Additively manufactured components including integrally formed passages, channels, and conduits, and methods of forming same

Abstract

To provide additively manufactured components including integrally formed passages, channels and conduits, and methods of forming the same.SOLUTION: An additively manufactured component 200 includes a unitary body 202. The unitary body has a component section 204 and a supplemental section 206. The component section 204 includes one or more passages 208A, 208B. The supplemental section 206 is disposed over the passages 208A, 208B of the component section 204, and includes channels 218A, 218B in communication with the one or more passages 208A, 208B. In addition, the unitary body 202 includes transition conduits 224A, 224B positioned within the component section 204 and the supplemental section 206. The transition conduits 224A, 224B fluidly couple the passages 208A, 208B and the channels 218A, 218B.SELECTED DRAWING: Figure 11

Description

[Technical field]

[0001] The present disclosure relates generally to additively manufactured components, and more specifically to additively manufactured components including integrally formed passages, channels, and conduits, and methods of forming the same. [Background technology]

[0002] Components or parts for various machines and mechanical systems can be constructed using additive manufacturing systems. Additive manufacturing systems are capable of constructing such components by successively layering powder material in a predetermined area and performing a material transformation process, such as sintering or melting, on the powder material. The material transformation process may change the physical state of the powder material from a granular composition to a solid material to construct the component. Components constructed using additive manufacturing systems have nearly identical physical attributes to conventional components that are typically made by performing machining processes (e.g., material removal processes) on stock materials. However, due to advantageous processes, components formed using additive manufacturing may include unique features and / or complex geometries that are difficult or impossible to obtain and / or construct using conventional machining processes.

[0003] However, the ability to easily form unique features and / or complex geometric shapes introduces new and / or additional manufacturing difficulties or problems. For example, when conduits or channels are exposed and / or formed to extend to the surface of the component, post-build processing performed on the additively manufactured component may create problems with the intended use of those conduits or channels. That is, when removing excess build material and / or resurfacing (e.g., grinding / planing) the surface of the component that contains the openings for the conduits or channels, undesirable burrs may form on the surface and / or extend into the openings. Burrs formed during post-build processes may obstruct, block, or otherwise clog the conduits or channels formed in the component, rendering the feature inoperable for its intended purpose. Although a burr removal process can be performed on the component to remove the formed burrs, the tool used to remove the burrs may reshape, reconfigure, and / or possibly damage the openings and / or portions of the conduits or channels. This is particularly common when the size or dimensions of the opening or conduit are small and / or when the conduit or channel does not extend directly perpendicular to the surface containing the opening (e.g., an angled conduit). Summary of the Invention

[0004] A first aspect of the present disclosure provides a component including a unitary body including a component section including at least one passage extending at least partially through the component section, the at least one passage including an opening having a first dimension; a supplemental section integrally formed with the component section, the supplemental section disposed on the at least one passage of the component section and including a channel extending at least partially through the supplemental section, the channel in fluid communication with the at least one passage of the component section; and a transition conduit positioned within the component section and the supplemental section, the transition conduit extending between the at least one passage of the component section and the channel of the supplemental section, fluidly coupling the at least one passage and the channel.

[0005] A second aspect of the disclosure provides a method for additively manufacturing a unitary body of a component, the unitary body including a component section including at least one passage extending at least partially through the component section, the at least one passage including an opening having a first dimension, a supplemental section integrally formed with the component section, the supplemental section disposed on the at least one passage of the component section and including a channel extending at least partially through the supplemental section, the channel in fluid communication with the at least one passage of the component section, and a transition conduit positioned within the component section and the supplemental section, the transition conduit extending between the at least one passage of the component section and the channel of the supplemental section, fluidly coupling the at least one passage and the channel; performing at least one post-build process on a component including the unitary body; and removing the supplemental section from the component section of the unitary body to expose a portion of the transition conduit and the at least one passage of the component section.

[0006] The illustrative aspects of the present disclosure are designed to solve the problems described herein and / or other problems not discussed.

[0007] These and other features of the present disclosure will be more readily understood from the following detailed description of the various aspects of the disclosure, taken in conjunction with the accompanying drawings which illustrate various embodiments of the present disclosure. [Brief description of the drawings]

[0008] [Figure 1] FIG. 2 is an exploded perspective view of a component including a component section and a supplemental section according to an embodiment of the present disclosure. [Diagram 2] FIG. 2 is a front view of a component including a component section and a supplemental section of FIG. 1 according to an embodiment of the present disclosure. [Diagram 3] 3 is a cross-sectional front view of the component of FIG. 2 taken along line CS-CS in accordance with an embodiment of the present disclosure. [Figure 4] 3 is a cross-sectional front view of the component of FIG. 2 with the supplemental section removed from the component section in accordance with an embodiment of the present disclosure. [Diagram 5] FIG. 5 is an enlarged view of a portion of the component section of FIG. 4 including a burr, according to an embodiment of the present disclosure. [Figure 6] FIG. 5 is an enlarged view of a portion of the component section of FIG. 4 with burrs removed, according to an embodiment of the present disclosure. [Figure 7] FIG. 13 is a cross-sectional front view of a component including a component section and a supplemental section according to an additional embodiment of the present disclosure. [Figure 8] 8 is a cross-sectional front view of the component of FIG. 7 with the supplemental section removed from the component section in accordance with an additional embodiment of the present disclosure. [Figure 9] FIG. 13 is a cross-sectional front view of a component including a component section and a supplemental section according to a further embodiment of the present disclosure. [Figure 10] 10 is a cross-sectional front view of the component of FIG. 9 with the supplemental section removed from the component section according to a further embodiment of the present disclosure. [Figure 11] FIG. 2 is a cross-sectional front view of a component including a component section, a supplemental section, and a number of passageways extending therein, according to an embodiment of the present disclosure. [Figure 12] FIG. 2 is a cross-sectional front view of a component including a component section, a supplemental section, and a number of passageways extending therein, according to an embodiment of the present disclosure. [Figure 13] FIG. 2 is a cross-sectional front view of a component including a component section, a supplemental section, a number of passages extending therein, and a manifold, according to an embodiment of the present disclosure. [Figure 14] FIG. 2 is a front view of a component including a component section and multiple supplemental sections according to an embodiment of the present disclosure. [Figure 15] 1 is a flowchart of an exemplary process for forming an additively manufactured component including a component section and a supplemental section, according to an embodiment of the present disclosure. [Figure 16] FIG. 1 illustrates a block diagram of an additive manufacturing system and process including a non-transitory computer readable storage medium storing code representing a component including a component section and a supplemental section in accordance with an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] It should be noted that the drawings of the present disclosure are not necessarily drawn to scale. The drawings are intended to illustrate only typical aspects of the present disclosure, and therefore should not be considered as limiting the scope of the present disclosure. In the drawings, like numbers represent like elements between the drawings.

[0010] As a first issue, in order to clearly explain the present disclosure, it becomes necessary to select specific terminology when referring to and describing the relevant machine components in this disclosure. When doing so, common industry terminology is used and utilized, whenever possible, with the same meaning as its accepted meaning. Unless otherwise noted, such terminology should be given a broad interpretation consistent with the context of this application and the scope of the appended claims. Those skilled in the art will appreciate that in many cases, a particular component may be referred to using several different or overlapping terms. What may be described herein as being a single part may include and be referred to in other contexts as being made up of multiple components. Alternatively, what may be described herein as comprising multiple components may be referred to elsewhere as a single part.

[0011] The following disclosure relates generally to additively manufactured components, and more specifically to additively manufactured components that include integrally formed passages, channels, and conduits, and methods of forming the same.

[0012] These and other embodiments are discussed below with reference to Figures 1-16. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for illustrative purposes only and should not be construed as limiting.

[0013] 1 and 2 show various views of a component 100 including a unitary body 102. Specifically, FIG. 1 shows a perspective exploded view of the component 100 including the unitary body 102, and FIG. 2 shows a front view of the component 100 including the unitary body 102. The component 100 including the unitary body 102 may be considered an "intermediately" formed component and / or a component that may be at an intermediate stage of processing. Thus, as discussed herein, the component 100 may be subjected to additional post-construction processes that are performed before and / or after the final configuration of the component 100 (e.g., a component section) may be utilized for its intended purpose.

[0014] In the non-limiting examples discussed herein, the component 100 may include and / or be formed as a unitary body 102 such that the component 100 is a single, continuous, and / or unseparated component or part. In the non-limiting examples shown in FIGS. 1-14 , because the component 100 includes a unitary body 102, the turbine shroud 100 may not require joining, bonding, and / or assembly of various parts to fully form the component 100. Rather, once a single, continuous, and / or unseparated unitary body 102 for the component 100 is constructed, as discussed herein, the unitary body 102 of the component 100 may include therein all desired features that may be utilized for the intended purpose for the final configuration of the component 100 (e.g., component portion).

[0015] In a non-limiting example, the unitary body 102 of the component 100, as well as the various components and / or features of the component 100, may be formed using any suitable additive manufacturing process and / or method. For example, the component 100, including the unitary body 102, may be formed by direct metal laser melting (DMLM) (also referred to as selective laser melting (SLM)), direct metal laser sintering (DMLS), electron beam melting (EBM), stereolithography (SLA), binder jetting, or any other suitable additive manufacturing process. Thus, the unitary body 102 of the component 100, as well as the various components and / or features integrally formed on and / or in the unitary body 102 of the component 100, may be formed during a single additive manufacturing process and / or method. Additionally, the component 100, and more specifically the unitary body 102, may be formed from any suitable material capable of undergoing an additive manufacturing process (see FIG. 15) performed by an additive manufacturing system (AMS). In non-limiting examples, the unitary body 102 of the component 100 may be formed from thermoplastics, metals, metal alloys, ceramics, glasses, and other suitable materials.

[0016] As shown in Figures 1 and 2, the unitary body 102 of the component 100 may include two separate parts and / or sections. That is, while the unitary body 102 is formed as a single continuous component or part, the unitary body 102 of the component 100 may be formed as two separate sections. In a non-limiting example discussed herein, the unitary body 102 may include a component section 104 and at least one supplemental section 106, respectively. As shown in Figure 2, the component section 104 and the supplemental section 106 may be integrally formed to form the unitary body 102 of the component 100. The component section 104 and the supplemental section 106 may be integrally formed using a (single) additive manufacturing process and / or AMS (see Figure 15). As discussed herein, the component section 104 and the supplemental section 106 may be separated from each other after formation via a (single) additive manufacturing process, after which the component section 104 may be utilized for its intended purpose, while the supplemental section 106 may be discarded. As discussed herein, component section 104 of component 100 may represent a “final” configuration, geometry, part, and / or assembly manufactured by AMS that may be used by the component, device, and / or system for its intended purpose.

[0017] As a result of being formed from the unitary body 102, as discussed herein, the component 100 may include various integrally formed features, components, and / or segments (e.g., component section 104) that may provide a desired function and / or operation to the final configuration of the component 100. That is, because the component 100 includes a unitary body 102 formed using any suitable (single) additive manufacturing process and / or method, the features, components, and / or segments of the component 100 may be integrally formed with the unitary body 102. The term "integral feature" or "integrally formed feature" may refer to a feature formed on or in the unitary body 102 during a (single) additive manufacturing process, a feature formed from the same material as the unitary body 102, and / or a feature formed on or in the unitary body 102, such that the feature is not fabricated using a separate process and / or raw material components that are separately subsequently constructed, joined, bonded, and / or assembled on or in the unitary body 102 of the component 100. Additionally, features formed within the unitary body 102 of the component 100 may be specific to the operation and / or function of the component sections 104 of the component 100 .

[0018] As shown in FIGS. 1 and 2, the component 100 may include at least one feature formed in the unitary body 102. More specifically, the component 100 may include at least one feature formed at least partially in, on, and / or through the component section 104 of the unitary body 102. In a non-limiting example shown in FIGS. 1 and 2, the feature formed in the unitary body 102, and more specifically, the component section 104, may be at least one passageway 108. The passageway 108 may be at least partially formed in and / or extend at least partially through the component section 104 of the unitary body 102. In a non-limiting example, the passageway 108 may extend only partially through the component section 104 and may be formed as a recess. In other non-limiting examples (see, e.g., FIG. 12), the passageway 108 may extend completely through the unitary body 102 and / or the component section 104 and may include two openings exposed and / or formed on a surface of the component section 104 of the component 100.

[0019] The passageway 108 may include an opening 110, as shown in Figures 1 and 2. That is, the passageway 108 may be at least partially defined by the opening 110 and / or the opening 110 may be in fluid communication with the passageway 108. The opening 110 may have a first predetermined dimension (D1). For example, if the opening 110 is substantially circular in shape, the opening 110 of the passageway 108 may include a first predetermined dimension (D1) corresponding to the circumference of the opening 110. As shown in the exploded view of Figure 1, and with brief reference to Figure 4, the passageway 108 and / or the opening 110 may be exposed and / or formed adjacent to a "finished" surface 112 formed on the component section 104 after the supplemental section 106 is removed, as discussed herein. Prior to removal of supplemental section 106, as discussed herein, the “finished” surface 112 may be considered a reference, artificial, and / or expected surface of component section 104 of component 100 that may be formed / located underneath and / or “covered” by supplemental section 106.

[0020] It is understood that the shapes and / or geometries of the passages 108 and / or openings 110 shown herein are exemplary. Thus, the passages 108 and / or openings 110 may include any geometric shape and / or size that may correspond to the intended function and / or operation for the component section 104. In addition, while shown as being uniform and / or substantially similar in shape to the remainder of the passage 108 that extends at least partially into the component section 104, it is understood that the openings 110 may vary in shape and / or dimensions from the passages 108. Furthermore, the number of passages 108 / openings 110 formed in the component section 104 of the unitary body 102 shown herein may also be exemplary, and the unitary body 102 of the component 100 may include a greater or lesser number of passages 108 and / or openings 110 than shown and discussed herein.

[0021] As discussed herein, the unitary body 102 of the component 100 may also include a supplemental section 106. The supplemental section 106 may be integrally formed with the component section 104 of the unitary body 102 for the component 100. That is, although shown exploded or separate from the component section 104 in FIG. 1, the supplemental section 106 may be formed integrally with, as a part of, and / or integrally with the component section 104 of the unitary body 102 (see FIG. 2). The dashed line (DL) shown in FIG. 2 may represent a location within the component 100 that separates or distinguishes the component section 104 from the supplemental section 106. In the non-limiting example shown in FIGS. 1 and 2, the supplemental section 106 may be integrally formed with at least a portion of the “finished” surface 112 of the component section 104. Additionally, as discussed herein, removal of the supplemental sections 106 from the component sections 104 of the unitary body 102 may substantially define and / or expose the “finished” surface 112 and the passages 108 / openings 110 (e.g., features) formed in the component sections 104 of the unitary body 102. Although shown as being formed on and / or integrally with the “finished” surface 112 of the component sections 104, it will be understood that the supplemental sections 106 may be formed on other portions or surfaces of the component sections 104 (see FIG. 12 ) and / or between a build surface 20 of the build plate 18 and the component sections 104 of the unitary body 102 (not shown), and the component 100 is built directly onto the build plate of an additive manufacturing system.

[0022] In a non-limiting example shown in FIGS. 1 and 2, the supplemental section 106 may include a geometry similar to the component section 104. That is, the supplemental section 106 may include a geometry, shape, and / or dimensions (e.g., width, depth) similar to or substantially identical to the portion of the component section 104 including the passageway 108 and / or opening 110. As a result, the supplemental section 106 may cover and / or be disposed on the component section 104 of the unitary body 102. More specifically, the supplemental section 106 may be disposed on and / or define the “finished” surface 112 and may substantially cover, be positioned adjacent to, and / or be disposed on the passageway 108 / opening 110 (e.g., features) formed in the component section 104. In another non-limiting example (not shown), the supplemental section 106 may include a geometry, shape, and / or dimensions (e.g., width, depth) substantially distinct from the component section 104 of the unitary body 102. In this non-limiting example, the supplemental section 106 may be sized and / or may include a geometry such that it can cover and / or be placed on only a portion of the component section 104, including features formed therein (e.g., passages 108 / openings 110). Thus, a separate portion of the component section 104, and more specifically, a portion of the "finished" surface 112 of the component section 104, may not be covered by the supplemental section 106 and may be fully exposed during post-build processing, as discussed herein.

[0023] As shown in FIGS. 1 and 2, the supplemental section 106 may also include at least one channel 118. More specifically, the channel 118 may be formed in and / or extend at least partially through the supplemental section 106. The channel 118 of the supplemental section 106 may be in fluid communication with the passages 108 / openings 110 (e.g., features) formed in the component section 104 of the unitary body 102. The channel 118 may allow a fluid (e.g., pressurized air) to flow through the passages 108 formed in the component section 104 of the unitary body 102 to remove unsintered powder material and / or particles that may remain undesirably in the passages 108 of the component section 104 after formation of the component 100. Additionally or alternatively, the channel 118 may allow a test fluid to flow through the passages 108 formed in the component section 104 to test operating parameters and / or characteristics of the passages 108. For example, where passage 108 may be formed as a cooling passage within component 100, channel 118 of supplemental section 106 may allow a test fluid to be provided to passage 108 to ensure that the test / actual flow rate and / or flow pressure meets the desired operating flow rate and / or flow pressure.

[0024] In the non-limiting example shown in FIGS. 1 and 2 , the channel 118 of the supplemental section 106 may also include an opening 120. Specifically, the channel 118 extending at least partially through the supplemental section 106 may include an opening 120 formed in, on, and / or through the surface 122 of the unitary body 102. As a result of forming the opening 120 of the channel 118 on the surface 122 of the unitary body 102, the channel 118 may be exposed in the component 100. In addition, forming the opening 120 of the channel 118 on the surface 122 of the unitary body 102 may also expose the passage 108 in the component formed "in-between" the component 100, since the channel 118 is in fluid communication with the passage 108 / opening 110 extending at least partially through the component section 104.

[0025] In a non-limiting example shown in FIGS. 1 and 2, the unitary body 102 of the component 100 may also include a transition conduit 124. The transition conduit 124 may be positioned within the component section 104 and the supplemental section 106. More specifically, the transition conduit 124 may be positioned within, formed / constructed within, and / or disposed within at least a portion of both the component section 104 and the supplemental section 106 of the unitary body 102. In a non-limiting example, the transition conduit 124 may extend between the transition between the component section 104 and the supplemental section 106 as defined by the dashed line (DL) shown in FIG. 2 and as discussed herein. The transition conduit 124 may be integrally formed using a (single) additive manufacturing process and / or AMS within the unitary body 102 and / or may be formed during the same additive manufacturing process and / or using the same AMS that may form features (e.g., passages 108, channels 118) within the unitary body 102 as discussed herein. As shown in Figures 1 and 2 and discussed herein, the transition conduit 124 may include a second dimension (D2) that is greater than the first dimension (D1) of the opening 110 of the passage 108 that extends at least partially through the component section 104.

[0026] FIG. 3 illustrates a cross-sectional front view of a portion of the unitary body 102 along line CS-CS of FIG. 2. As shown in FIG. 3, and with continued reference to FIGS. 1 and 2, the transition conduit 124 of the unitary body 102 can also extend between the passage 108 of the component section 104 and the channel 118 of the supplemental section 106. Thus, the transition conduit 124 can fluidly couple the passage 108 extending through the component section 104 and the channel 118 extending through the supplemental section 106 of the unitary body 102. In the non-limiting example illustrated in FIGS. 1-3, the transition conduit 124 can also be frusto-conical in shape and / or geometry. More specifically, the transition conduit 124 can include a first end 126 (see FIG. 3) positioned directly adjacent and in direct fluid communication with the opening 110 of the passage 108 formed in the component section 104, and a second end 128 (see FIG. 3) positioned opposite the first end 126. The second end 128 may be positioned immediately adjacent to and in direct fluid communication with the channel 118 positioned within the supplemental section 106. In a non-limiting example, the first end 126 of the transition conduit 124 may be formed, constructed, and / or defined in the component section 104 of the unitary body 102, and the second end 128 of the transition conduit 124 may be formed, constructed, and / or defined in the supplemental section 106 of the unitary body 102. The first end 126 of the transition conduit 124 may include or have a dimension (e.g., a third dimension) (D3) that may be (slightly) larger than the first dimension (D1) of the opening 110 of the passageway 108. The second end 128 of the transition conduit 124 may include a second dimension (D2) that is larger than the first dimension (D1) of the opening 110 of the passageway 108 and is larger than the third dimension (D3) of the first end 126. 3, the second dimension (D2) may be substantially similar to the dimensions of the channel 118 of the supplemental section 106 of the unitary body 102. Thus, based on the frustoconical shape of the transition conduit 124, the entire transition conduit 124 may include dimensions (e.g., D2, D3) that are greater than the opening 110 of the passageway 108, and the difference in dimensions may increase as the distance between the opening 110 and the second end 128 of the transition conduit 124 increases.

[0027] The formation and / or positioning of the transition conduit 124 within the unitary body 102 may prevent, eliminate, and / or reduce undesirable results and / or effects imparted to the component 100 after performing post-build processes on the unitary body 102 and the various sections / features. That is, once the component 100 is additively manufactured to include the component section 104, the supplemental section 106, and the various features therein (e.g., the passages 108, the channels 118, etc.), the unitary body 102 of the component 100 may undergo various post-build processes. The post-build processes may include, for example, the removal of the supplemental section 106 from the component section 104 of the unitary body 102. As discussed herein, the supplemental section 106 may be removed from the component section 104 such that the component section 104 of the component 100 may represent a "final" configuration that may be used by the component, apparatus, and / or system for its intended purpose. As shown in Figures 3 and 4, the supplemental section 106 can be removed from the component section 104 at a dashed line (DL), also identified in the figures as a separation line (SL) (see Figure 3). As shown in Figure 3, the separation line (SL) can pass through a transition conduit 124 that extends between and fluidly couples the passageway 108 of the component section 104 and the channel 118 of the supplemental section 106. Additionally, as discussed herein with respect to Figure 2, the dashed reference line / separation line (SL) can identify where the component section 104 ends within the unitary body 102 and / or where the supplemental section 106 begins within the unitary body 102. Thus, as discussed herein, the supplemental section 106 can be completely removed from the component section 104 along the separation line (SL) during a post-construction removal process.

[0028] The supplemental section 106 may be removed from the component section 104 using any suitable material removal technique and / or process. For example, the unitary body 102 of the component 100 may be machined (e.g., cut, milled, etc.) along the parting line (SL) to remove the supplemental section 106 completely from the component section 104. In another non-limiting example, the unitary body 102 of the component 100 may be subjected to an electrical discharge machining process to remove the supplemental section 106 from the component section 104 along the parting line (SL). As a result of removing the supplemental section 106 from the component section 104, the "finished" surface 112 of the component section 104 may be exposed, formed, and / or defined. Additionally, the remaining portion 130 of the transition conduit 124, including the first end 126, as well as the passageway 108 and the opening 110 of the component section 104 may be exposed through the "finished" surface 112.

[0029] The supplemental section 106 of the unitary body 102 for the component 100 can be formed by AMS to include predetermined construction characteristics that are substantially similar or distinct from the predetermined construction characteristics of the component section 104 of the unitary body 102. In a non-limiting example where the predetermined construction characteristics differ between the supplemental section 106 and the component section 104, the material density or material porosity of the supplemental section 106 can be different from the material density or material porosity of the component section 104. More specifically, the material density or material porosity of the supplemental section 106 can be less than the material density or material porosity of the component section 104. The reduced material density or material porosity of the supplemental section 106 can make it easier to remove the supplemental section 106 from the component section 104. In a non-limiting example discussed herein with respect to Figures 1-4, the supplemental section 106 can be removed from the component section 104 at a separation line (SL), which can also coincide with a dashed line (DL) that distinguishes the supplemental section 106 from the component section 104. As discussed herein, component section 104 may not include supplemental section 106, and therefore may not include any portion of supplemental section 106 that includes reduced density or porosity. The AMS may construct supplemental section 106 to include predetermined build characteristics distinct from those of component section 104, for example, by adjusting the intensity or power output for the energy emitting devices used to form supplemental section 106 and component section 104, and / or the speed for the energy emitting devices used to form supplemental section 106 and component section 104.

[0030] In other non-limiting examples (see FIGS. 9 and 10 ), the separation line (SL) at which the supplemental section 106 is removed from the component section 104 may not coincide with the dashed line (DL) that distinguishes the supplemental section 106 from the component section 104. Thus, a portion of the component section 104 may be removed with the supplemental section 106 and / or a portion of the supplemental section 106 may remain with the component section 104. In these examples, the component section 104 and the supplemental section 106 may include similar predetermined construction characteristics.

[0031] In a non-limiting example, once the supplemental section 106 is removed from the component section 104, the component section 104 of the component 100 may be implemented, installed, and / or utilized for its intended purpose. That is, the component section 104, including the transition conduit 124, the passageway 108, and the remaining portion 130 of the opening 110, may be considered a completed, final, and / or ready-to-use component that may be utilized for its intended purpose and / or used within an intended device without additional post-construction processing.

[0032] 5, an enlarged portion of the component section 104 of FIG. 4 is shown after a machining process has been performed on the unitary body 102 to remove the supplemental section 106. In a non-limiting example, a burr 132 may form along the “finished” surface 112 and / or extend into the transition conduit 124. That is, when a machining process is performed to remove the supplemental section 106 from the component section 104, excess material or burr 132 may form, be forced inward, and / or extend from the “finished” surface 112 into the transition conduit 124. As shown in the non-limiting example, the burr 132 that extends into the transition conduit 124 does not close, obstruct, and / or otherwise block the passageway 108 (e.g., allowing fluid to flow in and / or out). That is, even with the burr 132, the passageway 108 of the component section 104 may still be exposed and / or capable of receiving and / or discharging fluid through the opening 110 and / or the transition conduit 124 including the burr 132. The passageway 108 of the component section 104 is not obstructed by burrs 132 as a result of the transition conduit 124, and more specifically, the remaining portion 130 of the transition conduit 124 formed immediately adjacent the "finished" surface 112, which includes a dimension that is greater than the first dimension (D1) of the opening 110 and / or the passageway 108. Thus, the passageway 108 of the component section 104 may be utilized for its intended purpose with no or negligible reduction in operation or operating parameters.

[0033] In another non-limiting example, the component section 104 of the unitary body 102 that is substantially free of the supplemental section 106 may undergo additional post-construction processes. For example, with continued reference to FIG. 5, it may be desirable to remove burrs 132 from the component section 104. Thus, after the supplemental section 106 is removed from the unitary body 102 using machining techniques, a deburring process may be performed on the component section 104. With reference to FIG. 6, the burrs 132 (shown in phantom) may be removed via a deburring process and / or using any suitable technique and / or system that may be configured to remove the burrs 132. Performing a deburring process on the component section 104 may also restore and / or reshape the remaining portion 130 of the transition conduit 124 to its original form, geometry, and / or shape prior to performing the removal process on the unitary body 102 of the component 100 (see, e.g., FIG. 3). Additionally, when performing a deburring process on the component section 104, the work tool and / or system performing the deburring process (e.g., a deburring tool) may only contact, restore, and / or reshape the remaining portion 130 of the transition conduit 124 while removing the burr 132. Thus, the configuration, geometry, and / or shape of the opening 110 and / or passageway 108 of the component section 104 may not change, may not be altered, and / or may maintain the desired / constructed geometry. Removing the burr 132 that may extend into the transition conduit 124 may ensure that the passageway 108 / opening 110 of the component section 104 may operate as intended and / or perform with the desired operating parameters and characteristics when utilized for that purpose.

[0034] 7-10 show additional non-limiting examples of the unitary body 102 of the component 100. More specifically, FIGS. 7-10 show front cross-sectional views of a portion of the unitary body 102 including integrally formed component section 104 and supplemental section 106 (e.g., FIGS. 7 and 9), as well as cross-sectional views of the supplemental section 106 removed from the component section 104 (e.g., FIGS. 8 and 10). It is understood that similarly numbered and / or named components may function in a substantially similar manner. Redundant descriptions of these components have been omitted for clarity.

[0035] In the non-limiting examples shown in Figures 7 and 8, the transition conduit 124 may be substantially uniform and / or linear in shape. That is, apart from the transition conduit 124 discussed herein with respect to Figures 1-6, the transition conduit 124 may not be frustoconical in shape and / or may include varying / converging dimensions. Rather, the transition conduit 124 shown in Figures 7 and 8 may be substantially linear and may include a single uniform dimension (D2) between the first end 126 and the second end 128. The uniform second dimension of the transition conduit 124 that extends between and fluidly couples the passage 108 and the channel 118 may be greater than the first dimension (D1) of the opening 110 and / or the passage 108. 8, once the supplemental section 106 is removed from the component section 104, the remaining portion 130 of the transition conduit 124 may include or maintain a uniform second dimension (D2) that may be greater than the first dimension (D1) of the opening 110. As similarly discussed herein with respect to FIGS. 5 and 6, the transition conduit 124, and more specifically the remaining portion 130 of the transition conduit 124 including the greater second dimension (D2), may prevent burrs 132 (see FIG. 5) from obstructing the passageway 108 / opening 110. Additionally or alternatively, the remaining portion 130 of the transition conduit 124 including the uniform second dimension (D2) may prevent the passageway 108 / opening 110 from being undesirably reshaped or reconfigured by a tool or system (e.g., a deburring tool) that may be used to remove burrs 132 extending into the transition conduit 124 after the supplemental section 106 is removed.

[0036] 9 and 10 , the passages 108 can extend through the component sections 104 at an angle (α). More specifically, the passages 108 extend at least partially through the component sections 104 at a non-perpendicular angle relative to a “finished” surface 112 (see FIG. 10 ) on the component sections 104 of the unitary body 102. Similarly, as discussed herein, when the supplemental sections 106 are removed from the component sections 104, the “finished” surface 112 may expose the angled or non-perpendicular passages 108 of the component sections 104.

[0037] 9 and 10 illustrate non-limiting examples in which the supplemental section 106 is not removed from the component section 104 at the reference line (RL) and / or the transition between the component section 104 and the supplemental section 106. That is, the supplemental section 106 may be removed from the component section 104 at a separation line (SL) that is separate from the reference line (RL) that marks the transition between the two sections 104, 106 of the unitary body 102. In non-limiting examples, the separation line (SL) may be positioned adjacent to and / or on the reference line (RL). As also discussed herein, the separation line (SL) may still be positioned through a transition conduit 124 formed, positioned, defined, and / or extending between the component section 104 and the supplemental section 106. However, separate from the non-limiting examples discussed herein with respect to Figures 1-8, the separation line (SL) shown in Figure 9 may be positioned only through a portion of the transition conduit 124 that is positioned, defined, and / or extends within the supplemental section 106 of the unitary body 102.

[0038] 10 , the supplemental section 106 may be removed at a separation line (SL) positioned adjacent and / or on the reference line (RL), and a portion of the supplemental section 106 may remain with the component section 104. That is, the final configuration formed from the unitary body 102 of the additively manufactured component 100 may include the unremoved or remaining portion 136 of the supplemental section 106. In this non-limiting example, the “finished” surface 112 may be formed by the remaining portion 136 of the supplemental section 106 of the unitary body 102 that is not removed and / or remains integrally formed with the component section 104. Exposing / defining the “finished” surface 112 formed from the remaining portion 136 of the supplemental section 106 may also expose the transition conduit 124, the passageway 108, and the remaining portion 130 of the opening 110 of the component section 104, as similarly discussed herein.

[0039] 11-13 show additional non-limiting examples of a unitary body 202 of a component 200. More specifically, FIGS. 11-13 show front cross-sectional views of a portion of a unitary body 202 including an integrally formed component section 204 and a supplemental section 206. In each of the non-limiting examples, the component section 204 may include a plurality of passages 208A, 208B extending therethrough, as discussed herein. It is understood that the number of passages 208 formed in the component sections 204 of the unitary body 202 shown herein may be exemplary, and that the unitary body 202 of the component 200 may include a greater or lesser number of passages 208 than shown and discussed herein.

[0040] In a non-limiting example shown in FIG. 11, the component section 204 can include a first passageway 208A and a separate second passageway 208B. The first passageway 208A can extend at least partially through the component section 204 and can include a first opening 210A having a first dimension (D1). The first passageway 208A can be substantially similar to the passageway 108 discussed herein with respect to FIGS. 1-6. The second passageway 208B of the unitary body 202 can extend at least partially through the component section 204 adjacent to the first passageway 208A. The second passageway 208B can also include a second opening 210B having a third dimension (D3).

[0041] 11, the supplemental section 206 may include a plurality of channels 218A, 218B each corresponding to one of the plurality of passages 208A, 208B formed in the component section 204. That is, the supplemental section 206 may include a plurality of corresponding channels 218A, 218B that may be disposed on, formed in, and / or cover, and extend into, a first opening 210A of the first passage 208A and a second opening 210B of the second passage 208B. For example, the supplemental section 206 may include a first channel 218A in fluid communication with the first passage 208A. The first channel 218A may include a first opening 220A formed through the surface 222 and may be in fluid communication with the first passage 208A via a first transition conduit 224A positioned between the first channel 218A and the first passage 208A. As also discussed herein, the first transition conduit 224A may extend, be formed, defined, and / or positioned between the component section 204 and the supplemental section 206 and fluidly couple the first channel 218A and the first passage 208A. As also discussed herein, the first transition conduit 224A may include a frusto-conical shape, and the entirety of the transition conduit 224A may include a dimension (e.g., D2) that is greater than a first dimension (D1) for the first opening 210A of the first passage 208A. Additionally, the difference in dimensions may increase as the first transition conduit 224A transitions into the first channel 218A and / or away from the first opening 210A.

[0042] 11, the supplemental section 206 may also include a separate second channel 218B. The second channel 218B may extend at least partially through the supplemental section 206 and may be in fluid communication with the second passage 208B. That is, the second channel 218B may extend at least partially through a portion of the supplemental section 206 that may be disposed on the second passage 208B and include an opening 220B formed in the surface 222. The second channel 218B may also be in fluid communication with the second passage 208B that extends at least partially through the component section 204.

[0043] In addition, as shown in FIG. 11, the unitary body 202 may include a second transition conduit 224B positioned within and / or extending between the component section 204 and the supplemental section 206. The second transition conduit 224B may extend between the second passage 208B of the component section 204 and the second channel 218B of the supplemental section 206 and fluidly couple the second passage 208B and the second channel 218B. In a non-limiting example shown in FIG. 11, the second transition conduit 224B may include a substantially uniform fourth dimension (D4), as similarly discussed herein with respect to FIGS. 7 and 8. The fourth dimension (D4) of the second transition conduit 224B may be greater than the third dimension (D3) of the second opening 210B of the second passage 208B. While shown as including a substantially uniform fourth dimension (D4), it is understood that the second transition conduit 224B may alternatively be formed to include a frusto-conical shape (see FIG. 12) and the entire second transition conduit 224B may include a dimension (e.g., D4) that is greater than the third dimension (D3) for the second opening 210B of the second passage 208B.

[0044] 12, the unitary body 202 of the component 200 may include similar features (e.g., passages 208A, 208B, openings 210A, 210B, and / or transition conduits 224A, 224B) such as those shown and discussed herein with respect to FIG 11. It is understood that similarly numbered and / or named components may function in a substantially similar manner. Redundant descriptions of these components have been omitted for clarity.

[0045] Separate from FIG. 11, the non-limiting example of FIG. 12 illustrates a supplemental section 206 including a single channel 218 extending therein. More specifically, the supplemental section 206 of the unitary body 202 can include a single channel 218 that can include a single opening 220 formed in and / or through a surface 222. In a non-limiting example, the single channel 218 can be in fluid communication with each of the first and second passages 208A and 208B that extend at least partially through the component section 204. The single channel 218 can also be in direct fluid communication and / or fluidly coupled with each of the first and second transition conduits 224A and 224B. Thus, the first transition conduit 224A can fluidly couple the first passage 208A to the single channel 218, and the second transition conduit 224B can similarly fluidly couple the second passage 208B to the single channel 218.

[0046] In a non-limiting example shown in FIG. 13, the supplemental section 206 may include a manifold 236 formed therein. The manifold 236 of the supplemental section 206 may be in fluid communication with each of the first channel 218A and the second channel 218B that extend at least partially through the supplemental section 206. As shown in FIG. 13, the manifold 236 may include a single opening 238 formed in the surface 222 of the supplemental section 206. The single opening 238 may be in fluid communication with multiple branches 240, 242 of the manifold 236. Each branch 240, 242 may correspond to and / or be fluidly coupled to a channel 218A, 218B of the supplemental section 206. For example, the first branch 240 of the manifold 236 may be fluidly coupled to the first channel 218A and the second branch 242 may be fluidly coupled to the second channel 218B. As discussed herein, the manifold 236 of the supplemental section 206 may also provide fluid flow to and / or from the passages 208A, 208B of the component section 204 via the channels 218A, 218B.

[0047] FIG. 14 illustrates a front view of a component 300 including a unitary body 302. In a non-limiting example, a component section 304 of the unitary body 302 may include a first passageway 308A and a second passageway 308B extending therethrough and in fluid communication with and / or fluidly coupled to a cavity 344 formed therein. As shown, the second passageway 308B may extend at least partially through the component section 304 at an angle (e.g., perpendicular) to the first passageway 308A. Thus, apart from the non-limiting examples discussed herein with respect to FIGS. 11-13, the second passageway 308B may be exposed on a "finished" surface (e.g., "finished" surface 112) separate from the first passageway 308A when the component section 304 is in a final form and / or configuration for use.

[0048] As a result, the unitary body 302 of the component 300 can include a first supplemental section 306A integrally formed with the component section 304 and a separate second supplemental section 306B. That is, the first supplemental section 306A can be integrally formed with the component section 304 and can be disposed over and / or cover the first passageway 308A / first opening 310A. The unitary body 302 shown in FIG. 14 can include a first channel 318A extending at least partially through the first supplemental section 306A and in fluid communication with the first passageway 308A. As similarly discussed herein, the unitary body 302 can also include a first transition conduit 324A extending between and / or positioned within the component section 304 and the first supplemental section 306A. The first transition conduit 324A may extend between the first passage 308A of the component section 304 and the first channel 318A of the first supplemental section 306A and fluidly couple the first passage 308A and the first channel 318A.

[0049] The second supplemental section 306B may be integrally formed with a separate portion of the component section 304 of the unitary body 302. That is, the second supplemental section 306B may be integrally formed with the component section 304 and may be disposed over and / or cover the second passageway 308B / second opening 310B. As shown in FIG. 14, the second supplemental section 306B of the unitary body 302 may include a second channel 318B extending at least partially through the second supplemental section 306B. The second channel 318B may be in fluid communication with the second passageway 308B. In a non-limiting example, the unitary body 302 may also include a second transition conduit 324B extending between and / or positioned within the component section 304 and the second supplemental section 306B. The second transition conduit 324B may extend between the second passage 308B of the component section 304 and the second channel 318B of the second supplemental section 306B to fluidly couple the second passage 308B and the second channel 318B. As similarly discussed herein, each of the first supplemental section 306A and the second supplemental section 306B may be removed along a respective separation line (SL1, SL2) to form a final configuration of the component 300 (e.g., component section 304) that may be utilized for its intended purpose.

[0050] Although shown as two separate supplemental sections 306A, 306B, it is understood that the non-limiting example shown in FIG. 14 may include a single supplemental section 306 that may be disposed over and / or cover both the first and second passages 308A, 308B. For example, a void 346 (shown in phantom) may be formed between the first and second supplemental sections 306A, 306B during an additive manufacturing build process on the unitary body 302 to separate and / or distinguish the first and second supplemental sections 306A, 306B. In another non-limiting example, the void 346 shown in FIG. 14 may include additively manufactured or built material that may bridge, be formed, extend, and / or define between the first and second supplemental sections 306A, 306B as a single, integral supplemental section of the unitary body 302.

[0051] Figure 15 shows a non-limiting exemplary process for forming a component using an additive manufacturing process and / or system. Specifically, Figure 15 is a flow chart illustrating an exemplary process for forming a component including a component section and a supplemental section. In some cases, the process may be used to form components 100, 200, 300 as discussed herein with respect to Figures 1-14.

[0052] In process P1, the unitary body of the component may be additively manufactured or constructed. That is, an additive manufacturing system (AMS) may perform a construction process (e.g., direct metal laser melting) and construct the unitary body of the component. The unitary body of the component may be constructed to include various sections and at least one feature formed therein. For example, the additively manufactured unitary body may include a component section including at least one passage extending at least partially through the component section. The passage may include an opening having a first dimension. In a non-limiting example, additively manufacturing the unitary body may include additively manufacturing the passage at a non-perpendicular angle relative to a finished surface of the unitary body. The additively manufactured unitary body may also include a supplemental section integrally formed with the component section. The supplemental section may be disposed on the passage of the component section and may include a channel extending at least partially through the supplemental section. The channel of the supplemental section may be in fluid communication with the passage of the component section. In addition, the additively manufactured unitary body may include a transition conduit positioned between and / or extending between the component section and the supplemental section. A transition conduit may extend between the passageway of the component section and the channel of the supplemental section to fluidly couple the passageway and the channel.

[0053] The transition conduit may also be additively manufactured to include a second dimension that is greater than the first dimension of the passage opening of the component section. In a non-limiting example, the second dimension of the transition conduit may be substantially uniform in shape and / or dimension. In another non-limiting example, the transition conduit may be additively manufactured in process P1 to be and / or include a frusto-conical shape. The frusto-conical transition conduit may be additively manufactured to include a first end positioned immediately adjacent to and in direct fluid communication with the passage opening extending into the component section. The first end of the frusto-conical transition conduit may have a third dimension that is greater than the first dimension of the passage opening of the component section. The frusto-conical transition conduit may also be additively manufactured to include a second end positioned opposite the first end. The second end may be positioned immediately adjacent to and in direct fluid communication with the channel positioned in the supplemental section. The second end may also have a second dimension that is greater than the first dimension of the passage opening and a third dimension of the transition conduit first end.

[0054] In an additional non-limiting example, the unitary body may include multiple passageways. More specifically, the additive manufacturing performed in process P1 may also include additively manufacturing a first passageway extending at least partially through the component section. The first passageway may include a first opening having a first dimension. In addition, process P1 may also include additively manufacturing a second passageway adjacent to the first passageway and extending at least partially through the component section. The second passageway may include a second opening having a third dimension.

[0055] As a result of forming two (or more) passages, the supplemental section may include at least one channel and / or the single body may include multiple transition conduits. Continuing with the above example, process P1 may include additively manufacturing a second channel that extends at least partially through the supplemental section and is in fluid communication with the second passage. The supplemental section may be disposed on the first opening of the first passage and the second opening of the second passage. In addition, process P1 may further include additively manufacturing a second transition conduit positioned within the component section and the supplemental section. The second transition conduit may extend between the second passage of the component section and the second channel of the supplemental section and fluidly couple the second passage and the second channel. In this non-limiting example, the (first) channel of the supplemental section is in fluid communication with the first passage via the (first) transition conduit, and the second channel of the supplemental section is in fluid communication with the second passage via the second transition conduit.

[0056] In another non-limiting example, where the component section includes a first passage and a second passage, process P1 may further include additively manufacturing a second supplemental section integrally formed with the component section and disposed over a second opening of the second passage. The second supplemental section may be separate from the (first) supplemental section and may include a second channel extending at least partially through the second supplemental section and in fluid communication with the second passage. Additionally, in a non-limiting example, additively manufacturing the unitary body in process P1 may include additively manufacturing a second transition conduit positioned within the component section and the second supplemental section. The second transition conduit may extend between the second passage of the component section and the second channel of the second supplemental section and fluidly couple the second passage and the second channel.

[0057] In any non-limiting example where the component section includes a first passage and a second passage and the supplemental section includes a first channel and a second channel, additively manufacturing the unitary body in process P1 may also include additively manufacturing a manifold in the supplemental section. The manifold additively manufactured in the unitary body of the component may be in direct fluid communication with the channel and the second channel of the supplemental section.

[0058] In process P2 (optionally shown in phantom), at least one post-build process may be performed on the component including the unitary body. Specifically, after integrally forming and / or additively manufacturing (e.g., process P1) the component sections and supplemental sections, one or more post-build processes may be performed on the unitary body of the component including the integrally formed component sections and supplemental sections. The post-build process performed on the component including the unitary body may prepare the unitary body of the component for use by the component, device, and / or system for its intended purpose. Performing at least one post-build process on the component including the unitary body may also include, for example, shot peening of the unitary body and / or recrystallization of the component including the unitary body.

[0059] In process P3, the supplemental section may be removed from the unitary body. That is, the supplemental section may be removed from the component section of the unitary body of the component. Removing the supplemental section from the additively manufactured unitary body component section may substantially expose, define, and / or form a "finished" surface of the component section for the unitary body. In addition, removing the supplemental section from the unitary body component section may also expose at least the remaining portion of the transition conduit and the passage of the component section. The supplemental section may be removed by performing any now known or later developed cutting process, such as, for example, electrical discharge machining (EDM), cutting wheel, etc. For example, removing the supplemental section may include machining the supplemental section through the transition conduit to define a finished surface of the component section of the unitary body / component. The finished surface may include the exposed / remaining portion of the transition conduit and the passage of the component section. By removing / machining the supplemental section through the transition conduit, at least a portion of the transition conduit including a second dimension that is greater than the first dimension of the opening / passage in the component section can remain in and / or on the component section of the component.

[0060] In process P4 (shown in phantom as an option), additional post-build processes may be performed on the unitary body. Specifically, after removing the supplemental section from the unitary body component section, additional post-build processes may be performed on the component section of the component to prepare the component section for its intended use and / or to provide the component section. In a non-limiting example where only a shot peening process is performed in process P2, the component section may undergo a recrystallization process without the supplemental section. Additionally or alternatively, a burr removal process may be performed following removal of the supplemental section. For example, if the supplemental section is removed from the component section using a machining process, a burr may be formed on the "finished" surface. The burr may extend from the remaining portion of the transition conduit and may extend at least partially into and / or adjacent to the opening / passage of the component section. Thus, process P4 may include performing a burr removal process after removing the supplemental section from the unitary body component section to remove at least one burr extending into and / or from the remaining portion of the transition conduit.

[0061] The components 100, 200, 300 can be formed in a number of ways. In one embodiment, the components 100, 200, 300 can be made by casting. However, as described herein, additive manufacturing is particularly suited for manufacturing the components 100, 200, 300 that include a unitary body. As used herein, additive manufacturing (AM) may include any process that produces an object through the formation of successive layers of material, rather than the removal of material as occurs in traditional processes. Additive manufacturing can form complex geometric shapes without the use of tools, molds, or fixtures of any kind, and with little or no waste material. Instead of machining components from solid billets of plastic or metal, much of which would be cut out and discarded, the material used in additive manufacturing is only the material needed to form the part. Additive manufacturing processes can include, but are not limited to, 3D printing, rapid prototyping (RP), direct digital manufacturing (DDM), binder jetting, selective laser melting (SLM), and direct metal laser melting (DMLM). In the current setup, DMLM or SLM have proven advantageous.

[0062] To illustrate an example of an additive manufacturing process, FIG. 16 shows a schematic / block diagram of an exemplary computerized additive manufacturing system 900 for generating an object 902. In this example, the system 900 is configured for DMLM. It is understood that the general teachings of this disclosure are equally applicable to other forms of additive manufacturing. The object 902 is shown as components 100, 200, 300 (see FIGS. 1-14). The AM system 900 generally includes a computerized additive manufacturing (AM) control system 904 and an AM printer 906. The AM system 900 executes code 920 including a set of computer executable instructions defining the components 100, 200, 300 to physically generate the object 902 using the AM printer 906, as described. Each AM process can use different feedstock materials in the form of, for example, fine powder, liquid (e.g., polymer), sheets, etc., the stock of which can be held in a chamber 910 of the AM printer 906. As shown, the applicator 912 may create a thin layer of raw material 914 that is spread as a blank canvas on the build plate 915 of the AM printer 906, from which each successive slice of the final object is created. In other cases, the applicator 912 may apply or print the next layer directly onto the previous layer as defined by code 920, for example, if a metal binder jetting process is used. In the example shown, the laser or electron beam 916 fuses the particles of each slice together as defined by code 920, although this is not necessary if a fast-setting liquid plastic / polymer is employed. Various parts of the AM printer 906 may move to accommodate the addition of each new layer, for example, after each layer, the build platform 918 may be lowered and / or the chamber 910 and / or the applicator 912 may be raised.

[0063] The AM control system 904 is shown implemented as computer program code in a computer 930. In this regard, the computer 930 is shown to include a memory 932, a processor 934, an input / output (I / O) interface 936, and a bus 938. Additionally, the computer 930 is shown to be in communication with external I / O devices / resources 940 and a storage system 942. In general, the processor 934 executes computer program code, such as the AM control system 904, stored in the memory 932 and / or the storage system 942 under instructions from the code 920 representing the components 100, 200, 300 described herein. During execution of the computer program code, the processor 934 can read data from and / or write data to the memory 932, the storage system 942, the I / O device 940, and / or the AM printer 906. The bus 938 provides a communication link between each of the components of the computer 930, and the I / O devices 940 may comprise any device 940 (e.g., keyboard, pointing device, display, etc.) that allows a user to interact with the computer. The computer 930 is only representative of various possible combinations of hardware and software. For example, the processor 934 may comprise a single processing unit or may be distributed across one or more processing units in one or more locations, such as, for example, on a client and a server. Similarly, the memory 932 and / or the storage system 942 may reside in one or more physical locations. The memory 932 and / or the storage system 942 may comprise any combination of various types of non-transitory computer-readable storage media, including magnetic media, optical media, random access memory (RAM), read-only memory (ROM), etc. The computer 930 may comprise any type of computing device, such as a network server, desktop computer, laptop, mobile device, mobile phone, pager, personal digital assistant, etc.

[0064] The additive manufacturing process begins by storing code 920 representing components 100, 200, 300 in a non-transitory computer-readable storage medium (e.g., memory 932, storage system 942, etc.). As previously described, code 920 includes a set of computer-executable instructions that define an outer electrode, which upon execution of the code by system 900 can be used to physically generate a tip. For example, code 920 may include a precisely defined 3D model of components 100, 200, 300, and can be generated from any of a variety of well-known computer-aided design (CAD) software systems, such as AutoCAD®, TurboCAD®, DesignCAD 3D Max, etc. In this regard, code 920 can be in any now known or later developed file format. For example, the code 920 may be in Standard Tessellation Language (STL) generated for 3D Systems' stereolithography CAD program, or in American Society of Mechanical Engineers (ASME) standard Additive Manufacturing File (AMF), an Extensible Markup Language (XML) based format designed to allow any CAD software to describe the shape and configuration of any three-dimensional object to be produced on any AM printer. The code 920 may be converted between different formats, converted to a set of data signals and transmitted, received as a set of data signals and converted to code, stored, etc., as needed. The code 920 may be an input to the system 900 and may come from a part designer, an intellectual property (IP) provider, a design firm, an operator or owner of the system 900, or from other sources. In any case, the AM control system 904 executes the code 920 to divide the components 100, 200, 300 into successive thin slices, which are then assembled using the AM printer 906 with successive layers of liquid, powder, sheet, or other material. In the DMLM example, each layer is melted and fused to the previous layer into the precise geometric shape defined by the code 920.Thereafter, components 100, 200, 300 may undergo any of a variety of finishing processes, such as those described herein for recontouring or other small scale machining, sealing, polishing, and the like.

[0065] Technical effects of the present disclosure include, for example, providing a component formed from a unitary body including a component section, a supplemental section, and a transition conduit that extends between and fluidly couples the passages of the component section and the channels of the supplemental section. The transition conduit positioned between the component section and the supplemental section of the unitary body allows the supplemental section to be removed from the component section without impeding passage of the component section and / or eliminates the risk of the passages being undesirably altered when performing post-build processes (e.g., deburring) on ​​the component section.

[0066] The flowcharts and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present disclosure. In this regard, each block in the flowcharts or block diagrams may represent a module, segment, or part of code, which includes one or more executable instructions for implementing the specified logical function. It should be noted that in some alternative implementations, the functions described in the blocks may be performed in a different order than that described in the figures. For example, two blocks shown in succession may in fact be executed substantially simultaneously, or may sometimes be executed in the reverse order depending on the functionality involved in those blocks. It should also be noted that each block of the block diagrams and / or flowchart diagrams, and combinations of blocks in the block diagrams and / or flowchart diagrams, may be realized by a dedicated hardware-based system that performs the specified functions or operations, or a combination of dedicated hardware and computer instructions.

[0067] As discussed herein, various systems and components are described as "obtaining" data. It is understood that the corresponding data can be obtained using any solution. For example, the corresponding system / component can generate data and / or be used to generate data, retrieve data from one or more data stores (e.g., databases), receive data from another system / component, etc. When data is not generated by a particular system / component, it is understood that another system / component can be implemented apart from the illustrated system / component that generates and provides data to the system / component and / or stores data for access by the system / component.

[0068] The above figures show some of the relevant processes according to some embodiments of the present disclosure. In this regard, each figure or block in the flow diagram of the figures represents a process related to the described method embodiment. It should also be noted that in some alternative implementations, the operations described in the figures or blocks may occur out of the order described in the figures, or may actually be performed substantially simultaneously or in reverse order, depending on the operations involved, for example. Also, those skilled in the art will recognize that additional blocks describing the process may be added.

[0069] The terminology used herein is merely for the purpose of describing certain embodiments and is not intended to limit the disclosure. As used herein, the singular forms "a", "an" and "the" are intended to include the plural unless otherwise specified. It will be further understood that the terms "comprise" and / or "comprising" as used herein specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or sets thereof. "Optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and the description includes instances in which the event occurs and instances in which it does not occur.

[0070] As used herein throughout the specification and claims, approximation language can be applied to modify any quantitative expression that can be reasonably varied without causing a change in the basic function involved. Thus, values ​​modified by terms such as "approximately," "about," and "substantially" are not limited to the exact value specified. In at least some instances, approximation language can correspond to the precision of the instrument for measuring the value. Here, and throughout the specification and claims, range limitations can be combined and / or substituted, and such ranges are identified and include all subranges encompassed therein, unless the context and language dictate otherwise. "About" applied to a particular value in a range applies to both values ​​and can indicate + / - 10% of the stated value, unless specifically dependent on the precision of the instrument for measuring the value.

[0071] The corresponding structures, materials, acts, and equivalents of all means-plus-function or step-plus-function elements in the following claims are intended to encompass any structures, materials, or acts for performing that function in combination with other specifically claimed claim elements. The description of the present disclosure has been presented for purposes of illustration and description, and is not intended to be exhaustive or to limit the disclosure to the disclosed form. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the disclosure. The present embodiment has been chosen and described in order to best explain the principles and practical application of the disclosure, and to enable others skilled in the art to understand the disclosure in its various embodiments with various modifications as appropriate for the particular use envisaged. [Explanation of symbols]

[0072] 18 Build Plate 20 Construction Surface 100 Component, turbine shroud 102 Single Body 104 Component Section 106 Supplementary Section Aisle 108 110 Opening 112 Finished Surface 118 Channels 120 Opening 122 Surface 124 Transition Conduit 126 First end 128 Second End 130 Remaining 132 Bali 136 Remaining 200 Components 202 Single Body 204 Component Section 206 Supplementary Section Aisle 208 208A 1st Passage 208B Second Passage 210A First opening 210B Second opening 218 Single Channel 218A 1st Channel 218B Second Channel 220 Opening 220A First Opening 220B opening 222 Surface 224A First Transition Conduit 224B Second Transition Conduit 236 Manifold 238 Single Opening 240 Branch 242 Branch 300 Components 302 Single Body 304 Component Section 306 Single Supplementary Section 306A First Supplementary Section 306B Second Supplementary Section 308A 1st Aisle 308B Second Passage 310A First opening 310B Second opening 318A 1st Channel 318B Second Channel 324A First Transition Conduit 324B Second Transition Conduit 344 Cavity 346 Void 900 Additive Manufacturing (AM) System 902 Object 904 AM Control System 906 AM Printer 910 Chamber 912 Applicator 914 Raw materials 915 Build Plate 916 Laser, Electron Beam 918 Building Platform 920 Code 930 Computer 932 Memory 934 Processor 936 Input / Output (I / O) Interface 938 Bus 940 External I / O devices and resources 942 Memory Systems P1 Process P2 Process P3 Process P4 Process D1 First dimension D2 Second dimension D3 The third dimension D4 The fourth dimension DL dashed line RL reference line SL separation line SL1 Separation Line SL2 separation line CS-CS line α angle

Claims

1. A machine component (200), the component (200) comprising a unitary body (102, 202, 302) of the component (200) that is additively manufactured, the unitary body (102, 202, 302) comprising: a component section (104, 204, 304) including at least one passageway (108) extending at least partially through said component section (104, 204, 304), the at least one passageway (108) including an opening (110, 220B) having a first dimension (D1); a supplemental section (206) integrally formed with said component section (104, 204, 304), the supplemental section (206) including a channel (118, 218A, 218B) disposed over said at least one passage (108) of said component section (104, 204, 304) and extending at least partially through said supplemental section (206), the channel (118, 218A, 218B) being in fluid communication with said at least one passage (108) of said component section (104, 204, 304); a transition conduit (124, 224A) positioned within said component section (104, 204, 304) and said supplemental section (206), the transition conduit (124, 224A) extending between said at least one passage (108) of said component section (104, 204, 304) and said channel (118, 218A, 218B) of said supplemental section (206) and fluidly coupling said at least one passage (108) and said channel (118, 218A, 218B); and wherein the transition conduit (124, 224A) includes a second dimension (D1) greater than the first dimension (D1) of the opening (110, 220B) of the at least one passage (108) of the component section (104, 204, 304).

2. The at least one passageway (108) a first passageway (208A) extending at least partially through said component section (104, 204, 304), said first passageway (208A) including a first opening (220A) having said first dimension (D1), said channel (118, 218A, 218B) of said supplemental section (206) being in fluid communication with said first passageway (208A); a second passageway (208, 208B) extending at least partially through said component section (104, 204, 304), said second passageway (208, 208B) including a second opening (210B) having a third dimension (D3); The component (200) of claim 1, comprising:

3. The supplemental section (206) is disposed over the second opening (210B) of the second passage (208, 208B), and the supplemental section (206) comprises: a second channel (218B, 318B) extending at least partially through said supplemental section (206) and in fluid communication with said second passage (208, 208B); The component (200) of claim 2 further comprising:

4. a second transition conduit (224B, 324B) positioned within said component section (104, 204, 304) and said supplemental section (206), said second transition conduit (224B, 324B) extending between said second passage (208, 208B) of said component section (104, 204, 304) and said second channel (218B, 318B) of said supplemental section (206) and fluidly coupling said second passage (208, 208B) and said second channel (218B, 318B); Further equipped with 4. The component (200) of claim 3, wherein the second transition conduit (224B, 324B) includes a substantially uniform fourth dimension (D4), the fourth dimension (D4) being greater than the third dimension (D3) of the second opening (210B) of the second passage (208, 208B).

5. The component (200) of claim 3, wherein the supplemental section (206) further comprises a manifold (236) in fluid communication with the channel (118, 218A, 218B) and the second channel (218B, 318B).

6. a second supplemental section (306B) integrally formed with said component section (104, 204, 304) and disposed over said second opening (210B) of said second passage (208, 208B), said second supplemental section (306B) comprising: a second channel (218B, 318B) extending at least partially through said second supplemental section (306B) and in fluid communication with said second passage (208, 208B); The component (200) of claim 2, comprising:

7. a second transition conduit (224B, 324B) positioned within said component section (104, 204, 304) and said second supplemental section (306B), said second transition conduit (224B, 324B) extending between said second passage (208, 208B) of said component section (104, 204, 304) and said second channel (218B, 318B) of said second supplemental section (306B) and fluidly coupling said second passage (208, 208B) and said second channel (218B, 318B); The component (200) of claim 6, further comprising:

8. the transition conduit (124, 224A) is frusto-conical; a first end (126) positioned immediately adjacent and in direct fluid communication with the opening (110, 220B) of the at least one passage (108), the first end (126) having a third dimension (D3) greater than the first dimension (D1) of the opening (110, 220B) of the at least one passage (108); a second end (128) positioned opposite the first end (126), the second end (128) positioned immediately adjacent and in direct fluid communication with the channels (118, 218A, 218B) positioned within the supplemental section (206); Including, The second end (128) the first dimension (D1) of the opening (110, 220B) of the at least one passageway (108); and the third dimension (D3) of the first end (126) of the transition conduit (124, 224A); The component (200) of claim 1 , having the second dimension (D2) greater than

9. 2. The component (200) of claim 1, wherein the at least one passage (108) extends at least partially through the component section (104, 204, 304) at a non-perpendicular angle to a finished surface (20, 112, 122, 222) of the unitary body (102, 202, 302), the finished surface (20, 112, 122, 222) of the unitary body (102, 202, 302) exposing the at least one passage (108).

10. A method of forming a machine component, the method comprising: A step (P1) of additively manufacturing a unitary body (102, 202, 302) of a component (200), said unitary body (102, 202, 302) comprising: a component section (104, 204, 304) including at least one passageway (108) extending at least partially through said component section (104, 204, 304), said at least one passageway (108) including an opening (110, 220B) having a first dimension (D1); a supplemental section (206) integrally formed with said component section (104, 204, 304), the supplemental section (206) including a channel (118, 218A, 218B) disposed on said at least one passage (108) of said component section (104, 204, 304) and extending at least partially through said supplemental section (206), the channel (118, 218A, 218B) being in fluid communication with said at least one passage (108) of said component (200) section; a transition conduit (124, 224A) positioned within said component section (104, 204, 304) and said supplemental section (206), the transition conduit (124, 224A) extending between said at least one passage (108) of said component section (104, 204, 304) and said channel (118, 218A, 218B) of said supplemental section (206) and fluidly coupling said at least one passage (108) and said channel (118, 218A, 218B); wherein the transition conduit (124, 224A) includes a second dimension (D1) greater than the first dimension (D1) of the opening (110, 220B) of the at least one passage (108) of the component section (104, 204, 304); performing (P2) at least one post-construction process on said component (200) including said unitary body (102, 202, 302); removing (P3) the supplemental section (206) from the component section (104, 204, 304) of the unitary body (102, 202, 302) to expose a portion of the transition conduit (124, 224A) and the at least one passageway (108) of the component section (104, 204, 304); A method comprising:

11. the transition conduit (124, 224A) is frusto-conical; a first end (126) positioned immediately adjacent and in direct fluid communication with the opening (110, 220B) of the at least one passage (108), the first end (126) having a third dimension (D3) greater than the first dimension (D1) of the opening (110, 220B) of the at least one passage (108); a second end (128) positioned opposite the first end (126), the second end (128) positioned immediately adjacent and in direct fluid communication with the channels (118, 218A, 218B) positioned within the supplemental section (206); Including, The second end (128) the first dimension (D1) of the opening (110, 220B) of the at least one passageway (108); and the third dimension (D3) of the first end (126) of the transition conduit (124, 224A); The method of claim 10, wherein the second dimension (D2) is greater than

12. a step (P3) of removing said supplemental section (206) from said component section (104, 204, 304) of said unitary body (102, 202, 302), machining the supplemental section (206) through the transition conduit (124, 224A) to define a finished surface (20, 112, 122, 222) of the unitary body (102, 202, 302) of the component (200), the finished surface (20, 112, 122, 222) including the portion of the exposed transition conduit (124, 224A) and the at least one passageway (108) of the component section (104, 204, 304); The method of claim 10 further comprising:

13. A step (P1) of additively manufacturing said unitary body (102, 202, 302), Additively manufacturing the at least one passageway (108) at a non-perpendicular angle to the finished surface (20, 112, 122, 222) of the unitary body (102, 202, 302). The method of claim 12 further comprising:

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