Use of different additive manufacturing processes to produce parts

Abstract

It provides the use of different additive manufacturing processes for producing parts. [Solution] A combination of additive manufacturing processes is provided that can generate different parts or features of a hybrid structure, such that a complex seed part or first section of the hybrid component can be formed using a first additive manufacturing process, and a second section of the hybrid component can be formed using different additive manufacturing processes. When the two components are manufactured, a mandrel can be incorporated into the first component to provide rigidity and resistance to deformation of the first component, both during and after the formation of the second component on the interface of the first component using the second additive manufacturing process. Finally, supports can be formed directly on the base plate so that the temperature of the base plate can rise to equilibrium with the temperature of the newly deposited material.

Description

Technical Field

[0001] Background Technical Field

[0001] This disclosure relates to a hybrid structure. More specifically, embodiments of this disclosure relate to joining additively manufactured components together.

Background Art

[0002] Background

[0002] Large structures can be assembled from smaller sub-components that are joined or bonded together. The sub-components can be joined together using physical joints such as bolted flanges or by joining processes such as welding. Multiple joining means or bonding means can be used to assemble larger structures. Additionally, sub-components of different materials can be joined or bonded so that the larger structure is a hybrid structure made from at least two different materials. For example, the first region of a larger component may use a material capable of withstanding high temperatures, and the second region of the larger component may use a material capable of withstanding large stresses or loads.

Summary of the Invention

Means for Solving the Problems

[0003] Summary

[0003] This disclosure may include one or more of the following features and combinations thereof. The description herein represents non-limiting embodiments of the invention.

[0004]

[0004] According to one embodiment of the present disclosure, an additively manufactured article is provided which is manufactured using two different additive manufacturing processes. The article comprises a first component and a second component. The first component has a first material and includes a printed inner surface, a printed outer surface, and an interface extending from the printed inner surface to the printed outer surface. The first component has first beading characteristics of a first additive manufacturing process. The second component is bonded to the interface of the first component and extends away from the interface of the first component. The second component has second beading characteristics of a second additive manufacturing process. The second additive manufacturing process is different from the first additive manufacturing process. The first material is a low thermal conductivity material. The interface is a flat surface.

[0005]

[0005] An article is presented in which the first component is a powder bed fusion component.

[0006]

[0006] An article is presented in which the first material is a nickel-chromium superalloy.

[0007]

[0007] An article is presented in which the second component is directly an energy deposition component.

[0008]

[0008] An article is presented in which the second component is made of a second material different from the first material.

[0009]

[0009] An article is presented in which the second material is an iron-nickel superalloy.

[0010]

[0010] An article is presented in which the first component further includes a plurality of ports extending away from the printed outer surface, and no ports are formed on the second component.

[0011]

[0011] An article is presented in which the cross-section of the first component is substantially circular, the first component further includes a member extending radially from the printed outer surface, and the second component includes a substantially smooth outer surface.

[0012]

[0012] An article is presented in which the interface is substantially circular and includes at least two lands extending circumferentially around the circle, and the second component is joined to at least two lands.

[0013]

[0013] An article is presented in which the interface has a first width between the printed inner surface and the printed outer surface, and each of at least two lands has a second width of 10 to 30 percent of the first width.

[0014]

[0014] An article having a second width of 0.5 mm to 1.5 mm is presented.

[0015]

[0015] An article is presented in which the second component extends perpendicularly away from the interface.

[0016]

[0016] An article is presented in which the second component has a conical shape and the second component comprises a plurality of wedge-shaped layers.

[0017]

[0017] An article is presented in which a second component is joined to a first component by either micro-welding or fusion bonding.

[0018]

[0018] According to one embodiment of the present disclosure, the present disclosure presents a method for manufacturing a hybrid structure, the method is The method involves forming a first component on a base plate by additive manufacturing, wherein the first component has a low thermal conductivity material and includes a proximal end on the base plate and a distal end opposite the proximal end. Removing the first component from the base plate at the proximal end, Machining the distal end of the first component to form an interface surface, forming the second component by additive manufacturing on the interface surface such that the second component is coupled to and extends away from the interface surface of the first component, having, The interface surface is planar.

[0019]

[0019] A method is presented in which the second component extends perpendicularly away from the first component at the interface surface.

[0020]

[0020] A method is presented in which forming the second component includes depositing a plurality of wedge-shaped layers such that the second component forms a conical shape.

[0021]

[0021] A method is presented in which the interface surface is substantially circular and includes at least two lands extending circumferentially around the circle, and the second component is formed on the at least two lands.

[0022]

[0022] A method is presented in which forming the first component includes powder bed fusion.

[0023]

[0023] A method is presented in which forming the second component includes direct energy deposition.

[0024]

[0024] A method is presented in which the low thermal conductivity material of the first component is a nickel-chromium superalloy and the second component includes an iron-nickel superalloy material.

[0025]

[0025] A method is presented in which removing the first component from the base plate includes machining the proximal end to form an upper surface.

[0026]

[0026] A method is presented in which the interface surface is parallel to the upper surface.

[0027]

[0027] A method is provided which further includes heat-treating the first component together with the second component.

[0028]

[0028] Further features and advantages, as well as the structure and operation of various embodiments, will be described in detail below with reference to the accompanying drawings. It should be noted that the specific embodiments described herein are not intended to be limiting. Such embodiments are presented herein for illustrative purposes only. Additional embodiments will be apparent to those skilled in the art based on the teachings contained herein.

[0029] Brief explanation of the drawing

[0029] The accompanying drawings incorporated herein and forming part thereof illustrate embodiments of the present disclosure, further illustrate the principles of the present disclosure together with the description, and enable those skilled in the art to manufacture and use the present disclosure. [Brief explanation of the drawing]

[0030] [Figure 1]

[0030] A perspective view of a hybrid structure according to one embodiment is shown. [Figure 2A]

[0031] A perspective view of the hybrid structure according to the embodiment is shown. [Figure 2B]

[0031] A perspective view of the hybrid structure according to the embodiment is shown. [Figure 2C]

[0031] A perspective view of the hybrid structure according to the embodiment is shown. [Figure 2D]

[0031] A perspective view of the hybrid structure according to the embodiment is shown. [Figure 2E]

[0031] A perspective view of the hybrid structure according to the embodiment is shown. [Figure 2F]

[0031] A perspective view of the hybrid structure according to the embodiment is shown. [Figure 2G]

[0031] A perspective view of the hybrid structure according to the embodiment is shown. [Figure 2H]

[0031] A perspective view of the hybrid structure according to the embodiment is shown. [Figure 3A]

[0032] A perspective view of an additively manufactured component placed on a base plate according to one embodiment is shown. [Figure 3B]

[0033] Figure 3A shows a detailed perspective view of the interface of an additively manufactured component according to one embodiment. [Figure 3C]

[0034] Figure 3A shows a detailed perspective view of the interface of an additively manufactured component according to one embodiment. [Figure 4]

[0035] A side cross-sectional view of a hybrid structure according to one embodiment is shown. [Figure 5A]

[0036] This shows a side cross-sectional view of a mandrel assembled into a component according to one embodiment. [Figure 5B]

[0037] This shows a side cross-sectional view of a mandrel assembled into a component according to one embodiment. [Figure 6]

[0038] A detailed side cross-sectional view of the mandrel and components of Figure 5A according to one embodiment is shown. [Figure 7A]

[0039] This shows a bottom view of a mandrel assembled into components according to one embodiment. [Figure 7B]

[0040] A detailed bottom view of the interface of the component shown in Figure 7A according to one embodiment is shown. [Figure 8]

[0041] A perspective view of a mandrel assembled into a component according to one embodiment is shown. [Figure 9]

[0042] A perspective view of a component including multiple support columns according to one embodiment is shown. [Figure 10]

[0043] A side view of a component including a first plurality of support columns and a second plurality of support columns according to one embodiment is shown. [Figure 11]

[0044] A plan view of a component including multiple support columns according to one embodiment is shown. [Figure 12A]

[0045] A side view of a component is shown illustrating different stages of machining the component according to one embodiment. [Figure 12B]

[0045] A side view of a component is shown illustrating different stages of machining the component according to one embodiment. [Figure 12C]

[0045] A side view of a component is shown illustrating different stages of machining the component according to one embodiment. [Figure 13]

[0046] This is a flowchart showing the steps of a method for manufacturing a hybrid structure according to one embodiment. [Modes for carrying out the invention]

[0031]

[0047] The features and advantages of the embodiments will become clearer from the detailed description below, along with the drawings, in which similar reference numerals identify corresponding elements throughout. In the drawings, similar reference numerals generally indicate identical, functionally similar, and / or structurally similar elements.

[0032] Detailed explanation

[0048] Different additive manufacturing processes have different advantages and disadvantages for additively manufacturing components. For example, powder bed fusion (PBF) can produce complex parts with intricate and detailed features and tight manufacturing tolerances. However, PBF is generally limited to smaller components based on the size of the tools currently available. In contrast, direct energy deposition (DED) or weld arc additive manufacturing (WAAM) can produce larger additively manufactured components, but these processes generally cannot achieve the same precision as PBF for forming more complex shapes, or may be more costly to add such detail to a component.

[0033]

[0049] The inventors have recognized and discovered that different parts or features of a hybrid structure can be generated by using a combination of additive manufacturing processes, such that a complex seed portion or first section of the hybrid component can be formed using a first additive manufacturing process, and a second section of the hybrid component can be formed using different additive manufacturing processes.

[0034]

[0050] The operating conditions of a component can determine its structural properties and / or shape. For example, if a component operates in a high-temperature environment and is manufactured from a material with high thermal conductivity, such as a copper alloy, the component may have thick walls because the material conducts heat easily. However, a component manufactured from a material with low thermal conductivity under the same operating conditions may have thinner walls to dissipate thermal energy. By manufacturing a hybrid structure with thick walls, manufacturability can be improved because the interface of the first component has a larger surface area on which the second additive manufacturing tool is positioned to form the second component. In contrast, manufacturing a hybrid structure with thin walls can be difficult because the additive manufacturing tolerances of the first component may be relatively large compared to the overall thickness of the component at the interface, and the second additive manufacturing tool must be precisely positioned on the thin interface. The inventors have recognized and discovered that, for example, in the case of thin-walled hybrid structures having correspondingly thin interface surfaces due to the use of low thermal conductivity materials, a second additively manufactured component can be directly formed on the flat interface surface of a first component to improve the reproducibility, integrity, and manufacturing yield of the joint. This disclosure describes inventive features of hybrid structures that can solve these and other problems discovered and overcome by the inventors by utilizing two or more additive manufacturing processes.

[0035]

[0051] The inventors have recognized and discovered that hybrid structures can be manufactured using two or more additive manufacturing techniques, thereby combining the advantages of a first additive manufacturing process, such as forming complex shapes, with a second additive manufacturing process, such as enabling the formation of large components at a relatively low cost. Generally, additively manufactured components are formed on a base plate. The base plate provides a solid and rigid base for the component, resisting deformation of the formed component during formation. The inventors have recognized and discovered that after a first component has been formed using the first additive manufacturing process, a mandrel can be incorporated into the first component to provide rigidity and resistance to deformation of the first component, even during and after the formation of the second component on the interface of the first component using the second additive manufacturing process.

[0036]

[0052] When additive manufacturing components are formed on a base plate, the initial layer of the component is at a high temperature, while the base plate remains at a low temperature. The base plate can be heated by conduction from the deposited layer of the component, but the temperature difference between the component and the base plate can still cause significant thermal stress within the component. Such thermal stress can cause deformation in the component during formation, resulting in low yield and components that do not meet stretch tolerances. The inventors have recognized and discovered that special structures, such as spaced supports, can be formed directly on the base plate before component formation, allowing the base plate temperature to rise and equilibrium with the temperature of the newly deposited material. Component formation can begin when the base plate temperature is substantially in equilibrium with the new material deposited on the supports.

[0037]

[0053] The inventors have recognized that additive-manufactured hybrid structures according to embodiments of the present invention offer greater design freedom than molded or welded parts, thus enabling greater design iterations, shorter lead times, and fewer parts for specific applications. For example, the inventors have recognized and discovered that conventional components with complex assemblies can be replaced with fewer additive-manufactured components joined together at interfaces.

[0038]

[0054] The embodiments of this disclosure will be described in detail with reference to the embodiments shown in the accompanying drawings. References such as “one embodiment,” “an embodiment,” and “some embodiments” indicate that one or more embodiments described may include certain features, structures, or characteristics, but not all embodiments may necessarily include such features, structures, or characteristics. Furthermore, such phrases do not necessarily refer to the same embodiment. In addition, where certain features, structures, or characteristics are described in relation to one embodiment, it is presented that any influence on such features, structures, or characteristics in relation to other embodiments, whether explicitly stated or not, is within the knowledge of those skilled in the art.

[0039]

[0055] In some embodiments of this disclosure, the terms “about” and “substantially” may refer to values ​​of a given quantity that vary within 20% of the value (e.g., ±1%, ±2%, ±3%, ±4%, ±5%, ±10%, ±20%). These values ​​are merely examples and are not intended to be limiting. The terms “about” and “substantially” may refer to percentages of a value as interpreted by those skilled in the art in light of the teachings herein.

[0040]

[0056] Spatially relative terms such as “down,” “below,” “bottom,” “up,” “top,” and similar terms may be used herein to facilitate description of the relationship between one element or feature shown in a figure and another element or feature. Spatially relative terms are intended to encompass different orientations of the device in use or operation, in addition to the orientation shown in the drawing. The device may be oriented in other ways (rotated 90 degrees or to other orientations), and the spatially relative descriptors used herein may be interpreted accordingly.

[0041]

[0057] Figure 1 shows an additively manufactured article 100 according to one embodiment. In some embodiments, the article 100 may be a hybrid structure comprising a first component 110 and a second component 112 bonded to the first component 110. The first component 110 and the second component 112 are each manufactured using additive manufacturing. Additive manufacturing is a process of manufacturing objects by depositing, joining, or solidifying materials under computer control. Materials such as molten plastics, liquids, or powder particles are added together layer by layer. As a result, additively manufactured parts are formed by basing up structural layers and fusing them together. These techniques allow users to generate complex additively manufactured objects from CAD models. The CAD model can be input into a 3D printer, which can form parts of the shape desired by the user.

[0042]

[0058] As described above, various technologies are available for additive manufacturing. In article 100, the first component 110 can be formed by a first additive manufacturing process, and the second component 112 can be formed by a second additive manufacturing process. The first additive manufacturing process differs from the second additive manufacturing process. The processes may differ, for example, in how the material is applied to the structure or how the material is fused to the structure once applied. For example, the first additive manufacturing process could be powder bed fusion, and the second additive manufacturing process could be direct energy deposition. Powder bed fusion applies layers of powder material and then applies an energy source to form a solid layer from the powder material. In contrast to this layer-by-layer application of heat, direct energy deposition supplies powder and heat simultaneously at the deposition site.

[0043]

[0059] Furthermore, the first and second additive manufacturing processes may be any of the following: laser powder bed fusion, laser powder direct energy deposition, wire feed direct energy deposition, welding arc additive manufacturing, binder jetting, and / or solid powder extrusion. In some embodiments, the first additive manufacturing process may be the same as the second additive manufacturing process. In some embodiments, the first component may be formed by a conventional manufacturing process such as casting, forging, machining, or other similar manufacturing processes, and the second component may be formed by additive manufacturing.

[0044]

[0060] As shown in Figures 1, 3A, and 4, the first component 110 may include an interface 132 at its distal end 122. The second component 112 can be formed directly on the interface 132 of the first component 110, for example, as shown in Figures 4 and 5. In some embodiments, article 100 may be a heat exchanger, nozzle, propellant tank, propellant tank and dome, propellant line, shaft, casing, or any other suitable component manufactured using additive manufacturing.

[0045]

[0061] Article 100 may include or have features corresponding to the respective advantages of the first and second additive manufacturing processes that form the first and second components 110 and 112, respectively. For example, the first component 110 may be manufactured using powder bed melting and may include complex features or shapes that would be impossible or prohibitively expensive to produce using other additive manufacturing processes or conventional manufacturing processes. Similarly, the second component 112 may be formed using, for example, powder-based direct energy deposition and can be used to create larger components. In some embodiments, the first component 110 may be manufactured using powder bed melting, direct energy deposition (wire-fed or powder-based), binder jetting, combined powder extrusion, or other additive manufacturing processes. In some embodiments, the second component 112 may be manufactured using powder bed melting, direct energy deposition (wire-fed or powder-based), binder jetting, combined powder extrusion, or other additive manufacturing processes.

[0046]

[0062] As shown in Figure 1, the first component 110 may have a first shape, and the second component 112 may have a second shape. For example, as shown in Figure 1, the first component 110 may include a cylindrical portion, and the second component 112 may include a cylindrical shape coupled to the first component 110. As illustrated in Figures 2A to 2H, the first component 110 and the second component 112 may include a plurality of different shapes and cross-sections. For example, the first component 110 and the second component 112 may be any combination of cylindrical, dome-shaped, conical, outward-facing hyperbola, square, rectangular, triangular, or any other polygonal shape. For example, as shown in Figure 2E, the first component 110 may be a cylindrical portion, and the second component 112 may be a plate. In some embodiments, the first component 110 may be a combination of shapes, and the second component 112 may be a combination of shapes. For example, as shown in Figures 1 and 2A to 2H, the first component 110 and the second component 112 have the same shape and a common cross-section at the interface 132.

[0047]

[0063] The first component 110 can form a first part or region of article 100 and can be coupled with a second component 112, for example, as shown in Figures 1, 2A to 2H, and 4. The first component 110 can be formed on a base plate 102 via a first additive manufacturing process, for example, as shown in Figure 3A. The base plate 102 may be a toolbed for the first additive manufacturing process. The base plate 102 can generally be a large metal plate. The base plate 102 may provide a flat surface on which the first component 110 can be formed. The base plate 102 can be hard and rigid so that components formed directly on the base plate 102 can resist deformation of material layers close to the base plate 102.

[0048]

[0064] The first component 110 includes, for example, a proximal end 120, a distal end 122, a printed inner surface 124, and a printed outer surface 126, as shown in Figures 3A and 4. The proximal end 120 of the first component 110 can be formed on the base plate 102, and the first component 110 can extend toward the distal end 122 away from the base plate 102. The first component 110 can be formed by first placing layers on the base plate 102 (possibly together with an intermediate delamination layer) to form the proximal end 120. Additional layers are formed layer by layer until the final layer of the distal end 122 is formed, thereby fabricating the first component 110.

[0049]

[0065] As illustrated in Figures 1, 3A, and 4, the distal end 122 of the first component 110 may be on the opposite side from the proximal end 120. The printed inner surface 124 can extend between the proximal end 120 and the distal end 122 and can form the inner diameter and circumference of the first component 110. As the first component 110 is formed, each layer defines the cross-section of the component. The innermost surface of the cross-section of each layer may be the printed inner surface 124. Depending on the manufacturing technique used to deposit each layer, the printed inner surface 124 may exhibit parasitic mass. Some manufacturing techniques may exhibit zero parasitic mass, while others may exhibit non-zero parasitic mass. In various embodiments, the exhibited parasitic mass may, at their discretion, be reduced or removed from the printed inner surface 124 by subsequent additional, conventional, or other processing techniques. When the first component 110 is cylindrical or conical, the printed inner surface 124 forms the inner diameter or circumference of the first component 110.

[0050]

[0066] As illustrated in Figures 1, 3A, and 4, the printed outer surface 126 extends between the proximal end 120 and the distal end 122 and can form the outer diameter and circumference of the first component 110. As the first component 110 is formed, each layer defines the cross-section of the component. The outermost surface of the cross-section of each layer may be the printed outer surface 126. The printed outer surface 126 can form the outer profile of the first component 110. Similar to the printed inner surface 124, the printed outer surface 126 may also exhibit parasitic mass, which, if present, can be optionally reduced or removed from the printed outer surface 126 by subsequent additional, conventional, or other processing techniques.

[0051]

[0067] In addition to the ribs 150, the first component 110 may include other features that increase the complexity of the first component 110 compared to the second component 112. For example, as shown in Figures 1 and 4, the first component 110 may include a plurality of members 152 extending away from the printed outer surface 126. In contrast, in some embodiments, the second component 112 may include a substantially smooth outer surface 164. The substantially smooth outer surface 164 does not have to include ports or members extending outward from the smooth outer surface 164. In some embodiments, the plurality of members 152 may include a plurality of ports. In some embodiments, the first component 110 may include a plurality of apertures or passages formed through the first component 110. In some embodiments, the plurality of members 152 may include arms, projections, ribs and / or mounting features extending outward away from the printed outer surface 126. In some embodiments, the plurality of members 152 may extend inward away from the printed inner surface 124. In some embodiments, the first component 110 is circular, and the multiple members 152 extend radially outward from the printed outer surface 126.

[0052]

[0068] The first component 110 may be formed from a first material 128, for example, as shown in Figure 4. In some embodiments, the first material 128 may be a low thermal conductivity material. For example, the first material 128 may be a nickel-chromium based superalloy such as Inconel 718 (IN718). In some embodiments, the first material 128 may have thermal conductivity properties of about 9.1 W / mKelvin to about 11.4 W / mKelvin. In some embodiments, the first material 128 may have room temperature thermal conductivity properties of about 10.0 W / mKelvin to about 11.0 W / mKelvin. In some embodiments, the first material 128 may have a thermal conductivity of about 10.4 W / mKelvin. Lower conductivity may increase the need for a mandrel. For higher conductivity materials, a mandrel may not be very useful. Because the material is deposited layer by layer, the material may have a pattern called beading. The beading may have a specific shape, size, or pattern that is characteristic of the manufacturing process used to form the first component 110. By examining this beading, a person skilled in the art may be able to understand what manufacturing process was used to produce the first component 110.

[0053]

[0069] After the first component 110 is formed on the base plate 102 by the first additive manufacturing process, the proximal end 120 of the first component 110 is removed from the base plate 102. For example, the proximal end 120 may be cut with an EDM wire to remove the first component 110 from the base plate 102. The first component 110 may be removed from the base plate 102 so that other machining operations that would be prohibited while the first component 110 is attached to the base plate 102 can be performed on the first component 110. For example, once the first component 110 is removed from the base plate 102, it can be machined to form the top surface 130 and the interface surface 132. Furthermore, once the first component 110 is removed from the base plate 102, it can be subjected to inspections such as dimensional inspection, material inspection, water flow testing, and other component testing procedures.

[0054]

[0070] The proximal end 120 may be machined to form an upper surface 130. The first component 110 may be clamped in place using a plurality of members 152, printed inner surfaces 124, or printed outer surfaces 126 to secure the first component 110 while the proximal end 120 is being machined. In some embodiments, the proximal end 120 may be machined by turning, machining, grinding, EDM wire cutting, or other suitable machining methods. The upper surface 130 may be a flat surface and may form a datum plane for machining downstream of the first component 110.

[0055]

[0071] The distal end 122 of the first component 110 may be machined to form an interface 132. As will be described in more detail below, a mandrel 200 may be assembled onto the first component 110 to hold it in place while the distal end 122 is being machined. In some embodiments, the distal end 122 may be machined by turning, machining, grinding, EDM wire cutting, or other suitable machining methods. In various embodiments, as illustrated in Figures 3A and 3B, the interface 132 is a flat surface, in other words, a surface in a plane parallel to the top surface 130. In other embodiments not shown in Figures 3A and 3B, the interface 132 is a conical surface, in other words, a surface in a cone with a peak substantially centered on the central axis of the first component 110 at a point closer to the proximal end 120 than the interface 132, or in an inverted cone with a peak substantially centered on the central axis at a point further from the proximal end 120 than the interface 132. In some embodiments, the interface 132 is substantially circular and can be formed with a roundness tolerance of + / - 0.25 mm via a first additive manufacturing process. As will be described in more detail below, the second component 112 is formed on the interface 132 to bond the first component 110 and the second component 112 to each other.

[0056]

[0072] The interface 132 may extend from the printed inner surface 124 to the printed outer surface 126, for example, as shown in Figures 3A, 3B, and 4. The interface 132 may have a first width 140 between the printed inner surface 124 and the outer surface 126, for example, as shown in Figure 4. In some embodiments, the first width 140 may be about 5 mm to about 25 mm. In some embodiments, the first width 140 may be about 7 mm to 15 mm. In some embodiments, the first width 140 may be about 10 mm. In various embodiments, the flat surface may have a flatness tolerance of 1 / 10,000 of an inch or less.

[0057]

[0073] As shown in Figure 4, the first component 110 may include a vertical surface 142 machined into the printed outer surface 126. The vertical surface 142 may be positioned spaced away from the interface 132 so that the interface 132 still extends between the printed inner surface 124 and the outer surface 126. However, in another embodiment, the vertical surface 142 is machined into the printed outer surface 126 so as to be in direct contact with the interface 132 at a 90-degree angle in embodiments where the interface 132 is planar, and as a result the interface 132 extends between the printed inner surface 124 and the vertical surface 142. In some embodiments, the vertical surface 142 may be used as a datum surface for checking the dimensions of the first component 110. For example, the vertical surface 142 may be machined into the inner or outer printed surfaces 124, 126 at the interface 132. As a result, the operator can use the machined surface to inspect other diametrical or radial features of the first component 110 relative to the vertical plane 142 and check the dimensional conformity of the first component 110. Figure 4 should be understood as a cross section that can be rotated (in the case of a circular component) or extended linearly at some angle (in the case of a non-circular component) in any of the components shown in Figures 2A to 2H.

[0058]

[0074] The interface 132 may include two or more interface lands 144, 146, for example, as shown in Figure 3C. Each interface land 144, 146 may be a projection extending circumferentially around the interface 132. The interface lands 144, 146 may have second widths 148, 149 smaller than the first width 140. In some embodiments, the second widths 148, 149 are equal, but in other embodiments they are different. In some embodiments, the second width 148 of the interface lands 144, 146 may be about 0.5 mm to about 3.0 mm. In some embodiments, the second width 148 of the interface lands 144, 146 may be about 0.5 mm to about 1.5 mm. In some embodiments, the second width 148 of the interface lands 144, 146 may be about 1.0 mm. In some embodiments, the second width 148 of the boundary surface lands 144, 146 may be about 2% to about 30% of the first width 140 of the boundary surface 132. In some embodiments, the second width 148 of the boundary surface lands 144, 146 may be about 5% to about 20% of the first width 140 of the boundary surface 132. In some embodiments, the second width 148 of the boundary surface lands 144, 146 may be about 10 percent of the first width 140 of the boundary surface 132.

[0059]

[0075] In some embodiments, the interface 132 may be positioned between environments of different temperatures and thus experience a thermal gradient. In some embodiments, the first normal width 141 and the second normal width 143 are substantially the same so that the interface 132 experiences a thermal gradient such as a thermal gradient across the bulk of the first component 110. In other embodiments, where the first normal width 141 (and therefore the local thickness of the interface 132 at the first width 140) is wider than the adjacent section of the first component 110 at the second normal width 143, the interface 132 may experience a larger thermal gradient than other sections of the first component 110. These thermal gradients may affect the integrity of the joint between the first component 110 and the second component 112. The thermal gradient at the joint can be reduced by reducing one or both of the first width 140 and the first normal width 141 at the interface 132. When the thermal conditions on each side of the interface lands 144 and 146 are different, a similar thermal gradient may exist across the interface lands 144 and 146.

[0060]

[0076] In some embodiments, the interface lands 144, 146 may project away from the interface 132. In some embodiments, the interface 132 may be adjacent to the interface lands 144, 146, for example, for the purpose of carrying a moving fluid, and may include a plurality of apertures or recesses between the interface lands 144, 146. In some embodiments, the interface lands 144, 146 may be spaced apart. In some embodiments, the first interface land 144 may extend away from the printed inner surface 124, and the second interface land 146 may extend away from the printed outer surface 126. In some embodiments, the first interface land 144 may be spaced apart from the printed inner surface 124. In some embodiments, the second interface land 146 may be spaced apart from the printed outer surface 126. In some embodiments, the interface lands may further include radially extending lands extending between the first interface land 144 and the second interface land 146.

[0061]

[0077] The second component 112 can be formed on the interface 132 of the first component 110 via a second additive manufacturing process. For example, if the second additive manufacturing process for the second component 112 is direct energy deposition, the additional material can be fused to the first component 110 to form the second component 112 on the interface 132 of the first component 110 as part of the second additive manufacturing process. In one embodiment, wire arc additive manufacturing (WAAM) can be used. In some embodiments, the additive manufacturing process fuses the second material 168 of the second component 112 to the interface 132 and the first material 128 of the first component 110.

[0062]

[0078] In some embodiments, the second component 112 may be formed on the respective interface lands 144, 146. The portions of the interface lands 144, 146 that fuse with the interface 132 and the second component 112 may be flat, improving the positional accuracy of the second additive manufacturing tool head relative to the first component 110 and the narrow interface shape. For example, a flat interface 132 may have a single height relative to the toolbed of the second additive manufacturing tool, thereby eliminating a height variable (Z-axis) in the positioning of the tool head. Thus, the tool head can be precisely positioned in the width direction or length direction (X-axis and Y-axis) so that the second component is precisely formed on the interface lands 144, 146. In various other embodiments, a conical interface with a height (Z-axis) that varies across the width of the interface may introduce additional tolerances when positioning the interface lands.

[0063]

[0079] As illustrated in Figures 1 and 4, the second component 112 is formed on the interface 132 of the first component 110 and can extend away from the first component 110. The second component 112 may include a proximal end 160, a distal end 162, and a substantially smooth outer surface 164. However, depending on the manufacturing technique used to deposit each layer, the outer surface 164 may exhibit parasitic mass. Some manufacturing techniques may exhibit zero parasitic mass, while others may exhibit non-zero parasitic mass. In various embodiments, the exhibited parasitic mass may be reduced or eliminated from the outer surface 164 by subsequent additional, conventional, or other processing techniques, at the discretion of the manufacturer. The second component 112 may be formed by a first placement layer to form the proximal end 160 directly on the interface 132. Additional layers are formed layer by layer to manufacture the second component 112 until the layer representing the distal end 162 is joined.

[0064]

[0080] The proximal end 160 of the second component 112 is coupled to the interface 132 of the first component 110, for example, as shown in Figure 4. In some embodiments, the proximal end 160, and therefore the second component 112, may extend perpendicularly away from the interface 132. In other embodiments, the second component 112 may be formed by a second additive manufacturing process together with one or more wedge-shaped layers 161 for the purpose of extending the proximal end 160, and therefore the second component 112, away from the vertical line. In other words, as the wedge-shaped layers 161 are deposited, the second component 112 may change from extending perpendicularly from the interface 132 to extending at an angle to the interface 132, so that the second component 112 can extend in the same overall direction as the first component 110, and as a result, both have a conical shape. However, in other embodiments, the first component 110 and the second component 112 may be positioned at different angles to each other to form a composite biconical shape.

[0065]

[0081] The distal end 162 may be on the opposite side of the proximal end 160 and may form the terminal end of the article 100. In some embodiments, a third component may be formed on the distal end 162 of the second component 112 to further extend the article 100. In some embodiments, the outer surface 164 may be substantially smooth such that the outer surface does not include any protruding features such as ports, arms, or other extension members.

[0066]

[0082] The second component 112 may have a second material 168. In some embodiments, the second material 168 may differ from the first material 128. In some embodiments, the second material 168 may be an iron-nickel based superalloy, such as HR-1. In some embodiments, the second material 168 may have second bead properties, based on how the second additive manufacturing process forms the second component 112. As the material is deposited layer by layer, the material may have a pattern called beading. The beading may have a specific shape, size, or pattern that is characteristic of the manufacturing process used to form the second component 112. By examining this beading, a person skilled in the art may be able to understand what manufacturing process was used to produce the second component 112.

[0067]

[0083] In some embodiments, the first component 110 may be heat-treated before the second component 112 is printed on it. In some embodiments, the hybrid structure of article 100 may be heat-treated as a single unit, either after the first component 110 has been heat-treated separately or as the first heat treatment. Heat treatment parameters beneficial to both the first material 128 and the second material 168 can be selected. For example, heat treatment parameters can be selected to increase the ductility of the first material 128 and the strength of the second material 168. In some embodiments, the heat treatment parameters may be selected to optimize the first material 128 and the second material 168 for the operating conditions to which article 100 will be exposed during use. In some embodiments, increasing the ductility of the first material 128 of the first component 110 may be important to reduce crack propagation in the first component 110, thereby increasing the toughness of the first component 110.

[0068]

[0084] Mandrel tool

[0085] In some embodiments, the mandrel 200 can be used during the manufacturing of article 100, for example, as shown in Figures 5A to 8, to maintain the roundness of the first component 110 during the formation of the second component 112. The mandrel 200 can provide any of several different functions. First, the mandrel 200 can be used to position the first component 110 during machining of the interface 132. Second, the mandrel 200 can be used to position the first component 110 on a second additive manufacturing toolbed, allowing the second component 112 to be precisely formed on the interface 132 of the first component 110. Third, the mandrel 200 can be used to position article 100 for further downstream machining operations after the second component 112 has been formed on the first component 110. Fourth, the mandrel 200 can be used to lift or transport the first component 110 and / or article 100 during manufacturing operations. It will be understood that the usefulness of the mandrel 200 in maintaining roundness as discussed herein also applies in relation to the non-circular articles 100 shown in Figures 2A to 2H. In this case, a suitable mandrel 200 may, depending on the circumstances, maintain the straightness of one or more walls or the angle between two walls.

[0069]

[0086] As illustrated in Figure 5A, the mandrel 200 may be removably coupled to the first component 110. In some embodiments, the mandrel 200 can be removably coupled to the first component 110 after the first component 110 has been formed by a first additive manufacturing process and removed from the base plate 102. In some embodiments, the mandrel 200 can be removably coupled to the first component 110 after the top surface 130 has been machined to the proximal end 120. The mandrel 200 may include a plate 210, a wedge 212, and a bolt 214. Each of these components will be described in turn. In one embodiment, one or both of the base plate 102 and the mandrel 200 may include a danibite used to position the first component 110 and to maintain its position when the wedge 212 is removed. This technique allows special access to the inner surface and some of its interior of the component 110 without losing positional control.

[0070]

[0087] The plate 210 is located on and in contact with the upper surface 130 of the first component 110. The plate 210 may also be configured to connect to and position the first component 110 in relation to a toolbed for machining the interface 132 or a second additive manufacturing toolbed for forming the second component 112. In some embodiments, the plate 210 may include a plurality of openings configured to be detachably connected to the toolbed. As illustrated in Figure 8, the plate 210 may include a central opening 220 configured to center a mandrel 200 and the first component 110 on the second additive manufacturing toolbed for forming the second component 112. In Figure 8, the component 110 is depicted as conical, but the mandrel technique discussed herein can be applied to the component 110 of any article 100 shown in Figures 2A–2H.

[0071]

[0088] The bolt 214 can be detachably coupled to the plate 210 and the wedge 212, for example, as shown in Figure 5A. The wedge 212 may include a through hole through which the shaft of the bolt 214 can extend, but which is sized to prevent the head of the bolt 214 from extending through the through hole. The shaft of the bolt 214 can extend through the wedge 212 and can also be coupled to the plate 210. In some embodiments, the bolt 214 can be screw-coupled to the plate 210.

[0072]

[0089] As illustrated in Figures 5A and 6, the wedge 212 can be inserted into the first component 110 from its distal end 122 and can be removably coupled to the plate 210. The wedge 212 may be configured to contact the printed inner surface 124 of the first component 110. As illustrated in Figure 5A, the wedge 212 may include a coupling portion 230, a wedge surface 232, a top surface 234, and a bottom surface 236, each of which will be described in turn.

[0073]

[0090] The coupling portion 230 is detachably coupled to the plate 210, for example, as shown in Figure 5A. In some embodiments, the coupling portion 230 may be a sleeve that overlaps a projection extending from the plate 210. In some embodiments, the coupling portion 230 may be coupled to the projection extending from the plate 210 by screw coupling. The wedge surface 232 may extend between the top surface 234 and the bottom surface 236. The top surface 234 may extend perpendicularly toward the wedge surface 232 away from the coupling portion 230. In some embodiments, the top surface 234 may extend at an oblique angle between the coupling portion 230 and the wedge surface 232. For example, as shown in Figure 5A, when the mandrel 200 is detachably coupled to the first component 110, the bottom surface 236 of the wedge 212 can be separated from the distal end 122 of the first component 110 so that the distal end 122 of the first component 110 can be machined to form an interface 132 between the machining tool and the bottom surface 236 of the wedge 212 without interference. As a result, the risk of accidental damage to the mandrel 200 by the machining tool is reduced.

[0074]

[0091] In some embodiments, the wedge surface 232 may be configured to contact the printed inner surface 124 of the first component 110, for example, as shown in Figures 5A, 6, and 7A-7B. In some embodiments, the printed inner surface 124 may have a smooth conical inner surface such that a substantial area of ​​the wedge surface 232 is in contact with the printed inner surface 124, for example, as shown in Figure 7B. In some embodiments, the printed inner surface 124 may include a plurality of ribs 150 that spread out in a wavy pattern around the circumference of the printed inner surface 124, forming a plurality of line contacts with the wedge surface 232, for example, as shown in Figure 7B. In some embodiments, the wedge surface 232 is in contact with only about 1% to 30% of the total surface area of ​​the printed inner surface 124. In some embodiments, the wedge surface 232 is in contact with less than 20 percent of the total surface area of ​​the printed inner surface 124. In some embodiments, the wedge surface 232 is in contact with less than 10 percent of the total surface area of ​​the printed inner surface 124. In some embodiments, the wedge surface 232 is in contact with less than 5 percent of the total surface area of ​​the printed inner surface 124. In some embodiments, the wedge surface 232 is in contact with approximately 5 percent to approximately 25 percent of the total length of the printed inner surface 124. In some embodiments, the wedge surface 232 is in contact with approximately 10 percent to approximately 20 percent of the total length of the printed inner surface 124.

[0075]

[0092] Generally, when any component is created, the component will have tolerances on all manufactured surfaces. Tolerances are small dimensional defects in a component that do not match the exact dimensions of an engineering drawing but fall within a small tolerance range of absolute dimensions. Some manufacturing processes have the ability to achieve dimensional tolerance ranges that are tighter or smaller than others. For example, surface machining can achieve tighter tolerance ranges than surface casting. In some embodiments, when a first component 110 is additively manufactured, the interface 132 of the first component 110 may have a roundness tolerance, i.e., a small dimensional range of a circular cross-section that is slightly elliptical. The mandrel 200 is configured to maintain a tight roundness tolerance of the interface 132 of the first component 110 after (1) the first component 110 has been formed by a first additive manufacturing process, and (2) when a second component 112 has been formed on the interface 132. For example, the mandrel 200 can be configured to maintain a roundness tolerance of the interface 132 between plus or minus (+ / -) 0.25 mm. If the interface 132 exceeds the tolerance, the second additive manufacturing tool may not be able to accurately form the second component 112 on the interface 132 or narrower interface lands 144, 146, thereby affecting the integrity of the joint between the first component 110 and the second component 112, or even causing a clear construction defect or a discarded part.

[0076]

[0093] In the illustrative embodiments shown in Figures 5A and 6, the first component 110 has a conical shape, and the wedge 212 has a corresponding conical shape. In some embodiments, a bolt 214 can be tightened to pull the wedge 212 toward the plate 210. As the wedge 212 moves parallel toward the plate 210, the wedge surface 232 of the wedge 212 first contacts the printed inner surface 124 of the first component 110. In some embodiments, the wedge surface 232 may first contact any portion of the printed inner surface 124 that is outside the desired roundness tolerance. As the wedge 212 continues to move parallel toward the first component 110, the wedge surface 232 exerts a force on the printed inner surface 124. In some embodiments, the force exerted by the wedge 212 can deform the first component 110, bringing it back within the roundness tolerance. In some embodiments, the force applied by the wedge 212 to the printed inner surface 124 can deform the first component 110 from its printed shape to a corrected shape. For example, the first component 110 may be slightly elliptical after the first additive manufacturing process and corrected to circular after the wedge 212 applies force to the printed inner surface 124. In some embodiments, the first component 110 may be within a desired roundness tolerance range after formation, and the force applied by the wedge 212 does not change the shape of the first component 110.

[0077]

[0094] In some embodiments, when the first component 110 or the second component 112 is formed, a large temperature difference exists throughout the component, which can result in a large stress gradient across the part. These stress gradients can cause deformation when the first component 110 and the second component 112 are additively fabricated. In some embodiments, the first component 110 is formed on a base plate 102. The base plate 102 is a hard and rigid base that does not deform during the formation of the first component 110 due to the internal stress gradient of the first component 110. In some embodiments, when the second component 112 is formed on the interface 132 of the first component 110, the internal stress of the second component 112 is large enough to cause deformation of both the second component 112 and the first component 110. In some embodiments, the mandrel 200 increases the rigidity of the first component 110 so that the roundness tolerance of the interface 132 can be maintained during the formation of the second component 112.

[0078]

[0095] In the exemplary embodiment shown in Figure 5B, the mandrel 200' is a cylindrical ring that exerts force against the vertical wall of a first component 110, such as a cylindrical component, as shown in Figures 1, 2B, and 2E. In some embodiments, the mandrel 200' may be an expanding mandrel including inner rings 240, 242 and an expanding outer ring 244. In some embodiments, the inner rings 240, 242 and the outer ring 244 may include opposing conical surfaces such that as the rings move relative to each other, the inner rings 240, 242 exert force on the expanding outer ring 244, and the expanding outer ring 244 exerts force perpendicular to the inner surface 124 of the first component 110. For example, a bolt 214 can be tightened to pull the inner ring 242 toward the inner ring 240 and plate 210. As the inner ring 242 moves parallel to the inner ring 240, the conical surface contacts the expanding outer ring 244, forcing the expanding outer ring 244 toward and in contact with the printed inner surface 124 of the first component 110. In some embodiments, the expanding outer ring 244 may first contact any portion of the printed inner surface 124 that is outside the desired roundness tolerance range. As the inner rings 240 and 242 continue to move parallel to each other, the expanding outer ring 244 applies force to the printed inner surface 124. In some embodiments, the force exerted by the expanding outer ring 244 can deform the first component 110, bringing it back within the roundness tolerance. In some embodiments, the force exerted by the expanding outer ring 244 on the printed inner surface 124 can deform the first component 110 from its printed shape to a modified shape.

[0079]

[0096] Thermal stress that delays the movement of the support column

[0097] In some embodiments, for example, as shown in Figures 9 to 12A, a plurality of columns 300 can be formed on the base plate 102 before the formation of the article 100. The plurality of columns 300 can be formed by additive manufacturing. In the exemplary embodiments shown in Figures 9 and 12A, the plurality of columns 300 can be formed as part of the same additive manufacturing process that forms the first component 110. The plurality of columns 300 can be arranged in the corresponding shape of the proximal end 120 of the first component 110. For example, as shown in Figure 9, the proximal end 120 of the first component 110 is cylindrical, and the plurality of columns 300 are arranged in a circular pattern. In some embodiments, each column of the plurality of columns 300 is spaced apart from adjacent columns of the plurality of columns 300. As illustrated exemplary in Figures 9 and 11, the plurality of columns 300 are spaced apart from each other circumferentially and are equally spaced apart from each other. Each column may be separated from each other by a gap. In some embodiments, the spacing between adjacent posts 300 can vary. The portion shown in Figure 9 may be asymmetrical in some embodiments as illustrated, or symmetrical in other embodiments as described elsewhere in this specification.

[0080]

[0098] Additive manufacturing generates heat within the layers of material deposited to form a component. Typically, older layers in the initially formed component are cooled in relation to the currently formed layer, which is being actively printed. A temperature gradient exists between the initially formed layer and the currently formed layer, but the thermal gradient and associated thermal stress can be addressed by changing the process geometry, printing temperature, and / or deposition rate. However, a problem arises when components are additively manufactured on a low-temperature base plate 102, because the base plate 102 requires more energy and time to heat up, while the formed component 110 is immediately hot. This creates a large thermal gradient and corresponding thermal stress across the formed component 110. This can lead to deformation of the component and / or a low manufacturing yield of the fitted part.

[0081]

[0099] In some embodiments, the temperature of the base plate 102 may rise due to the heat generated by the additively manufactured component 110. However, due to the size difference between the base plate 102 and the component 110, a large thermal gradient will generally exist at the interface between the component 110 and the base plate 102 while the temperature of the base plate 102 is rising. For example, as shown in Figure 10, a plurality of struts 300 are formed on the base plate 102, and then the component 110 is formed on the struts 300. The struts 300 are at a first temperature as they are formed. In some embodiments, heat from the struts 300 can be transferred to local areas of the base plate 102 beneath each strut of the struts 300, such that the local area of ​​the base plate 102 reaches a second temperature. As the struts 300 continue to be formed and their height increases, the second temperature of the base plate 102 continues to rise. In some embodiments, when the first temperature of the multiple support columns 300 and the second temperature of the base plate 102 are substantially equal or at a steady-state temperature, the thermal stress is low enough to allow the full hoop component 110 to form on the multiple support columns 300 with reduced risk of deformation. In some embodiments, the multiple support columns 300 delay the formation of thermal stress in the component 110.

[0082]

[0100] In some embodiments, when the multiple support columns 300 have a height H, the first temperature of the multiple support columns 300 and the second temperature of the base plate 102 are substantially equal and / or at steady-state temperatures. In some embodiments, when the multiple support columns 300 have a height H of about 2 mm to about 15 mm, the first temperature of the multiple support columns 300 and the second temperature of the base plate 102 are substantially equal. In some embodiments, when the multiple support columns 300 have a height H of about 6 mm to about 12 mm, the first temperature of the multiple support columns 300 and the second temperature of the base plate 102 are substantially equal. In some embodiments, when the multiple support columns 300 have a height H of about 10 mm, the first temperature of the multiple support columns 300 and the second temperature of the base plate 102 are substantially equal.

[0083]

[0101] In some embodiments, the temperatures are substantially equal when the first temperature of the multiple support columns 300 and the second temperature of the base plate 102 are between approximately 80°C and approximately 120°C. In some embodiments, the temperatures are substantially equal when the first temperature of the multiple support columns 300 and the second temperature of the base plate 102 are between approximately 90°C and approximately 110°C. In some embodiments, the temperatures are substantially equal when the first temperature of the multiple support columns 300 and the second temperature of the base plate 102 are both around 100°C. In some embodiments, the temperatures are substantially equal when the second temperature of the base plate 102 is within approximately 20 percent of the first temperature of the multiple support columns 300. In some embodiments, the temperatures are substantially equal when the second temperature of the base plate 102 is within approximately 10 percent of the first temperature of the multiple support columns 300. In some embodiments, the temperatures are substantially equal when the second temperature of the base plate 102 is within approximately 5 percent of the first temperature of the multiple support columns 300.

[0084]

[0102] In some embodiments, a transition region 350 may be formed between a plurality of supports 300 and a component 110. The transition region 350 may connect adjacent supports of the plurality of supports 300 and may provide a geometric shape for transferring thermal stress to the full hoop component. In some embodiments, the transition region 350 forms an arch between adjacent supports of the plurality of supports. In some embodiments, the arch has a radius defined by the gap between adjacent supports. In some embodiments, the arch may be formed by a composite radius.

[0085]

[0103] In some embodiments, a second set of struts 370 may be formed on the first component 110 and may be configured to reduce circumferential strain between the first region 372 and the third region 376. In some embodiments, the second set of struts 370 may maintain the roundness of the component 110 between adjacent full hoop regions 372, 376 of the component 110, for example, as shown in Figure 10. In some embodiments, the second set of struts 370 may be spaced circumferentially around the component 110. In some embodiments, the second set of struts 370 may extend between two full hoop regions 372, 376 of the first component 110, separated by a non-hoop region 374 of the component 110. For example, the first region 372 may extend entirely around the component 110, the second region 374 may extend above the first region 372 and may include multiple apertures extending through the second region 374, and the third region may extend above the second region 374 and may extend entirely around the component 110. Multiple supports 370 may extend between the first region 372 and the third region 376 such that the third region 376 is supported radially and circumferentially by the first region 372 via the multiple supports 370.

[0086]

[0104] In some embodiments, the multiple struts 300 and the second multiple struts 370 are formed together with the component 110, for example, as shown in Figure 12A. In some embodiments, the multiple struts 300 are partially machined after the formation of the first component 110 and before the second component 112 is joined to the first component 110, for example, as shown in Figure 12B. In some embodiments, the partial machining of the multiple struts 300 may form a datum plane for the first component 110 so that other features of the component 110 can be machined relative to the partially machined multiple struts 300. In some embodiments, the multiple struts 300 are machined so that they can be completely removed from the article 100 after the first component 110 and the second component 112 have been joined together, for example, as shown in Figure 12C. In some embodiments, the second set of support columns 370 are partially machined so as not to be removed from the article 100 after the first component 110 and the second component 112 have been joined together, for example, as shown in Figure 12C.

[0087]

[0105] Exemplary manufacturing steps for forming article 100

[0106] Figure 13 shows an exemplary method 400 for manufacturing a hybrid structure such as article 100. Method 400 includes the following steps:

[0088]

[0107] Step 402: The first component 110 can be formed on the base plate 102 via a first additive manufacturing process. The first additive manufacturing process may be one of laser powder bed fusion, laser powder direct energy deposition, wire feed direct energy deposition, welding arc additive manufacturing, binder jetting, and / or solid powder extrusion. In some embodiments, a plurality of struts 300 can be formed directly on the base plate 102, and the first component 110 can be formed on a plurality of struts.

[0089]

[0108] Step 404: The first component 110 may be heat-treated while attached to the base plate 102. For example, the first component 110 may be heat-treated by hot isostatic pressing (HIP) or other heat treatment.

[0090]

[0109] Step 406: The first component 110 can be removed from the base plate 102. For example, the proximal end 120 can be cut with an EDM wire at the base of a plurality of supports 300, either through or on its body, to remove the first component 110 from the base plate 102. In various embodiments, the heat treatment step 404 can be repeated after removal from the base plate 102 to complete step 406.

[0091]

[0110] Step 408: The proximal end 120 of the first component 110 may be machined to form the upper surface 130. The first component 110 may be clamped in place using a plurality of members 152, printed inner surfaces 124, or printed outer surfaces 126 to secure the first component 110 while the proximal end 120 is being machined. In some embodiments, the proximal end 120 may be machined by turning, machining, grinding, EDM wire cutting, or other suitable method.

[0092]

[0111] Step 410: The mandrel 200 (or 200') can be assembled onto the first component 110 to secure the first component 110. The plate 210 of the mandrel 200 can be positioned on and in contact with the upper surface 130 of the first component 110. The wedge 212 of the mandrel 200 can be inserted into the first component 110 from its distal end 122 and can be removably coupled to the plate 210 via a bolt 214. The wedge 212 can be configured to contact the printed inner surface 124 of the first component 110.

[0093]

[0112] Step 412: When the mandrel 200 is installed and fixed on the first component 110, the distal end 122 of the first component 110 can be machined to form the interface 132. In some embodiments, the distal end 122 can be machined by turning, machining, grinding, EDM wire cutting, or other suitable method. Other features of the first component 110, such as the vertical surface 142 and member 152, can also be machined in step 412.

[0094]

[0113] Step 414: Pre-inspection of the first component 110 can be completed, such as dimensional inspection, material inspection, water flow test, and other component test procedures. In some embodiments, the mandrel 200 may be removed for inspections such as water flow tests. In some embodiments, the mandrel 200 may remain in place for inspections such as dimensional inspections.

[0095]

[0114] Step 416: With the mandrel 200 attached, the first component 110 can be transferred to the second additive manufacturing tool. For example, the mandrel 200 may be used to support the first component 110 for transport in order to avoid damage to the first component 110.

[0096]

[0115] Step 418: The second component 112 can be formed directly on the interface 132 of the first component 110 via a second additive manufacturing process. The second additive manufacturing process may be one of the following: laser powder bed fusion, laser powder direct energy deposition, wire feed direct energy deposition, welding arc additive manufacturing, binder jetting, and / or solid powder extrusion.

[0097]

[0116] Step 420: The article 100, which includes the first component 110 and the second component 112 together, is heat-treated. For example, heat treatment parameters can be selected that increase the ductility of the first material 128 and further increase the strength of the second material 168, for the mutual benefit of the entire components of the article 100.

[0098]

[0117] Step 422: The article 100 is machined to the final desired shape and to include the final desired features. In some embodiments, the mandrel 200 may be removed for step 422, and a different set of tools may be used to machine the final features of the article 100. In some embodiments, the final machining process may include turning, machining, grinding, EDM wire cutting, or other suitable machining methods.

[0099]

[0118] conclusion

[0119] This disclosure presents additive-manufactured articles produced using two different additive manufacturing processes, the articles being, A first component having a first material, comprising a printed inner surface, a printed outer surface, and an interface extending from the printed inner surface to the printed outer surface, wherein the first component has first beading characteristics of a first additive manufacturing process, A second component is bonded to the interface of a first component and extends away from the interface, having second beading characteristics of a second additive manufacturing process, wherein the second additive manufacturing process is different from the first additive manufacturing process. The first material is a material with low thermal conductivity, and The interface is a plane.

[0100]

[0120] An article is presented in which the first component is a powder bed fusion component.

[0101]

[0121] An article is presented in which the first material is a nickel-chromium superalloy.

[0102]

[0122] An article is presented in which the second component is the direct energy deposition component.

[0103]

[0123] An article is presented in which the second component is a second material different from the first material.

[0104]

[0124] An article is presented in which the second material is an iron-nickel superalloy.

[0105]

[0125] An article is presented in which the first component further includes a plurality of ports extending away from the printed outer surface, and no ports are formed on the second component.

[0106]

[0126] An article is presented in which the first component has a substantially circular cross-section and further includes a member extending radially from the printed outer surface of the first component, and the second component has a substantially smooth outer surface.

[0107]

[0127] An article is presented in which the interface is substantially circular and includes at least two lands extending circumferentially around the circle, and a second component is joined to at least two lands.

[0108]

[0128] An article is presented in which the interface has a first width between the printed inner surface and the printed outer surface, and each of at least two lands has a second width of 10% to 30% of the first width.

[0109]

[0129] The presenter has an item with a second width of 0.5 mm to 1.5 mm.

[0110]

[0130] An article is presented in which the second component extends perpendicularly away from the interface.

[0111]

[0131] An article is presented in which the second component has a conical shape and the second component comprises multiple wedge-shaped layers.

[0112]

[0132] An article is presented in which a second component is joined to a first component by either micro-welding or fusion bonding.

[0113]

[0133] This disclosure presents a method for manufacturing a hybrid structure, and the method is: The method involves forming a first component on a base plate by additive manufacturing, wherein the first component has a low thermal conductivity material and includes a proximal end on the base plate and a distal end opposite the proximal end. The first component is removed from the base plate at the proximal end, The distal end of the first component is machined to form an interface, The method includes forming the second component on the interface by additive manufacturing such that the second component is bonded to the interface of the first component and extends away from the interface, The interface is a plane.

[0114]

[0134] A method is presented in which the second component extends perpendicularly away from the first component at the interface.

[0115]

[0135] A method has been proposed for forming a second component, which involves depositing multiple wedge-shaped layers such that the second component forms a cone shape.

[0116]

[0136] A method is presented in which the interface is substantially circular and includes at least two lands extending circumferentially around the circle, and the second component is formed on at least two lands.

[0117]

[0137] A method has been proposed for forming the first component, which includes powder bed fusion.

[0118]

[0138] A method has been proposed in which the formation of the second component involves direct energy deposition.

[0119]

[0139] A method is presented in which the first component is a nickel-chromium superalloy with low thermal conductivity and the second component is an iron-nickel superalloy material.

[0120]

[0140] A method is presented for removing the first component from the base plate, which includes machining the proximal end to form the upper surface.

[0121]

[0141] A method has been proposed in which the interface is parallel to the top surface.

[0122]

[0142] A method is presented which further includes heat-treating the first component together with the second component.

[0123]

[0143] This disclosure presents an article, and the article is, A first component including the interface and interior surface, A mandrel detachably coupled to a first component, comprising a plate and a wedge detachably coupled to the plate. A second component is coupled to the interface of a first component and extends away from the interface, wherein the mandrel is configured to maintain the roundness of the first component when the second component is coupled to the first component. Includes.

[0124]

[0144] This disclosure presents an article, and the article is, A first component including the interface and interior surface, A mandrel that is detachably coupled to the first component and applies force to the inner surface of the first component, thereby counteracting internal stresses within the first component and changing the shape of the first component to a modified shape. A second component coupled to the interface of a first component and extending away from the interface of the first component, the second component being configured to change shape in response to the attachment and detachment of a mandrel from the first component and to changes in the shape of the first component from a modified shape, Includes.

[0125]

[0145] An article is presented in which the first component includes the upper surface opposite the interface and the plate is in contact with the upper surface.

[0126]

[0146] An object in which a wedge comes into contact with the inner surface is presented.

[0127]

[0147] The presented items have a wedge that contacts less than 20 percent of the inner surface.

[0128]

[0148] An article is presented in which the inner surface contains multiple ribs and a wedge is in contact with multiple ribs.

[0129]

[0149] An object is presented in which the bottom surface of a wedge is positioned at a distance from the interface.

[0130]

[0150] An article is presented in which a mandrel further includes a bolt configured to detachably connect a plate to a wedge.

[0131]

[0151] An article is presented in which a plate includes a central opening configured to center a first component on a toolbed for the manufacture of a second component.

[0132]

[0152] This disclosure presents a method for manufacturing a hybrid structure, and the method is: Forming the first component on a base plate through additive manufacturing, Remove the first component from the base plate, Insert the mandrel into the first component, Machining the interface to the first component, Forming a second component on the interface of a first component via additive manufacturing, Includes, The mandrel is configured to maintain the roundness of the first component during the formation of the second component.

[0133]

[0153] A method has been proposed for the mandrel to maintain a roundness tolerance of + / - 0.25 mm of the first component while the second component is being formed.

[0134]

[0154] A method is presented in which the mandrel has a plate and a wedge that is detachably attached to the plate.

[0135]

[0155] Removing the first component from the base plate includes machining the top surface of the first component. The top surface is on the opposite side of the interface, and, A method is presented in which the mandrel plate contacts the upper surface.

[0136]

[0156] A method has been proposed in which the interface is parallel to the top surface.

[0137]

[0157] Inserting the mandrel into the first component is The first component is to place a plate on its upper surface, Inserting a wedge into the first component at the distal end of the first component opposite the upper surface, The wedge is engaged with the conical inner surface of the first component, The plate and wedge are joined together to center the first component on the mandrel, A method having this has been presented.

[0138]

[0158] A method has been proposed in which the mandrel does not substantially deform the first component.

[0139]

[0159] A method for forming the first component, including powder bed fusion, has been proposed.

[0140]

[0160] A method has been proposed in which the formation of the second component involves direct energy deposition.

[0141]

[0161] A method is presented in which the first component comprises a nickel-chromium superalloy and the second component comprises an iron-nickel superalloy material.

[0142]

[0162] This disclosure presents a method for additively manufacturing components, and the method is: This involves forming multiple support columns on a base plate, and forming multiple support columns means forming multiple support columns that heat the base plate. The formation of multiple support columns continues until the first temperature of the multiple support columns becomes substantially equal to the second temperature of the base plate. The first temperature becomes substantially equal to the second temperature, and the components are formed on multiple supports. Includes, Multiple support columns are configured to delay the formation of thermal stress within the component.

[0143]

[0163] A method has been proposed in which each of the multiple support columns is positioned with a circumferential spacing from adjacent columns.

[0144]

[0164] A method has been proposed in which each of the multiple support columns is arranged at substantially equal intervals around the circumference of the multiple support columns.

[0145]

[0165] A method has been proposed in which the first and second temperatures are in equilibrium between 80 and 120 degrees Celsius.

[0146]

[0166] A method has been proposed in which the first and second temperatures are in equilibrium at approximately 100 degrees Celsius.

[0147]

[0167] A method has been proposed in which multiple support columns extend only 2 to 15 millimeters from the base plate.

[0148]

[0168] A method has been proposed in which multiple support columns extend approximately 10 millimeters from the base plate.

[0149]

[0169] A method is presented which further includes removing multiple support columns and cylindrical components from the base plate.

[0150]

[0170] A method is presented which further includes machining multiple support columns to form a datum surface.

[0151]

[0171] A method is presented which further includes machining a cylindrical component in order to remove multiple support columns.

[0152]

[0172] The cylindrical component further includes a first cylindrical feature and a second cylindrical feature, and a second set of supports extending between the first and second features, A method is presented in which a second set of supports is configured to reduce circumferential strain between the first and second cylindrical features.

[0153]

[0173] A method is presented in which each support column of the second set of support columns is positioned with a circumferential gap between it and adjacent support columns of the second set of support columns.

[0154]

[0174] A method is presented which further includes removing a second set of supports from a cylindrical component. It should be understood that the “Detailed Description” section, and no other section, is intended to be used to interpret the claims. Other sections may illustrate one or more but not all embodiments as intended by the inventors, and are therefore not intended in any way to limit the present disclosure or the appended claims.

[0155]

[0175] While this disclosure describes exemplary embodiments for, for example, fields and applications, it should be understood that this disclosure is not limited thereto. Other embodiments and modifications thereof are possible and within the scope and spirit of this disclosure. For example, without limiting the generality of this paragraph, embodiments are not limited to the hardware and / or entities shown in the figures and / or described herein. Furthermore, embodiments (whether expressly described herein or not) have significant utility to fields and applications beyond the examples described herein.

[0156]

[0176] Embodiments have been described herein with the help of function-based blocks, which illustrate implementations of specific functions and their relationships. The boundaries of these function-based blocks are arbitrarily defined herein for the sake of clarity. Alternative boundaries may be defined as long as the specified functions and relationships (or their equivalents) are performed appropriately. Furthermore, alternative embodiments may execute function blocks, steps, operations, methods, etc., using a different order than that described herein.

[0157]

[0177] References herein to “an embodiment,” “some embodiments,” “an example,” or similar phrases indicate that the embodiments described may include certain features, structures, or characteristics, but not all embodiments may necessarily include such features, structures, or characteristics. Furthermore, such phrases do not necessarily refer to the same embodiment. Moreover, where certain features, structures, or characteristics are described in relation to an embodiment, incorporating such features, structures, or characteristics into other embodiments, whether or not they are explicitly mentioned or described herein, would be within the knowledge of those skilled in the art. In addition, some embodiments may be described using the expressions “combined” and “connected” along with their derivatives. These terms are not necessarily intended to be synonymous with each other. For example, some embodiments may be described using the terms “connected” and / or “combined” to indicate that two or more elements are in direct physical or electrical contact with each other. However, the term “combined” may also mean that two or more elements are not in direct contact with each other but still cooperate or interact with each other.

[0158]

[0178] The scope and breadth of this disclosure should not be limited by any of the above-described embodiments, which are merely illustrative, but should be defined solely by the appended claims and their equivalents. [Explanation of symbols]

[0159] 100 goods 102 Base Plate 110 Component 1 112 Second Component 120 Proximal end 122 Distal end 124 Printed interior 126 printed outer surfaces 128 1st material 130 Top 132 Interface 140 1st width 141 First normal width 142 Vertical plane 143 Second normal width 144, 146 Boundary surface land 148, 149 2nd width 150 Ribs 152 components 160 Proximal end 161 Wedge-shaped layers 162 Distal end 164. A virtually smooth exterior. 168 Second material 200 Mandrels 210 Plate 214 volts 220 Center opening 230 Joining part 232 Wedge-shaped surface 234 Top surface 236 Bottom 240 Inner Ring 242 Inner ring 244 Expanded outer ring 300 pillars 350 Transition area 370 Post 372 1st area 374 Second area 376 Third area

Claims

1. Additive-manufactured articles manufactured using two different additive manufacturing processes, A first component having a first material, comprising a printed inner surface, a printed outer surface, and an interface extending from the printed inner surface to the printed outer surface, and having first beading characteristics of a first additive manufacturing process, A second component coupled to the interface of the first component and extending away from the interface, having second beading characteristics of a second additive manufacturing process, wherein the second additive manufacturing process is different from the first additive manufacturing process, and the second component, Includes, The first material is a low thermal conductivity material, and The interface is a flat surface of the article.

2. The article according to claim 1, wherein the first component is a powder bed fusion component.

3. The article according to claim 2, wherein the first material is a nickel-chromium superalloy.

4. The article according to claim 2, wherein the second component is a direct energy deposition component.

5. The article according to claim 1, wherein the second component comprises a second material different from the first material.

6. The article according to claim 5, wherein the second material is an iron-nickel superalloy.

7. The article according to claim 1, wherein the first component further includes a plurality of ports extending away from the printed outer surface, and no ports are formed on the second component.

8. The article according to claim 1, wherein the cross-section of the first component is substantially circular, the first component further includes a member extending radially from the printed outer surface, and the second component includes a substantially smooth outer surface.

9. The article according to claim 1, wherein the interface is substantially circular and includes at least two lands extending circumferentially around the circle, and the second component is coupled to the at least two lands.

10. The article according to claim 9, wherein the interface has a first width between the printed inner surface and the printed outer surface, and each of the at least two lands has a second width of 10 to 30 percent of the first width.

11. The article according to claim 9, wherein the second width is 0.5 mm to 1.5 mm.

12. The article according to claim 1, wherein the second component extends perpendicularly away from the interface.

13. The article according to claim 12, wherein the second component comprises a plurality of wedge-shaped layers such that the second component has a conical shape.

14. The article according to claim 1, wherein the second component is joined to the first component by either micro-welding or fusion bonding.

15. A method for manufacturing a hybrid structure, Forming a first component on a base plate by additive manufacturing, wherein the first component has a low thermal conductivity material and includes a proximal end on the base plate and a distal end opposite to the proximal end. The first component is removed from the base plate at the proximal end, The distal end of the first component is machined to form an interface, The second component is formed on the interface by additive manufacturing such that the second component is bonded to the interface of the first component and extends away from the interface. Includes, The interface is a plane, in this method.

16. The method according to claim 15, wherein the second component extends perpendicularly away from the first component at the interface.

17. The method according to claim 16, wherein forming the second component includes depositing a plurality of wedge-shaped layers such that the second component forms a cone shape.

18. The method according to claim 15, wherein the interface is substantially circular and includes at least two lands extending circumferentially around the circle, and the second component is formed on the at least two lands.

19. The method according to claim 15, wherein forming the first component includes powder bed fusion.

20. The method according to claim 19, wherein forming the second component includes direct energy deposition.

21. The method according to claim 20, wherein the low thermal conductivity material of the first component is a nickel-chromium superalloy, and the second component comprises an iron-nickel superalloy material.

22. The method according to claim 15, wherein removing the first component from the base plate includes machining the proximal end to form an upper surface.

23. The method according to claim 22, wherein the interface is parallel to the upper surface.

24. The method according to claim 15, further comprising heat-treating the first component together with the second component.

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