clauses, further comprising: recording the geometric key and the component identifier in a database for later retrieval.

[0099] 8. The method according to any of the preceding clauses, further comprising: assigning at least one component identifier and the geometric key to the component pair; determining a first geometric shape using the geometric key; and forming the first geometric shape on the first mating surface of the first component of the component pair.

[0100] 9. A method according to any of the preceding clauses, wherein the first mating surface further defines a trigger feature and the second mating surface defines a trigger, wherein the trigger engages with the trigger feature only when the pair of components are properly paired, and the method further includes: performing an action in response to the trigger feature engaging with the trigger.

[0101] 10. A component pair comprising: a first component, the first component including a first mating surface, the first mating surface defining a first geometric shape associated with a geometric key; and a second component, the second component including a second mating surface, the second mating surface defining a second geometric shape, the second geometric shape being determined using the geometric key and complementary to the first geometric shape, wherein the first component and the second component can be properly mated together only when the first geometric shape is received by the second geometric shape.

[0102] 11. The component pair according to any preceding clause, wherein the first geometry of the first mating surface comprises a male feature, and wherein the second geometry of the second mating surface comprises a female feature, the male feature and the female feature forming an interlocking component.

[0103] 12. A component pair according to any preceding clause, wherein the first geometry of the first mating surface comprises a plurality of bolt holes spaced in an uneven pattern around the first mating surface, and wherein the second geometry of the second mating surface is a plurality of bolt studs spaced in the uneven pattern around the second mating surface, and wherein the uneven pattern comprises the plurality of bolt holes being not equidistant around the circumferential direction and varying in position along the radial direction.

[0104] 13. The component pair according to any preceding clause, wherein the first mating surface and the second mating surface are mounting flanges.

[0105] 14. A component pair according to any of the preceding clauses, further comprising: a trigger feature positioned near the first mating surface of the first component; and a trigger positioned near the second mating surface of the second component, wherein the trigger engages with the trigger feature only when the component pair is properly paired.

[0106] 15. The component pair according to any preceding clause, wherein the controller performs an action in response to the trigger feature being engaged.

[0107] 16. The component pair according to any preceding clause, wherein the first geometry comprises a plurality of dovetail pins extending from the first mating surface, and wherein the second geometry comprises a plurality of tails defined in the second mating surface.

[0108] 17. A component pair according to any preceding clause, wherein the first component is a first tube having a non-circular cross-sectional profile, and wherein the second component is a second tube received within the first tube, the second tube having a complementary non-circular cross-sectional profile.

[0109] 18. A method for forming a component pair, the method comprising: assigning a geometric key to the component pair; determining a first geometric shape using the geometric key; forming the first geometric shape on a first mating surface of a first component of the component pair; determining a second geometric shape using the geometric key; and forming the second geometric shape on a second mating surface of a second component of the component pair.

[0110] 19. A method according to any preceding clause, further comprising: assigning a component identifier associated with the geometric key to the component pair; and marking the first component and the second component using the component identifier.

[0111] 20. The method according to any of the preceding clauses, further comprising: recording the geometric key and the component identifier in a database for later retrieval.

Claims

1. A method for forming a component pair, characterized in that The method comprises: obtaining a geometry key associated with a component identifier of a first component, the first component defining a first mating surface having a first geometry; determining a second geometric shape using the geometric key, the second geometric shape being complementary to the first geometric shape; and forming the second geometric shape on a second mating surface of a second component of the component pair; Wherein, using the geometric key to determine the second geometric shape comprises: generating data indicative of said second geometry using said geometry key and a mathematical algorithm; or Data indicative of the second geometric shape is generated using the geometry key and a geometry creation algorithm.

2. The method according to claim 1, characterized in that Further including: The first component and the second component are mated by combining the second geometry of the second mating surface with the first geometry of the first mating surface.

3. The method according to claim 1, characterized in that in, The geometry key is encrypted.

4. The method according to claim 1, characterized in that: in, Forming the second geometry includes additive manufacturing at least a portion of the second component.

5. The method according to claim 1, characterized in that Further including: The geometry key and the component identifier are recorded in a database for later recall.

6. The method according to claim 1, characterized in that Further including: assigning at least one component identifier and the geometry key to the component pair; determining a first geometric shape using the geometric key; and The first geometric shape is formed on the first mating surface of the first component of the component pair.

7. The method according to claim 1, characterized in that in, The first mating surface further defines a trigger feature, and the second mating surface defines a trigger, wherein the trigger engages the trigger feature only when the pair of components are properly mated, the method further comprising: An action is performed in response to the trigger feature engaging the trigger.

8. A component pair, characterized in that: include: a first component, the first component comprising a first mating surface, the first mating surface defining a first geometric shape associated with a geometric key; and a second component, the second component including a second mating surface, the second mating surface defining a second geometric shape, the second geometric shape being determined using the geometric key and being complementary to the first geometric shape, wherein the first component and the second component can be properly mated together only when the first geometric shape is received by the second geometric shape; Wherein, using the geometric key to determine the second geometric shape comprises: generating data indicative of said second geometry using said geometry key and a mathematical algorithm; or Data indicative of the second geometric shape is generated using the geometry key and a geometry creation algorithm.

9. The component pair according to claim 8, characterized in that: in, The first geometry of the first mating surface comprises a male feature, and wherein the second geometry of the second mating surface comprises a female feature, the male feature and the female feature forming an interlocking assembly.

10. The component pair according to claim 8, characterized in that: in, The first geometry of the first mating surface comprises a plurality of bolt holes spaced in a non-uniform pattern around the first mating surface, and wherein the second geometry of the second mating surface is a plurality of bolt studs spaced in the non-uniform pattern around the second mating surface, and wherein the non-uniform pattern comprises the plurality of bolt holes being not equidistant around a circumferential direction and varying in position along a radial direction.

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