Methods for manufacturing additively manufactured structures for internal combustion engines, and those additively manufactured structures

Abstract

To provide a method for manufacturing additively manufactured structures that use certain metal alloys that have higher strength, lighter weight and higher operating temperature than existing internal combustion engines.SOLUTION: A method for manufacturing an additively manufactured structure (200) for an internal combustion engine includes: identifying a start point on a build plate for construction of the additively manufactured structure (200); and identifying a forming orientation of the additively manufactured structure (200) relative to the build plate such that surface areas of an internal body surface (210) and each internal port surface (214) are at least approximately 20 degrees offset from a direction parallel to the build plate for the additively manufactured structure (200) such that no portion of the surface areas is equivalent to an area of a circle having a radius of 5 mm or larger.SELECTED DRAWING: Figure 2A

Description

[Technical Field]

[0001] The present disclosure relates generally to methods for manufacturing additively manufactured articles for internal combustion engines, and more specifically to additively manufactured articles using specific metal alloys that have higher strength, lighter weight, and higher operating temperatures than existing internal combustion engines. Applications of additively manufactured articles are being considered for use in various components and component combinations of internal combustion engines. For example, internal combustion engines manufactured using additively manufactured articles have been used in unmanned aerial vehicles, drones, and missiles. Additionally, other applications are being considered. Additively manufactured articles can also be used in other types of assemblies, other types of vehicles, other types of equipment, and as construction materials. [Background technology]

[0002] Traditionally, internal combustion engines (ICEs) are made of steel, are heavy, and are typically manufactured by casting, requiring multiple parts to be machined and assembled. This can result in tolerance buildup and shimming. Existing casting techniques have limitations on engine operating temperatures and issues with geometric consistency and engine timing.

[0003] Therefore, those skilled in the art continue to conduct research and development to improve the manufacturing techniques for internal combustion engine components. Summary of the Invention

[0004] This specification discloses methods for manufacturing additively manufactured objects for internal combustion engines, and examples of such additively manufactured objects. The following is a non-exhaustive list of examples of the subject matter of the present disclosure, and some examples may or may not be claimed.

[0005] In one embodiment, a method of manufacturing an additively manufactured object for an internal combustion engine according to the present disclosure includes: (1) identifying a starting point on a build plate for building an additively manufactured object including a body portion and at least two gas ports, the body portion defining an outer body surface and at least one inner body bore, each inner body bore defining an inner body surface, each gas port defining an outer port surface and an inner port bore, and each inner port bore defining an inner port surface; and (2) identifying a build orientation of the additively manufactured object relative to the build plate such that the inner body surface and each inner port surface have a surface area offset by an angle of at least about 20 degrees relative to a direction parallel to the build plate, such that no portion of the surface area of ​​the inner body surface or each inner port surface corresponds to an area of ​​a circle with a radius of 5 mm or greater.

[0006] In one embodiment, an additively manufactured object for an internal combustion engine according to the present disclosure includes a body portion and at least two gas ports. The body portion defines an outer body surface and an inner body bore. The inner body bore defines an inner body surface. Each gas port defines an outer port surface and an inner port bore. Each inner port bore defines an inner port surface. The surface areas of the inner body surface and each inner port surface are offset by an angle of at least about 20 degrees relative to a direction parallel to the build plate such that no portion of the surface area corresponds to an area of ​​a circle with a radius of 5 mm or greater.

[0007] In yet another embodiment, a method of manufacturing an additively manufactured object for an internal combustion engine according to the present disclosure includes: (1) identifying a starting point on a build plate for construction of an additively manufactured object including a body portion and at least two gas ports, the body portion defining an outer body surface and an inner body bore, the body bore defining an inner body surface, each gas port defining an outer port surface and an inner port bore, and each port bore defining an inner port surface; (2) identifying a build orientation of the additively manufactured object relative to the build plate such that the inner body surface and each inner port surface do not have a surface area corresponding to an area of ​​a circle with a radius of 5 mm or greater, and the surface area of ​​the additively manufactured object is offset at an angle of at least about 20 degrees relative to a direction parallel to the build plate; and (3) preparing the build plate and a metal powder bed for construction of the additively manufactured object. (4) welding a first layer of the additive structure and a first layer of support material to the build plate using laser powder bed fusion, the first layer extending from the build plate to a selected location on an outer portion of the additive structure to provide support during build; (5) repeating the build plate preparation and welding of the first layer to continue additive manufacturing of the additive structure and the support material until the welding of a final layer; (6) removing the support material from the additive structure; (7) grinding, polishing, cleaning, and / or honing the inner body surface of the body bore; (8) applying a wear resistant coating to at least a portion of the inner body surface of the body bore in preparation for subsequent contact with a piston or piston ring; and (9) direct age hardening the additive structure to improve tensile strength.

[0008] Other embodiments of the method of manufacturing an additively manufactured object for an internal combustion engine according to the present disclosure, and the additively manufactured object, will be apparent from the following detailed description, the accompanying drawings, and the claims. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a flow diagram illustrating an example method for manufacturing an additively manufactured object for an internal combustion engine. [Figures 2A-2C]1A-1D are side views of examples of additively manufactured objects for internal combustion engines with different configurations of internal fluid flow paths. [Figure 3] FIG. 1B is a cross-sectional side view of an additively manufactured example for an internal combustion engine, showing the additive manufacturing at 25% completion. [Figure 4] FIG. 1 is a cross-sectional side view of an additively manufactured example for an internal combustion engine, showing the additive manufacturing completed at 50%. [Figure 5] FIG. 1B is a cross-sectional side view of an additively manufactured example for an internal combustion engine, showing the additive manufacturing at 75% completion. [Figure 6] FIG. 1 shows a cross-sectional side view of an additively manufactured internal combustion engine embodiment in a 100% additively manufactured state. [Figure 7] 1 is a flow diagram illustrating another embodiment of a method for manufacturing an additive manufactured object for an internal combustion engine; [Figure 8] 1 is a flow diagram illustrating yet another embodiment of a method for manufacturing an additive manufactured object for an internal combustion engine; [Figure 9] 1 is a flow diagram illustrating yet another embodiment of a method for manufacturing an additive manufactured object for an internal combustion engine; [Figure 10] 1 is a flow diagram illustrating yet another embodiment of a method for manufacturing an additive manufactured object for an internal combustion engine; [Figure 11] FIG. 1B is a cross-sectional side view of an example additively manufactured object for an internal combustion engine after completion of additive manufacturing and before completion of post-processing. [Figures 12A-12B] FIG. 10 is a flow diagram illustrating another embodiment of a method for manufacturing an additive manufactured object for an internal combustion engine. [Figure 13] 12A-12B are a flow diagram illustrating yet another embodiment of a method for manufacturing an additively manufactured object for an internal combustion engine. [Figure 14] FIG. 13 is a flow diagram illustrating an embodiment of preparing a build plate in the method of FIGS. 12A-12B. [Figure 15] FIG. 1 is a block diagram illustrating an unmanned aerial vehicle manufacturing and service method implementing one or more embodiments of the internal combustion engine additive manufacturing method of the present disclosure. [Figure 16] FIG. 1 is a schematic diagram illustrating an unmanned aerial vehicle incorporating one or more embodiments of an additive manufacturing method for an internal combustion engine, manufactured using one or more embodiments of the manufacturing method for an additive manufacturing method for an internal combustion engine of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0010] According to various embodiments of the methods 100, 700, 800, 900, 1000, 1200, 1300, and 1400 and additively manufactured object 200 disclosed herein, various techniques for manufacturing the additively manufactured object 200 are identified, and various features and characteristics of the additively manufactured object 200 are identified. For example, an additive manufacturing method for an internal combustion engine established by these techniques includes printing an internal combustion engine on a build plate. The orientation of the printed engine on the build plate (see, for example, FIG. 6 ) is set such that an inner surface of one or more gas ports defined therein by the gas ports does not have a flat portion corresponding to an area of ​​a circle with a radius of 5 millimeters or more, the flat portion having an inclination angle of less than 20 degrees relative to the horizontal direction of the build plate. In other embodiments, the inclination angle is not less than 25 degrees. In yet other embodiments, the inclination angle is not less than 30 degrees. The gas ports include, for example, intake ports and exhaust ports. In other embodiments, the gas port includes an internal fluid flow path (eg, a coolant flow path).

[0011] For example, the additively manufactured object 200 may include a modeling engine designed for additive manufacturing, and prior to machining, the orientation of the modeling engine on the build plate (see, e.g., FIG. 6 ) may be such that the interior surface of one or more gas ports defined therein has no flat portion corresponding to the area of ​​a circle with a radius of 5 millimeters or greater, and that the inclination angle relative to the horizontal of the build plate is less than 20 degrees. In other embodiments, the inclination angle is no less than 25 degrees. In yet other embodiments, the inclination angle is no less than 30 degrees. The gas ports may include, for example, intake ports and exhaust ports. In other embodiments, the gas ports may include internal fluid channels (e.g., coolant channels).

[0012] In 3D printing, horizontally extending additive parts are built along support structures. Fluid passages in internal combustion engines are difficult, and in some cases impossible, to machine. Conversely, significant time can be saved if the passages do not need to be machined to remove support structures. However, to ensure proper performance, the passages must be smooth. To eliminate the need for support structures, the additive part can be oriented or designed so that its internal flat surfaces are offset from the horizontal by a set angle, such as 20 to 30 degrees (see Figure 6, for example).

[0013] In various embodiments, additively manufactured objects do not include or require supports to support internal passages. For example, an additively manufactured internal combustion engine does not include or require supports that contact the internal surfaces of gas ports (e.g., functional pathways) and are subsequently removed. On the other hand, external heat dissipation fins may use contact supports, especially if the fins are thin, to prevent the fins from bending during fabrication. However, because using supports on ports can have a significant impact on performance and variability, supports are often not used, or at least are avoided, for ports. Depending on the engine type, essential parts of the engine may be used as permanent load supports. Unlike temporary supports, permanent supports do not need to be machined away.

[0014] If any two surfaces of a given extent converge at an edge with a region that is inclined at an angle of less than 20 degrees relative to the horizontal of the build plate, the edge has a filleted transition, and the region has an equivalent surface area radius of less than 3 millimeters. In other examples, the region has an equivalent surface area radius of less than 5 millimeters. While it is inevitable that some edges will be "horizontal," such regions are acceptable as long as the unsupported surface area defined by the corresponding surface region is limited.

[0015] When an engine defines an engine cylinder bore, the cylinder bore is configured with a material sleeve, with the engine material intersecting multiple ports to define a continuous bore. Powder removal holes are also defined at the intersections. When the bore is machined, no material remains within the ports, and the bore is machined to a precise shape. The sleeve provides additional material to the cylinder bore, which is then milled to precise specifications. If the sleeve extends across multiple ports, it can provide additional structure during fabrication, which can be removed by machining operations originally required for tolerance adjustment. Holes are also provided in the sleeve corresponding to the locations of the ports to facilitate powder removal.

[0016] For example, Figure 11 shows a completed part, including a continuous sleeve and cleanout holes, but without internal port supports. The powder removal holes are small holes for removing powder from the exhaust port, and are formed according to rules regarding the slope angle and filleted transitions of the internal surface. Figures 2A-2C show an example of a part after final machining, where the sleeve has been machined to smooth the interface with the gas port.

[0017] In various embodiments, the additively manufactured internal combustion engine includes a metal alloy material that is resistant to hot cracking and maintains a tensile strength of greater than 30 kilopounds per square inch for 1,000 hours at an operating temperature of 475°F. In other embodiments, the metal alloy material includes aluminum and / or magnesium. In yet other embodiments, the alloy can be strengthened by direct age hardening.

[0018] In various embodiments, in laser powder bed fusion, the laser is configured to preheat, postheat, or a combination of both, the additive manufacturing material to prevent cracking. For example, in the building of magnesium alloys, preheating and / or postheating reduced cracking in the build.

[0019] In various embodiments, the internal combustion engine further includes a wear-resistant coating applied to the engine cylinder bore. The coating has a Vickers hardness of 400 or greater and 2800 or less. In other embodiments, the coating includes nickel-silicon-carbide. In yet other embodiments, the coating includes tungsten carbide. For example, nickel-silicon-carbide has been applied to AlSi10Mg and Scalmalloy after chemical composition optimization.

[0020] With reference to FIGS. 1 , 2A-2C , 3 , 4 , and 7-10 , the present disclosure relates to, by way of example, methods 100, 700, 800, 900, 1000 for manufacturing an additively manufactured object 200 for an internal combustion engine. FIG. 1 illustrates an example embodiment of the method 100 for manufacturing an additively manufactured object 200 for an internal combustion engine. Each of FIGS. 2A-2C is a cross-sectional side view of an example embodiment of the additively manufactured object 200 for an internal combustion engine. FIG. 3 is a cross-sectional side view of an example embodiment of the additively manufactured object 200 for an internal combustion engine, where additive manufacturing is 25% complete. FIG. 4 is a cross-sectional side view of an example embodiment of the additively manufactured object 200 for an internal combustion engine, where additive manufacturing is 50% complete. FIG. 7 is a flow diagram illustrating an example embodiment of a method 700 for manufacturing an additively manufactured object 200 for an internal combustion engine, in combination with FIG. 1 . FIG. 8 is a flow diagram illustrating an example embodiment of a method 800 for manufacturing an additively manufactured object 200 for an internal combustion engine, in combination with FIG. 1 . Figure 9, in combination with Figure 1, is a flow diagram illustrating an example embodiment of a method 900 for manufacturing an additive manufactured object 200 for an internal combustion engine. Figure 10, in combination with Figure 1, is a flow diagram illustrating an example embodiment of a method 1000 for manufacturing an additive manufactured object 200 for an internal combustion engine.

[0021] 1 , 2A-2C, and 3 , in one or more embodiments, a method 100 of manufacturing an additively manufactured object 200 for an internal combustion engine (see FIG. 1 ) includes identifying 102 a starting point 302 on a build plate 304 for constructing the additively manufactured object 200. The additively manufactured object 200 includes a body portion 202 and at least two gas ports 204. The body portion 202 defines an outer body surface 206 and at least one inner body bore 208. Each inner body bore 208 defines an inner body surface 210. Each gas port 204 defines an outer port surface 212 and an inner port bore 213. Each port bore 213 defines an inner port surface 214. At 104, a build orientation 306 of the additively manufactured object 200 relative to the build plate 304 is determined, where an orientation is determined in which the surface area of ​​the main body inner surface 210 and each port inner surface 214 is inclined at least approximately 20 degrees relative to a direction parallel to the build plate 304 of the additively manufactured object 200 so that there is no portion of the surface area corresponding to a circle with a radius of 5 mm or more on either the main body inner surface 210 or each port inner surface 214.

[0022] In another embodiment of the method 100, the build orientation 306 of the additively manufactured object 200 relative to the build plate 304 is specified such that the surface areas of the main body inner surface 210 and each port inner surface 214 are inclined at least about 25 degrees relative to a direction parallel to the build plate 304 of the additively manufactured object 200, such that neither the main body inner surface 210 nor each port inner surface 214 has a surface area corresponding to a circle with a radius of 5 mm or greater. In yet another embodiment, the build orientation 306 of the additively manufactured object 200 relative to the build plate 304 is specified such that the surface areas of the main body inner surface 210 and each port inner surface 214 have a surface area corresponding to a circle with a radius of 5 mm or greater.

[0023] In yet another embodiment of the method 100 , the body 202 includes an engine cylinder 216 and the at least two gas ports 204 include an intake port 218 and an exhaust port 220 .

[0024] In yet another embodiment, the method 100 further includes preparing 106 a build plate 304 and a metal powder bed for constructing the additively manufactured object 200. At 108, a first layer of the additively manufactured object 200 and a first layer of support material 308 are welded to the build plate 304 using laser powder bed fusion. The support material 308 extends from the build plate 304 to a selected location on an outer portion of the additively manufactured object 200 to provide support during construction. At 110, the preparation 106 of the build plate 304 and the welding 108 of the first layer are repeated to continue layer-by-layer construction of the additively manufactured object 200 and support material 308 until the final layer is welded. In yet another embodiment, this additive manufacturing process forms an internal fluid channel 222 in the additively manufactured object 200 for cooling. Referring to FIG. 2A , in some embodiments, the internal fluid channel 222 for enhanced cooling is located near the body bore 208. Referring to FIG. 2B , in another embodiment, internal fluid channels 222 for cooling enhancement are provided near one or more of the at least two gas ports 204. Referring to FIG. 2C , in yet another embodiment, internal fluid channels 222 for cooling enhancement are provided near the body bore 208 and near one or more of the at least two gas ports 204. In yet another embodiment, during this additive manufacturing process, the body inner surface 210 and each port inner surface 214 are built without supports 308 to the build plate 304. In yet another embodiment, this additive manufacturing process builds external cooling fins 223 extending from the body outer surface 206 of the body portion 202. In yet another embodiment, internal surface areas of the additively manufactured body 200 that are difficult to access for machining are built without supports 308 to the build plate 304. In yet another embodiment, the welding 108 is performed with a melt laser.

[0025] 1-4 and 7, in one or more embodiments, a method 700 (see FIG. 7) for manufacturing an additively manufactured object 200 for an internal combustion engine includes the method 100 shown in FIG. 1. The method 700 includes step 702, which continues from step 108 in FIG. 1, in which filleted transition portions 224 are formed at the connection portions between the at least two gas ports 204 and the body portion 202, integrating the port inner surface 214 of each of the at least two gas ports 204 with the body inner surface 210. The radius of the filleted transition portions 224 is less than about 3 mm where the transition surface 226 of the filleted transition portions 224 has an inclination angle of less than about 20 degrees with respect to a direction parallel to the build plate 304.

[0026] In yet another embodiment of the method 700, the radius of the filleted transition portion 224 is less than about 5 mm where the transition surface 226 of the filleted transition portion 224 has an inclination angle of less than about 20 degrees relative to a direction parallel to the build plate 304.

[0027] In yet another embodiment of method 700, additive manufacturing forms a metal sleeve 310 having a plurality of powder removal holes 402 in the inner body surface 210 of the body bore 208, thereby facilitating subsequent post-processing of the inner body surface 210. In yet another embodiment of method 700, additive manufacturing forms a plurality of continuous cylindrical walls that provide free edges during additive manufacturing for at least two gas ports 204 that intersect the body bore 208. In this embodiment, the continuous cylindrical walls are subsequently machined in subsequent post-processing to expose the at least two gas ports 204 to the body bore 208.

[0028] In yet another embodiment of the method 700, the metal powder comprises a metal alloy material that maintains a tensile strength of greater than 30 kilopounds per square inch for 1,000 hours at an operating temperature of 475°F.

[0029] In other embodiments of the method 700, the metal alloy material comprises an aluminum alloy material, a magnesium alloy material, or any other suitable metal alloy material in any suitable combination.

[0030] 1 , 2A-2C , 3 , and 8 , in one or more embodiments, a method 800 (see FIG. 8 ) of manufacturing an additively manufactured object 200 for an internal combustion engine includes the method 100 shown in FIG. 1 . In the method 800, preparing 106 the build plate 304 includes preheating 802 a metal powder bed prior to welding 108 a first layer. Also, at 802, a previously welded layer is preheated prior to welding a next layer of the additively manufactured object 200 during additive manufacturing. This preheating can reduce thermal gradients in the additively manufactured object 200. At 804, after welding 108 a first layer, the metal powder bed is postheated. Also, at 804, a currently welded layer is postheated prior to preparing a next layer of the additively manufactured object 200 during additive manufacturing. This postheating can reduce thermal gradients in the additively manufactured object 200. 804 of the method 800 then continues to 110 of FIG. 1 . In yet another embodiment, this pre-heating 802 is performed by a pre-heat laser.

[0031] 1 , 2A-2C, 3, and 9, in one or more embodiments, a method 900 (see FIG. 9) of manufacturing an additively manufactured object 200 for an internal combustion engine includes the method 100 shown in FIG. 1. The method 900 includes step 902, continuing from step 108 shown in FIG. 1, in which the metal powder bed is post-heated after the welding of the first layer 108. Also, at 902, the current welded layer is post-heated before preparing the next layer of the additively manufactured object 200 during additive manufacturing. This post-heating can reduce the temperature gradient in the additively manufactured object 200. In yet another embodiment, this post-heating 902 is performed by a post-heat laser.

[0032] 1 , 2A-2C, 3, and 10, in one or more embodiments, a method 1000 (see FIG. 10) for manufacturing an additively manufactured object 200 for an internal combustion engine includes the method 100 shown in FIG. 1. The method 1000 includes step 1002, continuing from step 110 in FIG. 1, in which support material 308 is removed from the additively manufactured object 200. At 1004, the inner body surface 210 of the body bore 208 is ground, polished, cleaned, and / or honed. At 1006, a wear-resistant coating 228 is applied to the inner body surface 210 of the body bore 208 in preparation for subsequent contact with a piston or piston ring.

[0033] In yet another embodiment of the method 1000, the wear resistant coating 228 comprises a nickel-silicon carbide coating, a tungsten carbide coating, or any other wear resistant coating in any suitable combination. In yet another embodiment, the method 1000 further comprises applying a strike plating to at least a portion of the additively manufactured body 200 prior to applying 1006 the wear resistant coating 228. The strike plating can be applied to the additively manufactured body 200 after a surface treatment such as, for example, grinding, polishing, cleaning, and / or honing 1004, and the wear resistant coating 228 can be applied over the strike plating. In yet another embodiment, the method 1000 further comprises applying an electroless nickel plating to at least a portion of the additively manufactured body 200 prior to applying 1006 the wear resistant coating 228. The electroless nickel plating can be applied to the additively manufactured body 200 after a surface treatment such as, for example, grinding, polishing, cleaning, and / or honing 1004, and the wear resistant coating 228 can be applied over the electroless nickel plating. In another embodiment, the electroless nickel plating may be applied over the strike plating.

[0034] In another embodiment, the method 1000 further includes improving the tensile strength by direct age hardening 1008 of the additively manufactured body 200. In yet another embodiment, the wear resistant coating 228 has a hardness of greater than or equal to 400 and less than or equal to 2800 on the Vickers hardness scale.

[0035] 1, 2A-2C, and 3, the present disclosure relates, by way of example, to an additively manufactured object 200 for an internal combustion engine. Each of Figures 2A-2C is a cross-sectional side view of an example embodiment of the additively manufactured object 200 for an internal combustion engine. Figure 3 is a cross-sectional side view of an example embodiment of the additively manufactured object 200 for an internal combustion engine, where additive manufacturing is 25% complete.

[0036] 2 and 3 , in one or more embodiments, an additively manufactured object 200 for an internal combustion engine includes a body portion 202 and at least two gas ports 204. The body portion 202 defines an outer body surface 206 and an inner body bore 208. The inner body bore 208 defines an inner body surface 210. Each gas port 204 defines an outer port surface 212 and an inner port bore 213. Each inner port bore 213 defines an inner port surface 214. The surface area of ​​the inner body surface 210 and each inner port surface 214 is angled at least about 20 degrees with respect to a direction parallel to the build plate 304 of the additively manufactured object 200, such that no portion of the surface area corresponds to the area of ​​a circle with a radius of 5 mm or greater.

[0037] In another embodiment of the additive manufactured object 200, the surface area of ​​the body inner surface 210 and each port inner surface 214 is inclined at an angle of at least about 25 degrees relative to a direction parallel to the build plate 304 of the additive manufactured object 200, such that no portion of the surface area corresponds to a circle with a radius of 5 mm or greater. In yet another embodiment, the surface area of ​​the body inner surface 210 and each port inner surface 214 is inclined at an angle of at least about 30 degrees relative to a direction parallel to the build plate 304 of the additive manufactured object 200, such that no portion of the surface area corresponds to a circle with a radius of 5 mm or greater.

[0038] In yet another embodiment of the additively manufactured object 200 , the body portion 202 includes an engine cylinder 216 and the at least two gas ports 204 include an intake port 218 and an exhaust port 220 .

[0039] Referring to Figure 2A, in yet another embodiment, the additively manufactured object 200 further includes internal fluid channels 222 proximate the body bore 208 to facilitate cooling. Referring to Figure 2B, in yet another embodiment, the internal fluid channels 222 are located proximate one or more of the at least two gas ports 204 to facilitate cooling. Referring to Figure 2C, in yet another embodiment, the internal fluid channels 222 are located proximate the body bore 208 and proximate one or more of the at least two gas ports 204 to facilitate cooling. In another embodiment, the additively manufactured object 200 further includes external cooling fins 223 extending from the outer body surface 206 of the body portion 202.

[0040] In another embodiment of the additively manufactured body 200, at the connection between the at least two gas ports 204 and the body portion 202, the port inner surface 214 of each of the at least two gas ports 204 is integral with the body inner surface 210, forming a filleted transition 224 between the body portion 202 and each gas port 204. Where the transition surface 226 of the filleted transition 224 has an inclination angle of less than about 20 degrees with respect to a direction parallel to the build plate 304, the radius of the filleted transition 224 is less than about 3 mm. In yet another embodiment, where the transition surface 226 of the filleted transition 224 has an inclination angle of less than about 20 degrees with respect to a direction parallel to the build plate 304, the radius of the filleted transition 224 is less than about 5 mm.

[0041] In yet another embodiment of the additively manufactured body 200, the additively manufactured body 200 comprises a metal alloy material that maintains a tensile strength of greater than 30 kilopounds per square inch for 1,000 hours at an operating temperature of 475°F. In yet another embodiment, the metal alloy material comprises an aluminum alloy material, a magnesium alloy material, or any other suitable metal alloy material in any suitable combination. In yet another embodiment, the additively manufactured body 200 achieves the tensile strength by direct age hardening.

[0042] In yet another embodiment of additively manufactured article 200, body portion 202 includes a wear-resistant coating 228 on inner body surface 210 of body bore 208 to prepare for subsequent contact with a piston or piston ring. In yet another embodiment, wear-resistant coating 228 has a hardness of greater than or equal to 400 and less than or equal to 2800 Vickers. In yet another embodiment, wear-resistant coating 228 includes a nickel-silicon carbide coating, a tungsten carbide coating, or any other wear-resistant coating in any suitable combination.

[0043] In yet another embodiment, the additively manufactured object 200 further comprises a strike plating on at least a portion of the additively manufactured object 200. For example, a wear resistant coating 228 is applied over the strike plating. In yet another embodiment, the additively manufactured object 200 further comprises an electroless nickel plating on at least a portion of the additively manufactured object 200. For example, the electroless nickel plating is applied over the strike plating. In another embodiment, the wear resistant coating 228 is applied over the electroless nickel plating.

[0044] 2A-2C, 3, 12A-12B, 13, and 14, the present disclosure relates to, by way of example, methods 1200, 1300, and 1400 for manufacturing an additively manufactured object 200 for an internal combustion engine. Each of FIGS. 2A-2C is a cross-sectional side view of an example embodiment of the additively manufactured object 200 for an internal combustion engine. FIG. 3 is a cross-sectional side view of an example embodiment of the additively manufactured object 200 for an internal combustion engine, where additive manufacturing is 25% complete. FIGS. 12A-12B illustrate an example embodiment of a method 1200 for manufacturing an additively manufactured object 200 for an internal combustion engine. FIG. 13, in combination with FIGS. 12A-12B, is a flow diagram illustrating an example embodiment of a method 1300 for manufacturing an additively manufactured object 200 for an internal combustion engine. FIG. 14, in combination with FIGS. 12A-12B, is a flow diagram illustrating an example embodiment of a method 1400 for manufacturing an additively manufactured object 200 for an internal combustion engine.

[0045] 2A-2C, 3, and 12A-12B, in one or more embodiments, a method 1200 of manufacturing an additively manufactured object 200 for an internal combustion engine (see FIGS. 12A-12B) includes identifying 1202 a starting point 302 on a build plate 304 for constructing the additively manufactured object 200. The additively manufactured object 200 includes a body portion 202 and at least two gas ports 204. The body portion 202 defines an outer body surface 206 and an inner body bore 208. The body bore 208 defines an inner body surface 210. Each gas port 204 defines an outer port surface 212 and an inner port bore 213. Each port bore 213 defines an inner port surface 214. In 1204, a build orientation 306 of the additively manufactured object 200 relative to the build plate 304 is determined, where an orientation is determined in which the surface area of ​​the main body inner surface 210 and each port inner surface 214 is inclined at least approximately 20 degrees relative to a direction parallel to the build plate 304 of the additively manufactured object 200 so that no portion of the surface area of ​​the main body inner surface 210 or each port inner surface 214 corresponds to an area of ​​a circle with a radius of 5 mm or more.

[0046] At 1206, a build plate 304 and a metal powder bed for building the additively manufactured body 200 are prepared. At 1208, a first layer of the additively manufactured body 200 and a first layer of support material 308 are welded to the build plate 304 using laser powder bed fusion. The support material 308 extends from the build plate 304 to selected locations on the outer portion of the additively manufactured body 200 to provide support during the build. At 1210, the preparation of the build plate 304 1206 and the welding of the first layer 1208 are repeated to continue the additive manufacturing of the additively manufactured body 200 and support material 308 until the final layer is welded. At 1212, the support material 308 is removed from the additively manufactured body 200. At 1214, the inner body surface 210 of the body bore 208 is ground, polished, cleaned, and / or honed. At 1216, a wear resistant coating 228 is applied to the inner body surface 210 of the body bore 208 in preparation for subsequent contact with the piston or piston ring. At 1218, direct age hardening of the additively manufactured body 200 is performed to improve tensile strength.

[0047] 2A-2C, 3, 12A-12B, and 13, in one or more embodiments, a method 1300 for manufacturing an additively manufactured object 200 for an internal combustion engine (see FIG. 13) includes the method 1200 shown in FIGS. 12A-12B. The method 1300 includes step 1302, which continues from step 1208 in FIG. 12A, in which filleted transition portions 224 are formed at the connection portions between the at least two gas ports 204 and the body portion 202, integrating the port inner surfaces 214 of the at least two gas ports 204 with the body inner surface 210. The radius of the filleted transition portions 224 is less than about 3 mm where the transition surfaces 226 of the filleted transition portions 224 have an inclination angle of less than about 20 degrees with respect to a direction parallel to the build plate 304.

[0048] In another embodiment, the method 1300 further includes post-heating 1304 the metal powder bed after welding 1208 the first layer. Also, at 1304, the current welded layer is post-heated prior to preparing 1206 the next layer of the additively manufactured body 200 during additive manufacturing. This post-heating can reduce temperature gradients in the additively manufactured body 200.

[0049] 2A-2C, 3, 12A-12B, and 14, in one or more embodiments, a method 1400 (see FIG. 14) of manufacturing an additively manufactured object 200 for an internal combustion engine includes the method 1200 shown in FIGS. 12A-12B. In this embodiment, preparing 1206 the build plate 304 shown in FIG. 12A includes preheating 1402 a metal powder bed prior to welding 1208 a first layer. Also, at 1402, during additive manufacturing, a previously welded layer is preheated prior to welding 1208 a next layer of the additively manufactured object 200. This preheating can reduce temperature gradients in the additively manufactured object 200.

[0050] 2A-2C, 3, 12A-12B, and 13, the method 1200 further includes applying a strike plating to at least a portion of the additively manufactured body 200 prior to applying 1216 the wear resistant coating 228. The strike plating may be applied to the additively manufactured body 200 after a surface treatment such as, for example, grinding, polishing, cleaning, and / or honing 1214, and the wear resistant coating 228 may be applied over the strike plating. In yet another example, the method 1200 further includes applying an electroless nickel plating to at least a portion of the additively manufactured body 200 prior to applying 1216 the wear resistant coating 228. The electroless nickel plating may be applied to the additively manufactured body 200 after a surface treatment such as, for example, grinding, polishing, cleaning, and / or honing 1214, and the wear resistant coating 228 may be applied over the electroless nickel plating. In another example, the electroless nickel plating may be applied over the strike plating.

[0051] The disclosed methods 100, 700, 800, 900, 1000, 1200, 1300, and 1400 for manufacturing an additively manufactured object 200 for an internal combustion engine, and embodiments of the additively manufactured object 200 for an internal combustion engine, can be associated with or used in the manufacture of unmanned aerial vehicles. While an example of an unmanned aerial vehicle is described, the disclosed embodiments and principles are applicable to other products in the aerospace industry, as well as other products in other industries, such as, for example, the automotive industry, the space industry, the construction industry, and other design and manufacturing industries. Thus, the disclosed embodiments and principles can be implemented in the manufacture of parts and accessories for types of vehicles other than unmanned aerial vehicles, as well as in the construction of various types of buildings.

[0052] In the foregoing detailed description, reference is made to the accompanying drawings, which illustrate specific embodiments described in the present disclosure. However, other embodiments that differ in structure or operation do not depart from the scope of the present disclosure. The same reference numerals may refer to the same feature, element, or component in different drawings. Throughout this disclosure, the term "an item" may refer to any one of multiple items individually or to multiple items collectively. Furthermore, in this specification, the term "a" or "an" refers to a feature, element, component, or step in the singular, but does not exclude the presence of multiple features, elements, components, or steps unless expressly stated otherwise.

[0053] Illustrative, non-exhaustive examples of the subject matter according to the present disclosure are described above, and these may, but are not necessarily, recited in the claims. The term "example" as used herein means that one or more features, structures, elements, components, properties, and / or process steps described in connection with that example are included in at least one aspect, embodiment, and / or implementation of the subject matter according to the present disclosure. Thus, terms such as "one example," "another example," "one or more examples," and similar terms in this disclosure may, but do not necessarily, refer to the same example. Furthermore, features characterizing one example may, but do not necessarily, include features characterizing any other example. Furthermore, features characterizing one example may, but do not necessarily, be combined with features characterizing any other example.

[0054] As used herein, a system, apparatus, device, structure, article, element, component, or hardware that is "configured" to perform a particular function refers to one that can perform that particular function without any modification, and not one that could perform that particular function with any modification. That is, a system, apparatus, device, structure, article, element, component, or hardware that is "configured" to perform a particular function refers to one that is specifically selected, made, implemented, used, programmed, and / or designed to perform that particular function. As used herein, "configured" refers to characteristics that a system, apparatus, structure, article, element, component, or hardware already possesses that enable the system, apparatus, structure, article, element, component, or hardware to perform that particular function without any modification. In this disclosure, a system, apparatus, device, structure, article, element, component, or hardware that is described as "configured" to perform a particular function may additionally or alternatively be described as "adapted" and / or "operable" to perform that function.

[0055] Unless otherwise specified, the terms "first," "second," "third," etc. are used herein merely as labels and do not impose any ordering, positional, or hierarchical requirements on the items to which these terms refer. Furthermore, a reference to, for example, a "second" item does not require or exclude the presence of, for example, a "first" item or lower ordinal items and / or a "third" item or higher ordinal items.

[0056] As used herein, the phrase "at least one," when used in connection with a list of items, means that one or more of the listed items may be used in various combinations, or that only one of the listed items may be required. For example, "at least one of item A, item B, and item C" includes, but is not limited to, item A, or item A and item B. This example also includes items A, B, and C, or items B and C. In other examples, "at least one" may mean, but is not limited to, two items A, one item B, and ten items C, four items B, and seven items C, or any other suitable combination. As used herein, the phrase "and / or" and the symbol " / " include any and all combinations of one or more of the associated listed items.

[0057] As used herein, the terms "coupled," "couple," and the like refer to two or more elements being joined, linked, fastened, attached, connected, in communication, or otherwise associated (e.g., mechanically, electrically, fluidly, optically, electromagnetically) with one another. In various embodiments, these elements may be directly or indirectly associated. As an example, element A may be directly associated with element B. As another example, element A may be indirectly associated with element B, e.g., through another element C. It should be noted that not all associations between the various elements of this disclosure are necessarily shown. Thus, other connections may exist than those shown.

[0058] As used herein, the term "about" refers to a condition that is not exactly the same as the described condition, but is close to the described condition and is capable of performing the desired function or achieving the desired result. As an example, the term "about" refers to a condition that is within an acceptable range of a predetermined tolerance or precision, for example, within 10% of the described condition. However, the term "about" does not exclude a condition that exactly matches the described condition. Also, as used herein, the term "substantially" refers to a condition that is essentially the same as the described condition and is capable of performing the desired function or achieving the desired result.

[0059] The blocks shown in Figures 1, 7-10, 12A-12B, 13, and 14 referenced above represent, for example, processes, steps, and / or portions thereof, and the lines connecting various blocks do not necessarily imply a particular order or dependency relationship between these processes or portions thereof. It should be noted that not all dependencies among the various processes disclosed are necessarily shown. Figures 1, 7-10, 12A-12B, 13, and 14, and the disclosures describing the processes of the methods described herein, do not necessarily dictate the order in which these processes are performed. Rather, while suggesting one exemplary order, it should be understood that the order of these processes may be changed as appropriate. Accordingly, specific illustrated processes may be modified, added, and / or omitted, and some processes may be performed in a different order or simultaneously. Furthermore, one skilled in the art will recognize that not all of the processes described need to be performed.

[0060] 2A-2C, 3-6, and 11 referenced in the above description depict functional elements, features, or components thereof and do not necessarily imply a specific, concrete structure. Therefore, the illustrated structures may be modified, added, and / or omitted. Furthermore, those skilled in the art will recognize that not all elements, features, and / or components shown and described in FIGS. 2A-2C, 3-6, and 11 need be included in every embodiment, and not all elements, features, and / or components described herein may be illustrated for each embodiment. Thus, some of the elements, features, and / or components shown and described in FIGS. 2A-2C, 3-6, and 11 may be combined in various ways without including other features shown in FIGS. 2A-2C, 3-6, and 11, other figures, and / or the accompanying disclosure, without such combinations being explicitly set forth herein. Similarly, additional features not limited to the presented embodiments may be combined with some or all of the features shown and described herein. Unless otherwise noted, the schematic diagrams of the above-described embodiments shown in Figures 2A-2C, 3-6, and 11 are not intended to imply architectural limitations on the exemplary embodiments. Rather, they illustrate one exemplary structure, which should be understood as being modifiable. Thus, illustrated structures may be modified, added, and / or omitted. Furthermore, elements, features, and / or components serving similar, or at least substantially similar, purposes in each of Figures 2A-2C, 3-6, and 11 are labeled with the same reference numerals, and such elements, features, and / or components may not be described in detail herein with reference to Figures 2A-2C, 3-6, and 11. Similarly, not all elements, features, and / or components are labeled with reference numerals in each of Figures 2A-2C, 3-6, and 11, but for consistency, the reference numerals associated with such elements, features, and / or components may be used herein.

[0061] Furthermore, references to features, advantages, or similar terms throughout this specification do not imply that all features and advantages that may be realized by the embodiments disclosed herein should or are included in any single embodiment. Rather, a description of features and advantages means that the particular feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment. Thus, references to features, advantages, and similar terms used in this disclosure do not necessarily refer to the same embodiment, although they may.

[0062] Embodiments of the subject matter disclosed herein may be described with reference to an unmanned aerial vehicle manufacturing and service method 1500 shown in FIG. 15 and an unmanned aerial vehicle 1600 shown in FIG. 16 . In one or more embodiments, the manufacturing methods 100, 700, 800, 900, 1000, 1200, 1300, and 1400 of an additively manufactured object 200 for an internal combustion engine and embodiments of the additively manufactured object 200 for an internal combustion engine of the present disclosure are applicable to the manufacture of unmanned aerial vehicles. The service method 1500 includes specification and design (block 1502) and material procurement (block 1504) of the unmanned aerial vehicle 1600 prior to the start of production. During production, component and subassembly manufacturing (block 1506) and system integration (block 1508) of the unmanned aerial vehicle 1600 occurs. The unmanned aerial vehicle 1600 then undergoes certification and delivery (block 1510) before entering service (block 1512). While in service, unmanned aerial vehicle 1600 undergoes routine maintenance and upkeep (block 1514), which may include upgrading, reconfiguring, refurbishing, etc., one or more systems of unmanned aerial vehicle 1600.

[0063] Each step of maintenance method 1500 may be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). System integrators include, but are not limited to, any number of aircraft manufacturers and major system subcontractors. Third parties include, but are not limited to, any number of vendors, subcontractors, and suppliers. Operators include, but are not limited to, airlines, leasing companies, military entities, service organizations, and the like.

[0064] 16 , unmanned aerial vehicle 1600 produced by maintenance method 1500 includes an airframe 1602 with multiple high-level systems 1604. Examples of high-level systems 1604 include one or more of a propulsion system, a hydraulic system, an electrical system, and an environmental system. The high-level systems 1604 may also include any other systems. While an aerospace industry example is shown here, the principles disclosed herein are applicable to other industries, such as the automotive industry. Thus, the principles disclosed herein are applicable not only to unmanned aerial vehicle 1600 but also to other vehicles, such as land vehicles, watercraft, and spacecraft.

[0065] Methods 100, 700, 800, 900, 1000, 1200, 1300, and 1400 for manufacturing additively manufactured object 200 for an internal combustion engine according to the present disclosure, and additively manufactured object 200 for an internal combustion engine, may be employed during any one or more stages of maintenance method 1500. For example, the parts or subassemblies produced during part and subassembly manufacturing (block 1506) may be manufactured or produced in a manner similar to the parts and subassemblies produced during the operation of unmanned aerial vehicle 1600 (block 1512). Additionally, one or more embodiments of the additively manufactured object, method, or combination thereof may be used during the production stage (blocks 1506 and 1508) to significantly improve, for example, the speed and cost of assembly of unmanned aerial vehicle 1600. Similarly, one or more embodiments of the additive manufacturing product, method, or combination thereof may be used, for example and without limitation, during the operation (block 1512) and / or maintenance and upkeep (block 1514) of the unmanned aerial vehicle 1600.

[0066] Features, advantages, and characteristics described herein with respect to one embodiment may be combined in any suitable manner in one or more other embodiments. Those skilled in the art will understand that embodiments described herein can be practiced without one or more of the specific features or advantages of a particular embodiment. Furthermore, additional features and advantages present in a particular embodiment may not be present in all embodiments. Furthermore, while various embodiments of the methods 100, 700, 800, 900, 1000, 1200, 1300, and 1400 for manufacturing an additively manufactured object 200 for an internal combustion engine according to the present disclosure, and the additively manufactured object 200 for an internal combustion engine, have been shown and described, various modifications will occur to those skilled in the art in light of this specification. The present application is intended to encompass such modifications and is limited only by the scope of the claims.

[0067] The present disclosure also includes the following notes:

[0068] Appendix 1. A method (100) for manufacturing an additively manufactured object (200) for an internal combustion engine, comprising: identifying (102) a starting point (302) on a build plate (304) for building an additively manufactured object (200) including a body portion (202) and at least two gas ports (204), the body portion (202) defining an outer body surface (206) and an inner body bore (208), the inner body bore (208) defining an inner body surface (210), each gas port (204) defining an outer port surface (212) and an inner port bore (213), and each port bore (213) defining an inner port surface (214); determining (104) a build orientation (306) of the additively manufactured object (200) relative to the build plate (304) such that the surface areas of the main body inner surface (210) and each port inner surface (214) are offset at an angle of at least about 20 degrees from a direction parallel to the build plate (304) of the additively manufactured object (200), such that no portion of the surface area corresponds to an area of ​​a circle with a radius of 5 mm or more; A method comprising:

[0069] Appendix 2. 2. The method of claim 1, wherein the build orientation (306) of the additive manufactured body (200) relative to the build plate (304) is an orientation in which the surface areas of the main body inner surface (210) and each port inner surface (214) are offset at an angle of at least about 25 degrees relative to a direction parallel to the build plate (304) of the additive manufactured body (200), so that no portion of the surface area of ​​the main body inner surface (210) or each port inner surface (214) has an area equivalent to a circle with a radius of 5 mm or more.

[0070] Appendix 3. 3. The method of claim 2, wherein the build orientation (306) of the additive manufactured body (200) relative to the build plate (304) is an orientation in which the surface areas of the main body inner surface (210) and each port inner surface (214) are offset at an angle of at least about 30 degrees relative to a direction parallel to the build plate (304) of the additive manufactured body (200), so that no portion of the surface area of ​​the main body inner surface (210) or each port inner surface (214) has an area equivalent to a circle with a radius of 5 mm or more.

[0071] Appendix 4. 2. The method of claim 1, wherein the body portion (202) includes an engine cylinder (216), and the at least two gas ports (204) include an intake port (218) and an exhaust port (220).

[0072] Appendix 5. Preparing (106) the build plate (304) and a metal powder bed for construction of the additively manufactured object (200); welding (108) a first layer of the additively manufactured object (200) and a first layer of support material (308) that extends from the build plate (304) to selected locations on an outer portion of the additively manufactured object (200) to provide support during build to the build plate (304) using laser powder bed fusion; 2. The method of claim 1, further comprising repeating (110) preparing (106) the build plate (304) and welding (108) the first layer to continue additive manufacturing of the additively manufactured body (200) and the support material (308) until welding of a final layer.

[0073] Appendix 6. 6. The method of claim 5, wherein the welding (108) is performed with a melting laser.

[0074] Appendix 7. 6. The method of claim 5, wherein the additive manufacturing process forms internal fluid flow paths (222) near the body bore (208) or near one or more of the at least two gas ports (204) to promote cooling.

[0075] Appendix 8. 6. The method of claim 5, wherein the additive manufacturing process forms external cooling fins (223) extending from the outer surface (206) of the main body portion (202).

[0076] Appendix 9. 6. The method of claim 5, wherein the body inner surface (210) and each port inner surface (214) are fabricated without support material (308) on the build plate (304) during the additive manufacturing.

[0077] Appendix 10. 6. The method of claim 5, wherein an internal surface area of ​​the additively manufactured object (200) that is difficult to access for machining is manufactured without support material (308) on the build plate (304) during the additive manufacturing.

[0078] Appendix 11. forming a filleted transition portion (224) (702) at a connection portion between the at least two gas ports (204) and the main body portion (202), the filleted transition portion (224) integrating each port inner surface (214) of the at least two gas ports (204) with the main body inner surface (210); 6. The method (700) of claim 5, wherein the radius of the filleted transition portion (224) is less than about 3 mm where the transition surface (226) of the filleted transition portion (224) is offset at an angle of less than about 20 degrees from a direction parallel to the build plate (304).

[0079] Appendix 12. 12. The method of claim 11, wherein the radius of the filleted transition portion (224) is less than about 5 mm where the transition surface (226) of the filleted transition portion (224) is offset at an angle of less than about 20 degrees from a direction parallel to the build plate (304).

[0080] Appendix 13. 6. The method of claim 5, wherein the additive manufacturing process forms a metal sleeve (310) having a plurality of powder removal holes (402) on the inner surface (210) of the body bore (208) to facilitate subsequent post-processing of the inner surface (210).

[0081] Appendix 14. 6. The method of claim 5, wherein the additive manufacturing process forms a plurality of continuous cylindrical walls that enable the additive manufacturing process to form unsupported edges of the at least two gas ports (204) that intersect with the body bore (208), and the continuous cylindrical walls are subsequently machined in post-processing to expose the at least two gas ports (204) to the body bore (208).

[0082] Appendix 15. 6. The method of claim 5, wherein the metal powder comprises a metal alloy material that maintains a tensile strength of greater than 30 kilopounds per square inch for 1,000 hours at an operating temperature of 475°F.

[0083] Appendix 16. 16. The method of claim 15, wherein the metal alloy material comprises at least one of an aluminum alloy material and a magnesium alloy material.

[0084] Appendix 17. The preparation (106) of the build plate (304) comprises: 6. The method (800) of claim 5, comprising preheating (802) the metal powder bed prior to welding (108) the first layer, and preheating (802) a previously welded layer of the additively manufactured body (200) prior to welding a next layer of the additively manufactured body (200), wherein the preheating reduces a temperature gradient in the additively manufactured body (200).

[0085] Appendix 18. 18. The method of claim 17, wherein the preheating (802) is performed by a preheating laser.

[0086] Appendix 19. 18. The method of claim 17, further comprising post-heating (804) the metal powder bed after welding (108) the first layer, and post-heating (804) the current welded layer before preparing a next layer of the additively manufactured body (200) during the additive manufacturing, wherein the post-heating reduces a temperature gradient in the additively manufactured body (200).

[0087] Appendix 20. 6. The method (900) of claim 5, further comprising post-heating (902) the metal powder bed after welding (108) the first layer, and post-heating (902) the current welded layer before preparing a next layer of the additively manufactured body (200) during the additive manufacturing, wherein the post-heating reduces a temperature gradient in the additively manufactured body (200).

[0088] Appendix 21. 21. The method of claim 20, wherein the post-heating (902) is performed by a post-heating laser.

[0089] Appendix 22. removing (1002) the support material (308) from the additively manufactured object (200); grinding, polishing, cleaning, and / or honing (1004) the inner body surface (210) of the body bore (208); 6. The method (1000) of claim 5, further comprising applying (1006) a wear-resistant coating (228) to at least a portion of the body inner surface (210) of the body bore (208) in preparation for subsequent contact with a piston or piston ring.

[0090] Appendix 23. 23. The method of claim 22, wherein the wear-resistant coating (228) comprises at least one of a nickel-silicon carbide coating and a tungsten carbide coating.

[0091] Appendix 24. 23. The method of claim 22, further comprising applying a strike plating to at least a portion of the additively manufactured body (200) prior to applying (1006) the wear resistant coating (228).

[0092] Appendix 25. 23. The method of claim 22, further comprising applying an electroless nickel plating to at least a portion of the additively manufactured body (200) prior to applying (1006) the wear resistant coating (228).

[0093] Appendix 26. 23. The method of claim 22, further comprising direct age hardening (1008) the additively manufactured body (200) to improve tensile strength.

[0094] Appendix 27. 27. The method of claim 26, wherein the wear-resistant coating (228) has a Vickers hardness of 400 or greater and 2800 or less.

[0095] Appendix 28. An additive manufactured object (200) for an internal combustion engine, comprising: a body portion (202) defining an outer body surface (206) and an inner body bore (208), the inner body bore (208) defining an inner body surface (210); at least two gas ports (204), each defining an outer port surface (212) and an inner port bore (213), each port bore (213) defining an inner port surface (214); An additive manufactured product, wherein the surface areas of the body inner surface (210) and each port inner surface (214) are offset at an angle of at least about 20 degrees relative to a direction parallel to the build plate (304) of the additive manufactured product (200), such that no portion of any of the surface areas corresponds to an area of ​​a circle with a radius of 5 mm or more.

[0096] Appendix 29. 29. The additive manufactured product of claim 28, wherein the surface areas of the body inner surface (210) and each port inner surface (214) are offset by at least about 25 degrees from a direction parallel to the build plate (304) of the additive manufactured product (200) such that no portion of any of the surface areas corresponds to an area of ​​a circle with a radius of 5 mm or more.

[0097] Appendix 30. 30. The additive manufactured product of claim 29, wherein the surface areas of the body inner surface (210) and each port inner surface (214) are offset by at least about 30 degrees from a direction parallel to the build plate (304) of the additive manufactured product (200) such that no portion of any of the surface areas corresponds to an area of ​​a circle with a radius of 5 mm or more.

[0098] Appendix 31. 29. The additively manufactured article of claim 28, wherein the body portion (202) includes an engine cylinder (216), and the at least two gas ports (204) include an intake port (218) and an exhaust port (220).

[0099] Appendix 32. 29. The additively manufactured article of claim 28, further comprising an internal fluid flow path (222) near the body bore (208) or near one or more of the at least two gas ports (204).

[0100] Appendix 33. 29. The additively manufactured article of claim 28, further comprising external cooling fins (223) extending from the outer body surface (206) of the body portion (202).

[0101] Appendix 34. the at least two gas ports (204) are connected to the body portion (202) such that each port inner surface (214) of the at least two gas ports (204) is integrated into the body inner surface (210) to form a filleted transition (224) between the body portion (202) and each of the at least two gas ports (204); 29. The additively manufactured article of claim 28, wherein the radius of the filleted transition portion (224) is less than about 3 mm where the transition surface (226) of the filleted transition portion (224) is offset at an angle of less than about 20 degrees relative to a direction parallel to the build plate (304).

[0102] Appendix 35. 35. The additively manufactured article of claim 34, wherein the radius of the filleted transition portion (224) is less than about 5 mm where the transition surface (226) of the filleted transition portion (224) is offset at an angle of less than about 20 degrees relative to a direction parallel to the build plate (304).

[0103] Appendix 36. 29. The additively manufactured article of claim 28, wherein the additively manufactured article (200) comprises a metal alloy material that maintains a tensile strength of greater than 30 kilopounds per square inch for 1,000 hours at an operating temperature of 475°F.

[0104] Appendix 37. 37. The additively manufactured object of claim 36, wherein the metal alloy material comprises at least one of an aluminum alloy material and a magnesium alloy material.

[0105] Appendix 38. 37. The additively manufactured body of claim 36, wherein the additively manufactured body (200) achieves the tensile strength by direct age hardening.

[0106] Appendix 39. The main body portion (202) is 29. The additively manufactured article of claim 28, comprising a wear-resistant coating (228) on the body inner surface (210) of the body bore (208) to prepare for subsequent contact with a piston or piston ring.

[0107] Appendix 40. 40. The additively manufactured article of claim 39, wherein the wear-resistant coating (228) has a hardness of 400 or greater and 2800 or less on the Vickers hardness scale.

[0108] Appendix 41. 40. The additively manufactured article of claim 39, wherein the wear-resistant coating (228) comprises at least one of a nickel-silicon carbide coating and a tungsten carbide coating.

[0109] Appendix 42. 29. The additively manufactured body of claim 28, further comprising a strike plating on at least a portion of the additively manufactured body (200).

[0110] Appendix 43. 29. The additively manufactured body of claim 28, further comprising electroless nickel plating on at least a portion of the additively manufactured body (200).

[0111] Appendix 44. A method (1200) for manufacturing an additive manufactured object (200) for an internal combustion engine, comprising: identifying (1202) a starting point (302) on a build plate (304) for building an additively manufactured object (200) including a body portion (202) and at least two gas ports (204), the body portion (202) defining an outer body surface (206) and an inner body bore (208), the inner body bore (208) defining an inner body surface (210), each gas port (204) defining an outer port surface (212) and an inner port bore (213), and each port bore (213) defining an inner port surface (214); determining (1204) a build orientation (306) of the additively manufactured object (200) relative to the build plate (304) such that the surface areas of the main body inner surface (210) and each port inner surface (214) are offset at an angle of at least about 20 degrees from a direction parallel to the build plate (304) of the additively manufactured object (200), such that no portion of the surface area corresponds to an area of ​​a circle with a radius of 5 mm or more; Preparing (1206) the build plate (304) and a metal powder bed for construction of the additively manufactured object (200); welding (1208) the first layer of the additively manufactured object (200) and a first layer of support material (308) that extends from the build plate (304) to selected locations on an outer portion of the additively manufactured object (200) to provide support during build to the build plate (304) using laser powder bed fusion; repeating (1210) the preparation (1206) of the build plate (304) and the welding (1208) of the first layer to continue additive manufacturing of the additively manufactured object (200) and the support material (308) until the welding of a final layer; removing (1212) the support material (308) from the additively manufactured object (200); grinding, polishing, cleaning, and / or honing (1214) the inner body surface (210) of the body bore (208); applying (1216) a wear-resistant coating (228) to at least a portion of the body interior surface (210) of the body bore (208) in preparation for subsequent contact with a piston or piston ring; and direct age hardening (1218) the additively manufactured body (200) to improve tensile strength.

[0112] Appendix 45. 45. The method of claim 44, further comprising forming a filleted transition portion (1302) at a connection portion between the at least two gas ports (204) and the main body portion (202) that integrates each port inner surface (214) of the at least two gas ports (204) with the main body inner surface (210), wherein a radius of the filleted transition portion (224) is less than about 3 mm where a transition surface (226) of the filleted transition portion (224) is offset at an angle of less than about 20 degrees with respect to a direction parallel to the build plate (304).

[0113] Appendix 46. 45. The method of claim 44, further comprising post-heating (1304) the metal powder bed after welding (1208) the first layer, and post-heating (1304) the current welded layer before preparing (1206) a next layer of the additively manufactured body (200) during the additive manufacturing, wherein the post-heating reduces a temperature gradient in the additively manufactured body (200).

[0114] Appendix 47. Preparing (1206) the build plate (304) includes: 45. The method (1400) of claim 44, comprising preheating (1402) the metal powder bed prior to welding (1208) the first layer, and preheating (1402) a previously welded layer prior to welding (1208) a next layer of the additively manufactured body (200) during the additive manufacturing, wherein the preheating reduces a temperature gradient in the additively manufactured body (200).

[0115] Appendix 48. 45. The method of claim 44, further comprising applying a strike plating to at least a portion of the additively manufactured body (200) prior to applying (1216) the wear resistant coating (228).

[0116] Appendix 49. 45. The method of claim 44, further comprising applying an electroless nickel plating to at least a portion of the additively manufactured body (200) prior to applying (1216) the wear resistant coating (228).

Claims

1. 1. A method for manufacturing an additively manufactured object for an internal combustion engine, comprising: identifying a starting point on a build plate for construction of an additively manufactured object comprising a body portion and at least two gas ports, the body portion defining an outer body surface and an inner body bore, the body bore defining an inner body surface, each gas port defining an outer port surface and an inner port bore, and each port bore defining an inner port surface; and specifying a build orientation of the additive manufacturing body relative to the build plate such that the surface areas of the main body inner surface and the inner surfaces of each port do not have a portion corresponding to an area of ​​a circle with a radius of 5 mm or more, and the surface areas are offset at an angle of at least about 20 degrees from a direction parallel to the build plate on the additive manufacturing body.

2. 2. The method of claim 1, wherein the printing orientation of the additive manufacturing body relative to the build plate is such that the surface areas of the main body inner surface and the port inner surfaces are offset at an angle of at least about 25 to 30 degrees with respect to a direction parallel to the build plate, such that no portion of the surface area of ​​the main body inner surface or the port inner surface has an area corresponding to a circle with a radius of 5 mm or more.

3. The method of claim 1 , wherein the body includes an engine cylinder and the at least two gas ports include an intake port and an exhaust port.

4. preparing the build plate and a metal powder bed for construction of the additively manufactured object; welding a first layer of the additive structure and a first layer of support material extending from the build plate to a selected location on an outer portion of the additive structure to provide support during build to the build plate using laser powder bed fusion; 10. The method of claim 1, further comprising repeating the preparation of the build plate and the welding of the first layer to continue additive manufacturing of the additive structure and the support material through welding of a final layer.

5. The method of claim 4 wherein the welding is performed with a melting laser.

6. 5. The method of claim 4, wherein the additive manufacturing process creates internal fluid channels adjacent the body bore or adjacent one or more of the at least two gas ports to facilitate cooling, and also creates external cooling fins extending from the body exterior surface of the body portion.

7. 5. The method of claim 4, wherein the body interior surface and each port interior surface are built without supports relative to the build plate during the additive manufacturing, and further wherein interior surface regions of the additively manufactured body that are difficult to access for machining are built without supports relative to the build plate.

8. forming a filleted transition portion at a connection portion between the at least two gas ports and the main body portion, the transition portion integrating an inner surface of each of the at least two gas ports with an inner surface of the main body; 5. The method of claim 4, wherein the radius of the filleted transition is less than about 3-5 mm where the transition surface of the filleted transition is offset at an angle of less than about 20 degrees relative to a direction parallel to the build plate.

9. 5. The method of claim 4, wherein the additive manufacturing process forms a metal sleeve having a plurality of powder removal holes in the interior body surface of the body bore to facilitate subsequent post-processing of the interior body surface, and further forms a plurality of continuous cylindrical walls that enable the additive manufacturing process to form unsupported edges of the at least two gas ports that intersect the body bore, and the continuous cylindrical walls are machined in subsequent post-processing to expose the at least two gas ports to the body bore.

10. 5. The method of claim 4, wherein the metal powder comprises a metal alloy material that maintains a tensile strength of greater than 30 kilopounds per square inch for 1,000 hours at an operating temperature of 475°F.

11. The method of claim 10 , wherein the metal alloy material comprises at least one of an aluminum alloy material and a magnesium alloy material.

12. The preparation of the build plate includes:

5. The method of claim 4, comprising preheating the metal powder bed prior to welding of the first layer, and preheating a previously welded layer prior to welding of a next layer of the additive manufactured body during the additive manufacturing, wherein the preheating reduces thermal gradients in the additive manufactured body.

13. The method of claim 12 , wherein the preheating is performed by a preheating laser.

14. 13. The method of claim 4 or 12, further comprising post-heating the metal powder bed after welding of the first layer, and post-heating a current welded layer before preparing a next layer of the additive manufactured body during the additive manufacturing, wherein post-heating reduces a temperature gradient in the additive manufactured body.

15. The method of claim 14 , wherein the post-heating is performed by a post-heating laser.

16. removing the support material from the additively manufactured object; grinding, polishing, cleaning, and / or honing the interior body surface of the body bore; 5. The method of claim 4, further comprising applying a wear-resistant coating to at least a portion of the interior body surface of the body bore in preparation for subsequent contact with a piston or piston ring.

17. The method of claim 16, wherein the wear-resistant coating comprises at least one of a nickel-silicon carbide coating and a tungsten carbide coating.

18. 17. The method of claim 16, further comprising applying a strike plating or an electroless nickel plating to at least a portion of the additively manufactured article prior to application of the wear resistant coating.

19. 17. The method of claim 16, further comprising direct age hardening the additively manufactured body to improve tensile strength.

20. 20. The method of claim 19, wherein the wear-resistant coating has a hardness of 400 or greater and 2800 or less on the Vickers hardness scale.

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