Cooling dual wall component of a gas

Abstract

A component comprising: a first wall; a second wall having a second wall thickness and positioned at a distance from the first wall; a coating layer applied to the first wall; an aperture formed in the coating and the first wall, the aperture defining an aperture centerline; and a projection coupled to the second wall and intersecting the bore centerline, the projection cooperating with the second wall to define a projection thickness greater than the second wall thickness.

Description

Background Technology

[0001] A gas turbine engine typically includes a compressor section, a turbine section, and a combustion section located between the compressor section and the turbine section. The compressor section includes multi-stage rotating compressor blades and stationary compressor impeller blades. The combustion section typically includes multiple combustion chambers. The turbine section includes multi-stage rotating turbine blades and stationary turbine impeller blades. The turbine blades and turbine impeller blades typically operate at high temperatures and are internally cooled.

[0002] Components of a gas turbine engine, such as the combustion chamber, rotating turbine blades, and stationary turbine blades, can have double walls defining a pressure chamber between them. During operation of the gas turbine engine, this component experiences high temperatures. A perforation can be formed in one of the walls to allow cooling fluid to enter the pressure chamber and cool the component. A coating can be applied to the wall to cover the perforation. The perforation needs to be reopened. During the reopening process, the thickness of the other wall can be reduced. Summary of the Invention

[0003] In one aspect, a component is provided. The component includes: a first wall; a second wall having a second wall thickness and positioned at a distance from the first wall; a coating applied to the first wall; a hole formed in the coating and the first wall, the hole defining a hole centerline; and a protrusion connected to the second wall and intersecting the hole centerline, the protrusion engaging with the second wall to define a protrusion thickness greater than the thickness of the second wall.

[0004] In one aspect, a method for manufacturing a component is provided. The method includes: positioning a first wall; positioning a second wall at a distance from the first wall, the second wall having a second wall thickness; forming a hole in the first wall, the hole defining a centerline; applying a coating to the first wall, a portion of the coating covering the hole; attaching a protrusion to the second wall such that the protrusion intersects the centerline of the hole; and removing a portion of the coating covering the hole. Attached Figure Description

[0005] To facilitate identification of any discussion of a particular element or action, one or more of the highest-order digits in the reference numerals indicate the drawing number in which the element was first introduced.

[0006] Figure 1 The illustration shows a longitudinal cross-section of a gas turbine engine taken along a plane containing the longitudinal axis or central axis.

[0007] Figure 2 The diagram illustrates the applicability to... Figure 1 A schematic cross-sectional view of a component used in a gas turbine engine.

[0008] Figure 3 The illustration shows a coated material. Figure 2 A schematic cross-sectional view of the component.

[0009] Figure 4 The diagram shows Figure 3 A schematic cross-sectional view of the component in the initial state of the process of reopening the hole.

[0010] Figure 5 The diagram shows Figure 3 A schematic cross-sectional view of the component in the final state of the process of reopening the hole.

[0011] Figure 6 The diagram shows Figure 3 A schematic cross-sectional view of the component in its operating state.

[0012] Figure 7 Another schematic cross-sectional view of the component is shown.

[0013] Figure 8 The illustration shows a coated material. Figure 7 A schematic cross-sectional view of the component.

[0014] Figure 9 The diagram shows Figure 7 A schematic cross-sectional view of the component in its operating state. Detailed Implementation

[0015] Before describing any embodiment of the invention in detail, it should be understood that the invention is not limited in its application to the details of the construction and arrangement of the components set forth in this description or illustrated in the following drawings. The invention can have other embodiments and can be practiced or performed in various ways. Furthermore, it should be understood that the wording and terminology used herein are for descriptive purposes and should not be considered limiting.

[0016] Various techniques relating to the systems and methods will now be described with reference to the accompanying drawings, wherein similar reference numerals always denote similar elements. The drawings discussed below in this patent document, as well as the various embodiments used to describe the principles of this disclosure, are merely illustrative and should not be construed in any way as limiting the scope of this disclosure. Those skilled in the art will understand that the principles of this disclosure can be implemented with any suitably arranged device. It should be understood that functions described as being performed by certain system elements can be performed by multiple elements. Similarly, for example, an element can be configured to perform functions described as being performed by multiple elements. Many of the inventive teachings of this application will be described with reference to exemplary, non-limiting embodiments.

[0017] Furthermore, it should be understood that, unless explicitly limited in some examples, the words or phrases used herein should be interpreted broadly. For example, the terms “including,” “having,” and “comprising,” and their derivatives, mean inclusion rather than limitation. Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” are also intended to include the plural forms. Additionally, the term “and / or” as used herein refers to and covers any combination and all possible combinations of one or more of the associated listed items. Unless the context clearly indicates otherwise, the term “or” is inclusive, meaning and / or. The phrases “associated with” and “related to,” and their derivatives, can mean including, being included in, interconnected with, containing, contained within, connected to or connected with, linked to or connected with, capable of communicating with, cooperating with, interleaving, juxtaposing, approaching, combining to or combined with, having, possessing the characteristics of, etc. Furthermore, although multiple embodiments or constructions may be described herein, any features, methods, steps, components, etc., described with respect to one embodiment are equally applicable to other embodiments unless otherwise specifically stated.

[0018] Furthermore, although the terms “first,” “second,” “third,” etc., may be used herein to refer to various elements, information, functions, or actions, these elements, information, functions, or actions should not be limited by these terms. Rather, these numerical adjectives are used to distinguish different elements, information, functions, or actions from one another. For example, without departing from the scope of this disclosure, a first element, first information, first function, or first action may be referred to as a second element, second information, second function, or second action, and similarly, a second element, second information, second function, or second action may be referred to as a first element, first information, first function, or first action.

[0019] Furthermore, in this specification, the term "axial" or "axially" refers to the direction along the longitudinal axis of the gas turbine engine. The term "radial" or "radially" refers to the direction perpendicular to the longitudinal axis of the gas turbine engine. The term "downstream" or "rear" refers to the direction along the flow direction. The term "upstream" or "forward" refers to the direction opposite to the flow direction.

[0020] Additionally, unless the context clearly indicates otherwise, the term "adjacent to" can mean: an element is fairly close to another element but not in contact with it, or that the element is in contact with another part. Furthermore, unless otherwise clearly stated, the phrase "based on" is intended to mean "at least partially based on". The terms "about" or "approximately" or similar terms are intended to cover variations in values ​​within normal industrial manufacturing tolerances for that dimension. If no industry standard is available, unless otherwise stated, twenty percent of the variation will fall within the meaning of these terms.

[0021] Figure 1 An example of a gas turbine engine 100 is illustrated, which includes a compressor section 102, a combustion section 104, and a turbine section 106 arranged along a central axis 112. The compressor section 102 includes a plurality of compressor stages 114, each compressor stage 114 including a set of fixed compressor blades 116 or adjustable guide vanes and a set of rotating compressor blades 118. A rotor 134 supports the rotating compressor blades 118 for rotation about the central axis 112 during operation. In some configurations, a single integral rotor 134 extends the length of the gas turbine engine 100 and is supported for rotation by bearings at both ends. In other configurations, the rotor 134 is assembled from a plurality of individual spools attached to each other, or may include a plurality of disc sections attached via one or more bolts.

[0022] The compressor section 102 is in fluid communication with the inlet section 108 to allow the gas turbine engine 100 to draw atmospheric air into the compressor section 102. During operation of the gas turbine engine 100, the compressor section 102 draws in atmospheric air and compresses it for delivery to the combustion section 104. The illustrated compressor section 102 is an example of a compressor section 102, wherein other arrangements and designs are possible.

[0023] In the illustrated configuration, the combustion section 104 includes a plurality of individual combustion chambers 120, each of which operates to mix a fuel stream with compressed air from the compressor section 102 and to combust the air-fuel mixture to produce a high-temperature, high-pressure combustion gas stream or exhaust gas stream 122. Of course, many other arrangements of the combustion section 104 are possible.

[0024] The turbine section 106 includes multiple turbine stages 124, each of which includes a plurality of stationary turbine blades 126 and a plurality of rotating turbine blades 128. The turbine stages 124 are arranged to receive exhaust gas 122 from the combustion section 104 at a turbine inlet 130 and to expand the gas to convert thermal and pressure energy into rotational or mechanical work. The turbine section 106 is connected to the compressor section 102 to drive the compressor section 102. For a gas turbine engine 100 used for power generation or as a prime mover, the turbine section 106 is also connected to a generator, pump, or other device to be driven. Similar to the compressor section 102, other designs and arrangements of the turbine section 106 are possible.

[0025] The exhaust section 110 is located downstream of the turbine section 106 and arranged to receive the expanded exhaust gas 122 flow from the final turbine stage 124 in the turbine section 106. The exhaust section 110 is arranged to effectively guide the exhaust gas 122 away from the turbine section 106 to ensure the efficient operation of the turbine section 106. Many variations and design differences are possible in the exhaust section 110. Therefore, the exhaust section 110 illustrated is merely one example of these variations.

[0026] The control system 132 is coupled to the gas turbine engine 100 and operates to monitor various operating parameters and control various operations of the gas turbine engine 100. In a preferred configuration, the control system 132 is typically microprocessor-based and includes memory devices and data storage devices for collecting, analyzing, and storing data. Additionally, the control system 132 provides output data to various devices, including monitors, printers, indicators, etc., which allow users to interact with the control system 132 to provide inputs or adjustments. In the example of a power generation system, the user can input a power output setpoint, and the control system 132 can adjust various control inputs to achieve that power output efficiently.

[0027] The control system 132 can control various operating parameters, including but not limited to variable inlet guide vane position, fuel flow rate and pressure, engine speed, valve position, generator load, and generator excitation. Of course, other applications may have fewer or more controllable devices. The control system 132 also monitors various parameters to ensure proper operation of the gas turbine engine 100. Some of the monitored parameters may include inlet air temperature, compressor outlet temperature and pressure, combustion chamber outlet temperature, fuel flow rate, generator power output, bearing temperature, etc. Many of these measurements are displayed to the user and recorded for later review if needed.

[0028] Figure 2The figure shows a schematic cross-sectional view of component 200. Component 200 can be a component of the gas turbine engine 100, such as combustion chamber 120, stationary turbine blade 126, rotating turbine blade 128, or any other suitable component.

[0029] Component 200 has two walls, including a first wall 202 and a second wall 204, the second wall 204 being positioned at a distance from the first wall 202. A pressurization chamber 206 is defined between the first wall 202 and the second wall 204. The pressurization chamber 206 may also be formed by an internal channel within a single wall. In this arrangement, the pressurization chamber 206 divides the single wall into the first wall 202 and the second wall 204.

[0030] The first wall 202 has: an inner surface 214 facing the pressurization chamber 206; and an outer surface 216 opposite to and away from the pressurization chamber 206. A hole 208 is formed in the first wall 202, penetrating from the outer surface 216 to the inner surface 214. The hole 208 defines a centerline 212.

[0031] The second wall 204 has: a second inner wall surface 218 facing the first inner wall surface 214 and towards the pressurization chamber 206; and a second outer wall surface 220 opposite to the second inner wall surface 218 and away from the pressurization chamber 206. The second wall 204 has a second wall thickness defined as the shortest distance between the second inner wall surface 218 and the second outer wall surface 220.

[0032] The protrusion 210 connects to the second wall 204 at the outer surface 220 of the second wall and intersects the centerline 212 of the hole. The protrusion 210 has a raised outer surface 224 facing away from the pressurization chamber 206. The protrusion 210 mates with the second wall 204 to define a protrusion thickness that is a linear distance between the inner surface 218 of the second wall and the outer surface 224 of the protrusion. The protrusion thickness is greater than the thickness of the second wall. The protrusion thickness varies along the second wall 204. In other configurations, the protrusion thickness may be the same along the second wall 204.

[0033] The protrusion 210 has a semi-circular cross-section. The protrusion 210 defines a protrusion centerline 222 collinear with the hole centerline 212. In other configurations, the protrusion 210 may have cross-sectional shapes other than semi-circular, such as elliptical, rectangular, etc. The protrusion 210 and the second wall 204 are made of the same material. The protrusion 210 and the second wall 204 are made of the same material and formed in a single continuous process. The protrusion 210 and the second wall 204 are formed by additive manufacturing, such as selective laser melting in a layer-by-layer process. In other configurations, the protrusion 210 and the second wall 204 may be formed by other single continuous processes such as casting, machining, forming, etc. The protrusion 210 and the second wall 204 may also be made of different materials and / or may be formed as two separate parts and joined together, for example, by welding or other joining methods.

[0034] The first wall 202, the second wall 204, and the protrusion 210 are made of the same material. The first wall 202, the second wall 204, the hole 208, and the protrusion 210 are formed in a single, continuous process. The first wall 202, the second wall 204, the hole 208, and the protrusion 210 are formed by additive manufacturing, such as selective laser melting in a layer-by-layer process. In other configurations, the first wall 202, the second wall 204, the hole 208, and the protrusion 210 can be formed by other single, continuous processes such as casting, machining, forming, etc. The first wall 202, the second wall 204, and the protrusion 210 may also be made of different materials and / or can be formed as separate parts and joined together, for example, by welding or other joining methods.

[0035] Figure 3 A schematic cross-sectional view of a component 200 having a coating 302 is shown. The coating 302 is applied to the first wall 202 at the outer surface 216 of the first wall. A portion of the coating 302 covers the hole 208.

[0036] Coating 302 has an inner coating surface 304 connected to the outer surface 216 of the first wall. Coating 302 has an outer coating surface 306 opposite to the inner coating surface 304. Coating 302 defines a coating thickness that is the shortest distance between the inner coating surface 304 and the outer coating surface 306. The coating thickness can vary along the first wall 202. Coating 302 is a thermal barrier coating, although other coatings are also possible. In other configurations, coating 302 may cover a portion of the hole 208.

[0037] Figure 4 The diagram shows Figure 3A schematic cross-sectional view of component 200 in the initial state of the process of reopening hole 208. Drill 402 is used to remove a portion of coating 302 covering hole 208. Drill 402 is a laser drill that generates a laser beam 404. The laser beam 404 can be a continuous laser beam or a pulse of laser beam. In other configurations, drill 402 can be other types of drills; for example, drill 402 can have a physical rotary cutting tool, such as a drill bit.

[0038] Figure 5 The diagram shows Figure 3 A schematic cross-sectional view of component 200 at the end of the process of reopening hole 208. The portion of coating 302 covering hole 208 is removed by laser beam 404. Hole 208 is reopened and extends through coating 302 and first wall 202. Laser beam 404 can pass through hole 208 and pressurization chamber 206 and strike second wall 204.

[0039] Figure 6 The diagram shows Figure 3 A schematic cross-sectional view of component 200 in its operating state. Hole 208 extends through coating 302 and first wall 202. A blind hole 602 is formed in second wall 204, the blind hole 602 having a blind hole end surface 604. The blind hole 602 is formed by laser beam 404 during the step of removing a portion of coating 302 covering hole 208.

[0040] Blind hole 602 defines a blind hole centerline 606 collinear with the hole centerline 212. Blind hole 602 and protrusion 210 cooperate to define a minimum wall thickness, which is the shortest distance between the blind hole end surface 604 and the outer surface 224 of the protrusion. The minimum wall thickness is equal to or greater than a second wall thickness.

[0041] Figure 7 Another schematic cross-sectional view of component 200 is shown. Component 200 includes a plurality of holes 208 formed in a first wall 202 and penetrating the first wall 202 from an outer surface 216 to an inner surface 214. The plurality of holes 208 are distributed along the first wall 202 and spaced apart from each other. Each of the plurality of holes 208 defines a hole centerline 212.

[0042] A plurality of protrusions 210 are connected to the second wall 204 at the outer surface 220 of the second wall. Each of the plurality of protrusions 210 has a semi-circular cross-section. Each protrusion 210 defines a protrusion centerline 222 collinear with the corresponding bore centerline 212. Each protrusion 210 has a protruding outer surface 224 facing away from the pressurization chamber 206. Each protrusion 210 mates with the second wall 204 to define a protrusion thickness that is a linear distance between the inner surface 218 of the second wall and the protrusion outer surface 224. The protrusion thickness is greater than the thickness of the second wall.

[0043] Multiple protrusions 210 have the same cross-sectional shape, the same size, and the same material. In other configurations, multiple protrusions 210 may have the same cross-sectional shape other than a semicircle, such as an ellipse, a rectangle, etc. Multiple protrusions 210 may have different cross-sectional shapes, different sizes, and / or different materials.

[0044] The plurality of protrusions 210 and the second wall 204 comprise the same material and are formed in a single, continuous process. The plurality of protrusions 210 and the second wall 204 are formed by additive manufacturing, such as selective laser melting in a layer-by-layer process. In other configurations, the plurality of protrusions 210 and the second wall 204 may be formed by other single, continuous processes such as casting, machining, forming, etc. The plurality of protrusions 210 and the second wall 204 may also comprise different materials and / or may be formed as two separate pieces and joined together, for example, by welding or other joining methods.

[0045] The first wall 202, the second wall 204, and the plurality of protrusions 210 comprise the same material. The first wall 202, the second wall 204, the plurality of holes 208, and the plurality of protrusions 210 are formed in a single continuous process. The first wall 202, the second wall 204, the plurality of holes 208, and the plurality of protrusions 210 are formed by additive manufacturing, such as selective laser melting in a layer-by-layer process or similar to additive manufacturing. In other configurations, the first wall 202, the second wall 204, the plurality of holes 208, and the plurality of protrusions 210 are formed in a single continuous process other than additive manufacturing, such as casting, machining, forming, etc. The first wall 202, the second wall 204, and the plurality of protrusions 210 may also comprise different materials and / or may be formed as separate parts and joined together, for example, by welding or other joining methods.

[0046] Figure 8 The illustration shows a coating 302. Figure 7 A schematic cross-sectional view of component 200. A coating 302 is applied to the first wall 202 at the outer surface 216 of the first wall. The inner surface 304 of the coating is connected to the outer surface 216 of the first wall. A portion of the coating 302 covers the corresponding hole 208.

[0047] The coating thickness is the shortest distance between the inner surface 304 and the outer surface 306 of the coating. The coating thickness varies along the first wall 202. Figure 8 In one configuration, the coating thickness decreases from one end of the first wall 202 to the other end. In other configurations, the coating thickness may vary along the first wall 202. The coating 302 may be a thermal barrier coating, and other coatings are also possible.

[0048] Figure 9 The diagram shows Figure 7 A schematic cross-sectional view of component 200 in its operating state. Multiple holes 208 pass through... Figure 4 and Figure 5 The process described in the text is reopened. Multiple holes 208 are reopened and extend through the coating 302 and the first wall 202.

[0049] During the step of removing the portion of coating 302 covering the plurality of holes 208, a plurality of blind holes 602 are formed in the second wall 204 and / or in the second wall 204 and the protrusion 210. Each of the plurality of blind holes 602 has a blind hole end surface 604. Each blind hole 602 defines a blind hole centerline 606 collinear with the hole centerline 212. Each blind hole 602 and its corresponding protrusion 210 cooperate to define a minimum wall thickness, which is the shortest distance between the blind hole end surface 604 and the outer surface 224 of the protrusion. The minimum wall thickness is equal to or greater than the second wall thickness. The minimum wall thickness is different for each blind hole 602 and its corresponding protrusion 210. In other configurations, the minimum wall thickness may be the same for the plurality of blind holes 602 and their corresponding protrusions 210.

[0050] During manufacturing, component 200 is first formed with a hole 208 penetrating a first wall 202. A coating 302 is then applied to the first wall 202, with a portion of the coating 302 covering the hole 208. The portion of the coating 302 covering the hole 208 is then removed to reopen the hole 208. The power of a drill 402 is set to remove the portion of the coating 302 covering the hole 208. During the step of removing the portion of the coating 302, a laser beam 404 of the drill 402 can penetrate the hole 208 and strike the second wall 204 at the region intersecting with the hole centerline 212. This may occur due to variations in coating thickness. Therefore, when the hole 208 is reopened, the thickness of the second wall can decrease at the region intersecting with the hole centerline 212. A protrusion 210 connects to the second wall 204 at the region intersecting with the hole centerline 212. The protrusion 210 is a localized material accumulation on the second wall 204 to ensure that a minimum wall thickness is maintained to accommodate variations in coating thickness. The minimum wall thickness is equal to or greater than the second wall thickness. The protrusion 210 reduces the complexity of manufacturing the coated double-walled component 200 with the hole 208 while maintaining the minimum wall thickness. No protrusion 210 connects to the second wall 204 in areas not intersecting with the hole centerline 212, which reduces material costs. The component 200, including the first wall 202, second wall 204, hole 208, and protrusion 210, can be manufactured through a single continuous process, such as additive manufacturing.

[0051] Component 200 can be a component of the gas turbine engine 100, such as combustion chamber 120, stationary turbine blades 126, rotating turbine blades 128, or any perforated double-walled component. Pressure chamber 206 can be an internal cooling passage. Orifice 208 can be a cooling hole to allow cooling fluid to enter or exit pressure chamber 206, thereby cooling the turbine components. Orifice 208 can be an impingement cooling hole or a film cooling hole for the turbine components.

[0052] Although exemplary embodiments of the present disclosure have been described in detail, those skilled in the art will understand that various modifications, substitutions, variations and improvements may be made to the content disclosed herein without departing from the spirit and scope of the broadest form of the disclosure.

[0053] Nothing described in this application should be construed as implying that any particular element, step, action, or function is an essential element that must be included within the scope of the claims: the scope of the patent subject matter is defined only by the permissible claims. Furthermore, unless the exact phrase "means for…" is followed by a participle, these claims are not intended to invoke a means-plus-function claim construction.

[0054] List of reference numerals in the attached figures

[0055] 100 gas turbine engine

[0056] 102 Compressor Section

[0057] 104 Combustion Section

[0058] 106 Turbine Section

[0059] 108 entrance section

[0060] 110 exhaust section

[0061] 112 central axis

[0062] 114 compressor stage

[0063] 116 Fixed compressor impeller

[0064] 118 rotary compressor blades

[0065] 120 Combustion Chamber

[0066] 122 waste gas

[0067] 124 turbo-grade

[0068] 126 Fixed Turbine Blade

[0069] 128 rotating turbine blades

[0070] 130 Turbo Inlet

[0071] 132 control system

[0072] 134 rotor

[0073] 200 parts

[0074] 202 First Wall

[0075] 204 Second Wall

[0076] 206 booster chamber

[0077] 208 holes

[0078] 210 protrusions

[0079] Centerline of 212 holes

[0080] 214 First wall inner surface

[0081] 216 First wall outer surface

[0082] 218 Second wall inner surface

[0083] 220 Second wall outer surface

[0084] 222 raised center line

[0085] 224 raised outer surface

[0086] 302 coating

[0087] 304 coating inner surface

[0088] 306 coating outer surface

[0089] 402 drilling rig

[0090] 404 laser beam

[0091] 602 blind hole

[0092] 604 blind hole end surface

[0093] 606 Blind Hole Centerline

Claims

1. A component comprising: First wall; The second wall has a second wall thickness and is positioned at a certain distance from the first wall; A coating is applied to the first wall; A hole, the hole being formed in the coating and the first wall, the hole defining a centerline; as well as A protrusion is connected to the second wall and intersects the center line of the hole. The protrusion cooperates with the second wall to define a protrusion thickness greater than the thickness of the second wall.

2. The component according to claim 1, wherein, The protrusion has a semi-circular cross-section.

3. The component according to claim 1, wherein, The protrusion is defined by a protrusion centerline that is collinear with the centerline of the hole.

4. The component according to claim 1, further comprising a blind hole formed in the second wall, wherein, The blind hole is defined by a blind hole centerline that is collinear with the centerline of the hole.

5. The component according to claim 4, wherein, The blind hole and the protrusion cooperate to define a minimum wall thickness, which is equal to or greater than the second wall thickness.

6. The component according to claim 5, wherein, The blind hole includes a blind hole end surface, wherein the protrusion includes a protrusion outer surface, and wherein the minimum wall thickness is the shortest distance between the blind hole end surface and the protrusion outer surface.

7. The component according to claim 1, wherein, The first wall, the second wall, the hole, and the protrusion are formed in a single, continuous process.

8. The component according to claim 1, wherein, The coating is defined with a coating thickness that varies along the first wall.

9. The component according to claim 1, wherein, The component is a component of a gas turbine engine, and the hole is a cooling hole.

10. A method for manufacturing a component, the method comprising: Position the first wall; The second wall is positioned at a certain distance from the first wall, and the second wall has a second wall thickness; A hole is formed in the first wall, the hole defining a centerline; A coating is applied to the first wall, a portion of which covers the hole; Connect the protrusion to the second wall such that the protrusion intersects the center line of the hole; as well as Remove the portion of the coating that covers the hole.

11. The method of claim 10, further comprising forming the protrusion having a semi-circular cross-section.

12. The method according to claim 10, wherein, The protrusion defines a protrusion centerline, and the connecting step further includes aligning the protrusion centerline with the hole centerline, such that the protrusion centerline and the hole centerline are collinear.

13. The method of claim 10, further comprising forming a blind hole in the second wall, wherein, The blind hole is defined by a blind hole centerline that is collinear with the centerline of the hole.

14. The method according to claim 13, wherein, The blind hole is formed during the removal step.

15. The method according to claim 13, wherein, The blind hole and the protrusion cooperate to define a minimum wall thickness, which is equal to or greater than the second wall thickness.

16. The method according to claim 15, wherein, The blind hole includes a blind hole end surface, wherein the protrusion includes a protrusion outer surface, and wherein the minimum wall thickness is the shortest distance between the blind hole end surface and the protrusion outer surface.

17. The method according to claim 10, wherein, The removal step is performed using a laser drilling process.

18. The method according to claim 10, wherein, The connection step further includes forming the second wall and the protrusion in a single, continuous process.

19. The method of claim 10, further comprising forming the first wall, the second wall, the hole, and the protrusion in a single continuous process.

20. The method of claim 10, further comprising using additive manufacturing to form the first wall, the second wall, the hole, and the protrusion.

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