Cavity plug for removing additive component from build plate
By designing a groove plug for additive manufacturing system, the problem of impurities entering the groove when parts are removed is solved, and the protection of part performance and reduction of subsequent cleaning costs are achieved.
Patent Information
- Application Number
- JP2024154665
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-10-02
- Filing Date
- 2024-09-09
- Publication Date
- 2025-05-09
AI Technical Summary
In additive manufacturing systems, some parts manufactured may contain cavity or grooves. If impurities such as debris are accidentally introduced into the cavity during removal, fluid may fail to pass through, which will affect the performance of the part, and cleaning these impurities will take time and cost.
A cavity plug is designed, which includes a housing, a first seal for closing the groove through the first wall of the part, and a locking mechanism located within the housing, the locking mechanism includes a locking arm that interacts with the first wall to ensure that the plug provides sealing when in place.
By using groove plugs, it is possible to effectively prevent impurities from being introduced into the groove when the parts are removed from the manufacturing platform, ensuring that the performance of the parts is not affected, and reducing the time and cost of subsequent cleaning and inspection.
Smart Images
Figure 2025072289000001_ABST
Abstract
Description
[Technical field]
[0001] This application and the resultant patent relate generally to additive manufacturing systems, and more particularly to sealing devices, such as cavity plugs, for preventing contamination of the internal cavities of an additive part when the additive part is removed from a build plate. [Background technology]
[0002] Additive manufacturing systems can be used to build complex parts. Additive manufacturing systems can build such parts by successively depositing powder material in a predetermined area and performing a material change process (such as sintering or melting) on the powder material. The material change process can change the physical state of the powder material from a granular composition to a solid material to build the part. Parts manufactured using additive manufacturing systems can have nearly the same physical attributes as conventional parts that are typically manufactured by performing machining on raw materials, etc.
[0003] Conventional additive manufacturing systems typically produce parts on a large, solid build plate. Many parts produced on conventional build plates may contain cavities or voids formed in the part. When the part is removed from the build plate, for example by sawing or wire EDM, a significant amount of swarf (i.e., metal chips, particles, abrasives, and other types of debris) may enter the cavities. Such internal contamination may block or impede fluid flow through the cavities, adversely affecting performance. As a result, post-processing and inspection to remove such contamination may be time-consuming and expensive. Summary of the Invention
[0004] Accordingly, the present application and resultant patent provide a cavity plug for a cavity extending through a first wall of a part manufactured with an additive manufacturing system, the cavity plug including an outer shell, a first seal sized to seal a cavity extending through a first wall of the part, and a locking mechanism disposed within the outer shell, the locking mechanism including a locking arm that engages the first wall to cause the cavity plug to seal in place.
[0005] The present application and resultant patent further provide a method of manufacturing a part having a cavity in an additive manufacturing system, the method can include forming the part on a build plate of the additive manufacturing system, inserting a cavity plug into the cavity to seal the cavity, locking the cavity plug in position relative to the cavity with a pair of locking arms, and removing the part from the build plate.
[0006] The present application and resultant patent further provide an additive manufacturing system for manufacturing a part having a cavity, the additive manufacturing system including a build plate for manufacturing the part on the build plate, and a cavity plug for sealing the cavity, the cavity plug including a pair of seals and a locking mechanism having a pair of locking arms for sealing the cavity plug within the cavity.
[0007] These and other features and improvements of the present application and any resulting patent will become apparent to those of ordinary skill in the art from a review of the following detailed description taken in conjunction with the several drawings and claims. [Brief description of the drawings]
[0008] [Figure 1] 1 is a schematic diagram of a gas turbine engine including a compressor, a combustor, a turbine, and an external load. [Diagram 2] FIG. 2 is a schematic diagram of a combustor that may be used with the gas turbine engine of FIG. 1. [Diagram 3] FIG. 1 is a block diagram of an additive manufacturing system including a control system. [Figure 4] FIG. 13 is a perspective view of the central cavity of the micro mix injector with the cavity plug partially installed. [Diagram 5] FIG. 13 is a perspective view of a micro mix injector with a cavity plug attached. [Figure 6] FIG. 2 is a front perspective view of a cavity plug as is described herein. [Figure 7] FIG. 7 is a side perspective view of the cavity plug of FIG. 6. [Figure 8] FIG. 7 is a cross-sectional view of the cavity plug of FIG. 6. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0009] Referring now to the drawings, where like numerals represent like elements in the several views, FIG. 1 illustrates a schematic diagram of a gas turbine engine 10 as is described herein. The gas turbine engine 10 may include a compressor 15. The compressor 15 compresses an incoming airflow 20. The compressor 15 delivers the compressed airflow 20 to a number of combustor cans 25. The combustor cans 25 mix the compressed airflow 20 with a pressurized fuel flow 30 and ignite the mixture to generate a hot combustion gas flow 35. Although only a single combustor can 25 is shown, the gas turbine engine 10 may include any number of combustor cans 25 arranged in a circumferential array, and the like. Alternatively, the combustor 25 may be an annular combustor. The combustion gas flow 35 is delivered to a turbine 40. The combustion gas flow 35 drives the turbine 40 to generate mechanical work. The mechanical work generated by the turbine 40 drives the compressor 15 via a rotor shaft 45. The turbine 40 and rotor shaft 45 may also drive an external load 50 (such as an electrical generator).
[0010] The gas turbine engine 10 may use natural gas, various types of synthetic gas, hydrogen fuel, liquid fuel, and / or other types of fuels and mixtures thereof. The gas turbine engine 10 may be any of several different gas turbine engines offered by General Electric Company of Schenectady, New York, such as, but not limited to, a 7 series or 9 series heavy duty gas turbine engine, and LM6000 and LM9000 aeroderivative gas turbine engines. The gas turbine engine 10 may be part of a simple cycle power generation system, a combined cycle power generation system, or other types of power generation systems. The gas turbine engine 10 may have other configurations and use other types of components. Other types of gas turbine engines may also be used herein. Multiple gas turbine engines, other types of turbines, and other types of power generation devices may also be used together herein.
[0011] 2 is a partial cross-sectional view of the combustor 25. The combustor 25 may incorporate a number of fuel injectors 52. The fuel injectors 52 may be coupled to a fuel nozzle assembly 53. In this example, the fuel injectors 52 may be bundled tube fuel injectors or the like. The combustor 25 is at least partially surrounded by an outer casing 54. The outer casing 54 forms a high pressure plenum 56 around the combustor 25. The high pressure plenum 56 may be in fluid communication with the compressor 15 or other source that provides the airflow 20 to the combustor 25. An end cover 58 is coupled to the outer casing 54. The end cover 58 may be in fluid communication with the fuel flow 30.
[0012] The fuel injectors 52 extend downstream from an end cover 58. The fuel injectors 52 may be in fluid communication with the end cover 58 to receive the fuel flow 30 therethrough. For example, a fluid conduit 60 may provide fluid communication between the end cover 58 and the fuel injectors 52. One end of an annular liner 62 (e.g., a combustion liner and / or transition duct) surrounds a downstream end 64 of the fuel injectors 52 to at least partially define a combustion chamber 66. The liner 62 defines a hot gas path 68 for directing the combustion gases 35 from the combustion chamber 66.
[0013] In operation, the air stream 20 flows toward the end cover 58 where it reverses direction to flow through one or more of the fuel injectors 52. The fuel stream 30 is provided to the fuel injector 52, and the fuel stream 30 and the air stream 20 are premixed or intermingled within the fuel injector 52 before being injected into the combustion chamber 66 and combusted.
[0014] FIG. 3 is a schematic / block diagram of an exemplary computational additive manufacturing system 100 for manufacturing a part 110 on a build plate 120 disposed on a build platform 130. The additive manufacturing system 100 can be used to manufacture the part 110 (such as a fuel injector 52 and other types of hot gas path parts). In this example, the additive manufacturing system 100 is designed for direct metal laser melting (DMLM) (i.e., a metal powder additive manufacturing process). It is understood that the general teachings of the present disclosure are equally applicable to other forms of additive manufacturing (such as binder jetting, E-beam, etc.). The additive manufacturing system 100 generally includes a computational additive manufacturing control system 140 and an additive manufacturing printer 150. The additive manufacturing system 100 executes code 160 including a set of computer executable instructions to physically generate the part 110 on the build plate 120 using the additive manufacturing printer 150. Each additive manufacturing process can use a different feedstock, for example in the form of a fine-grained metal powder 175, a stock of which can be held in a chamber 170 of the additive manufacturing printer 150. For example, the part 110 can be made of a metal or metal alloy. An applicator 180 forms a thin layer of feedstock 190 that can be spread as a blank canvas to form each successive slice of the final part 110. In the illustrated example, a laser or electron beam 200 is positioned above the build plate 120 and melts particles for each slice, as defined by code 160. Although one laser or electron beam 200 is shown, it is understood that the additive manufacturing system 100 may include any number of lasers or electron beams. Various parts of the additive manufacturing printer 150 can be moved to accommodate the addition of each new layer.
[0015] The additive manufacturing control system 140 is shown as implemented in a computer 210 as computer program code, where the computer 210 is shown to include a memory 220, a processor 230, an input / output (I / O) interface 240, and a bus 250. Additionally, the computer 210 is shown to be in communication with an external I / O device / resource 260 and an external storage system 270. In general, the processor 230 executes computer program code (such as the additive manufacturing control system 140) under direction from the code 160 representing the part 110, which may be stored in the memory 220 and / or the storage system 270. The computer 210 is merely representative of the various possible combinations of hardware and software that may be used herein.
[0016] The additive manufacturing process begins with a non-transitory computer-readable storage medium (e.g., memory 220, storage system 270, etc.) storing code 160 that represents part 110. As previously described, code 160 includes a set of computer-executable instructions that define part 110, which can be used to physically generate part 110. For example, code 160 can include a 3D model that precisely defines part 110 and can be generated from any of a wide variety of known computer-aided design (CAD) software systems. Additive manufacturing system 100 executes code 160, divides part 110 into a series of thin slices, and assembles the part with successive layers of powder using additive manufacturing printer 150. In the DMLM example, each layer can be melted or sintered to the precise shape defined by code 160 and fused to the previously existing layers. Part 110 can then undergo any of a variety of finishing processes (e.g., simple machining, sealing, polishing, assembly to another part, and similar processes).
[0017] 4 and 5 show a part 110 manufactured by the additive manufacturing system 100. In this example, the part may be a fuel injector 300 similar to the fuel injector 52 described above. Specifically, the fuel injector 300 may be a pre-mix or micro-mix injector 310. Generally, the micro-mix injector 310 may have a first plate or wall 320, a second plate or wall 330, and a side wall 340 therebetween. Then, several pre-mix or micro-mix tubes 350 extend from the first wall 320 to the second wall 330. A central cavity 360 extends between the first wall 320 and the second wall 330. The micro-mix tubes 350 surround the central cavity 360. As described above, when the part 110 is removed from the build plate 120 (shown in FIG. 5), shavings and other debris may get into the central cavity 360. This debris can be difficult to remove and cause operational problems (the micro-mixing tube 350, on the other hand, is easy to clean because it runs straight from the first wall 320 to the second wall 330).
[0018] 5-8 illustrate a cavity plug 370 as described herein. The cavity plug 370 may be sized to fill and seal the central cavity 360 of the micro mix injector 310. The cavity plug 370 may include an outer shell 380. The outer shell 380 is shown as cylindrical, but may be any suitable shape. The outer shell 380 may be made of a substantially rigid material, such as stainless steel. The outer shell 380 is covered at a top or first end 390 by a top cover 400 and a top cover seal 410. The top cover 400 and top cover seal 410 may have a diameter that is larger than the diameter of the outer shell 380, but is capable of penetrating the first wall 320 of the micro mix injector 310 to seal within or at the top of the central cavity 360. The outer shell 380 may be sealed closed at a second or bottom end 420 by a bottom flange 430 and a bottom flange seal 440. The bottom flange 430 and bottom flange seal 440 may have a diameter smaller than the diameter of the outer shell 380, but capable of penetrating the second wall 330 of the micro mixing injector 310 and sealing within the central cavity 360. The seals 410, 440 may be made from any substantially flexible and / or form-fitting material. Other parts and configurations may be used herein.
[0019] The cavity plug 370 can include a locking mechanism 450. The locking mechanism 450 can include a pair of pivot locking arms 460. The locking arms 460 can have a recess or contour that corresponds to the shape of the wall 320, 330 or other element of the part 110. Each locking arm 460 can pivot about a pivot rod 470. The pivot rod 470 can be attached to the outer shell 380. Each locking arm 460 can pivot along a pivot slot 480 in the outer shell 380. The locking arms 460 can be moved by a pivot spring 490. The pivot spring 490 is compressed and released by a locking bolt 500. The locking bolt 500 can have a handle 510 for easy turning. Other types of linear motion devices (pneumatic cylinders, hydraulic cylinders, servos, etc.) can also be used. Other components and other configurations can also be used herein.
[0020] In use, the micro mix jetter 310 or other type of part 110 is manufactured with the additive manufacturing system 100 as described above. Before the micro mix jetter 310 is removed from the build plate 120, the cavity plug 370 can be placed in the central cavity 360. The locking bolt 500 is turned, engaging the locking arm 460 under the first wall 320 of the micro mix jetter 310. This movement causes the top cover 400 and top cover seal 410 to penetrate the first wall 320 and engage at the top and interior of the central cavity 360, while the bottom flange 430 and bottom flange seal 440 penetrate the second wall 330 and engage at the top and interior of the central cavity 360. This pulling action compresses the seals 410, 440, forming an airtight seal. The micro-mix injector 310 can be removed from the build plate 120 without risk of contaminating the central cavity 360, and thus the cavity plug 370 can be removed. The micro-mix injector 310 can then be further processed as desired. Other parts and configurations may be used herein.
[0021] It is apparent that the foregoing description relates only to specific embodiments of the present application and the resulting patent. Numerous changes and modifications may be made herein by those skilled in the art without departing from the general spirit and scope of the invention as defined by the following claims and their equivalents.
[0022] Further aspects of the invention are provided by the following embodiments. [Embodiment 1] 1. A cavity plug for a cavity extending through a first wall of a part manufactured with an additive manufacturing system, the cavity plug comprising: an outer shell, a first seal sized to seal a cavity extending through a first wall of the part, and a locking mechanism disposed within the outer shell, the locking mechanism including a locking arm that engages the first wall to cause the cavity plug to seal in place. [Embodiment 2] 2. The cavity plug of embodiment 1, wherein the outer shell includes a top cover and the first seal is disposed around the top cover. [Embodiment 3] 3. The cavity plug of embodiment 1 or 2, wherein the outer shell has a first diameter and the top cover has a second diameter, the second diameter being greater than the first diameter. [Embodiment 4] A cavity plug as described in any one of embodiments 1 to 3, wherein the part includes a second wall, the cavity extends through the second wall, and the outer shell includes a second seal sized to seal the cavity extending through the second wall of the part. [Embodiment 5] The cavity plug of any one of embodiments 1 to 4, wherein the outer shell has a bottom flange and the second seal is disposed around the bottom flange. [Embodiment 6] The cavity plug of any one of embodiments 1 to 5, wherein the outer shell has a first diameter and the bottom flange has a second diameter, the second diameter being shorter than the first diameter. [Embodiment 7] The cavity plug according to any one of the first to sixth embodiments, wherein the locking arm includes a pair of locking arms. [Embodiment 8] A cavity plug as described in any one of embodiments 1 to 7, wherein the outer shell includes a pair of pivot slots, and the pair of locking arms pivot within the pivot slots. [Embodiment 9] The cavity plug according to any one of the first to eighth embodiments, wherein each locking arm of the pair of locking arms pivots about a pivot rod. [Embodiment 10] The cavity plug according to any one of the first to ninth embodiments, wherein the locking mechanism includes a pivot spring that transmits power to the pair of locking arms. [Embodiment 11] The cavity plug according to any one of the first to tenth embodiments, wherein the locking mechanism includes a locking bolt that transmits power to the pivot spring. [Embodiment 12] The cavity plug according to any one of the preceding embodiments, wherein the locking bolt includes a handle. [Embodiment 13] The cavity plug of any one of embodiments 1 to 12, wherein the component includes a fuel injector. [Embodiment 14] 14. The cavity plug of any one of embodiments 1 to 13, wherein the part comprises a micro-mixing injector. [Embodiment 15] 1. A method for manufacturing a part having a cavity in an additive manufacturing system, the method comprising: forming the part on a build plate of the additive manufacturing system; inserting a cavity plug into the cavity to seal the cavity; locking the cavity plug in position relative to the cavity with a pair of locking arms; and removing the part from the build plate. [Embodiment 16] 1. An additive manufacturing system for manufacturing a part having a cavity, comprising: a build plate for manufacturing the part on the build plate; and a cavity plug for sealing the cavity, the cavity plug including a pair of seals and a locking mechanism having a pair of locking arms for sealing the cavity plug within the cavity. [Embodiment 17] 17. An additive manufacturing system as described in embodiment 16, wherein the cavity plug includes an outer shell, and a top cover and a first seal of the pair of seals seal around the outer shell. [Embodiment 18] 18. An additive manufacturing system as described in embodiment 16 or 17, wherein the outer shell includes a bottom flange and a second seal positioned around the bottom flange of the pair of seals. [Embodiment 19] An additive manufacturing system as described in any one of embodiments 16 to 18, wherein the outer shell includes a pair of pivot slots and the pair of locking arms pivot within the pivot slots. [Embodiment 20] An additive manufacturing system described in any one of embodiments 16 to 19, wherein the locking mechanism includes a locking bolt and a pivot spring that transmits power to a pair of locking arms. [Explanation of symbols]
[0023] 10 Gas Turbine Engine 15 Compressor 20 Air Flow 30 Fuel flow 40 Turbine 45 rotor shaft 50 External Load 52 fuel injector 53 Fuel Nozzle Assembly 54 Outer casing 56 High Pressure Plenum 58 End cover 60 Fluid conduit 64 Downstream end 66 Combustion chamber 68 Hot Gas Path 130 Modeling Platform 150 Additive Manufacturing Printer 160 Code 170 Chamber 175 Fine grain metal powder 180 Applicator 190 Raw materials 200 Electron Beam 210 Computer 220 Memory 230 Processor 240 Interface 250 Bus 260 resources 300 fuel injector 310 Micro Mixing Injector 340 side wall 350 Micro Mixing Tube 370 Cavity Plug 380 Outer Shell 390 First End 400 Top lid 420 bottom end 430 Bottom Flange 440 Bottom Flange Seal 450 Locking mechanism 470 Pivot Rod 480 pivot slot 490 Pivot Spring 500 Locking Bolt 510 Handle
Claims
1. A cavity plug (370) for a cavity (360) extending through a first wall (320) of a part (110) produced with an additive manufacturing system (100), said cavity plug (370) comprising: An outer shell (380); a first seal (410) sized to seal a cavity (360) extending through a first wall (320) of the component (110); and a locking mechanism (450) disposed within said outer shell (380); Including, The locking mechanism (450) includes a locking arm (460) that engages the first wall (320) to hold the cavity plug (370) in place to seal.
2. The cavity plug (370) of claim 1, wherein the outer shell (380) includes a top cover (400) and the first seal is disposed about the top cover.
3. 3. The cavity plug (370) of claim 2, wherein the outer shell (380) has a first diameter and the top cover (400) has a second diameter, the second diameter being greater than the first diameter.
4. 2. The cavity plug (370) of claim 1, wherein the part (110) includes a second wall (330), the cavity (360) extends through the second wall, and the outer shell (380) includes a second seal (440) sized to seal the cavity (360) extending through the second wall (330) of the part (110).
5. The cavity plug (370) of claim 4, wherein the outer shell (380) has a bottom flange (430) and the second seal (440) is disposed about the bottom flange (430).
6. 6. The cavity plug (370) of claim 5, wherein the outer shell (380) has a first diameter and the bottom flange (430) has a second diameter, the second diameter being less than the first diameter.
7. The cavity plug (370) of claim 1, wherein the locking arm (460) comprises a pair of locking arms (460).
8. The cavity plug (370) of claim 7, wherein said outer shell (380) includes a pair of pivot slots (480), said pair of locking arms (460) pivoting within said pivot slots (480).
9. The cavity plug (370) of claim 8, wherein each locking arm of the pair of locking arms (460) pivots about a pivot rod (470).
10. The cavity plug (370) of claim 7, wherein the locking mechanism (450) includes a pivot spring (490) that transfers power to the pair of locking arms (460).
11. The cavity plug (370) of claim 10, wherein the locking mechanism (450) includes a locking bolt (500) that transmits power to the pivot spring (490).
12. The cavity plug (370) of claim 11, wherein the locking bolt (500) includes a handle (510).
13. The cavity plug (370) of claim 1, wherein the component (110) comprises a fuel injector (300).
14. The cavity plug (370) of claim 1, wherein the part (110) comprises a micro-mixing injector (310).
15. A method of manufacturing a part (110) having a cavity (360) with an additive manufacturing system (100), comprising: forming the part (110) on a build plate (120) of the additive manufacturing system (100); inserting a cavity plug (370) into said cavity (360) to seal said cavity (360); locking said cavity plug (370) in position relative to said cavity (360) by a pair of locking arms (460); and Removing the part (110) from the build plate (120). A method comprising: