Cantilever mask for openings in additive manufacturing parts

Abstract

To provide a mask for protecting openings in a surface of an additively manufactured part.SOLUTION: A mask 100 is provided for an additively manufactured part 102 including a plurality of spaced openings 106 in a surface of the part 102. The mask 100 is made with the part 102 and includes an attachment ligament 120 configured to integrally couple to the part 102 between the openings 106 in a cantilever fashion. First and second cover members 130, 140 include proximal ends 132, 142 integrally coupled to the attachment ligament 120, and distal ends 134, 144 extending at least partially over respective portions of the plurality of openings 106. A detachment member 152 extends from each of the first and second cover members 130, 140. The attachment ligament 120 is the sole connection to the part 102. The mask 100 may have an umbrella shape in cross-section.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present disclosure generally relates to post - manufacturing processing of components, and more particularly, to masks for protecting openings on the surface of additive - manufactured components.

Background Art

[0002] Additive manufacturing (AM) includes a variety of processes that manufacture components by the successive formation of layers of material rather than by the removal of material. As such, in additive manufacturing, complex geometries can be formed without the use of any kind of tool, mold, or fixture and with little or no waste of material. Instead of machining components from solid billets of material where most of the material is cut away and discarded, the materials used in additive manufacturing are only those required to form the components. Thus, many industrial components, such as turbine rotor blades, are preferably fabricated by additive manufacturing.

[0003] Following formation by additive manufacturing, the components can be further processed. In one example, the components may be subjected to shot peening where peening material, such as metal shot, impacts the surface of the component. In another example, the components may be coated with a protective layer to protect the underlying material from the harsh environments in which the components are used. For example, a thermal barrier coating (TBC) can be applied to the outer surface of a turbine rotor blade to protect the blade from high temperatures during use.

[0004] Some components may include openings on their surfaces that need to be protected during post - manufacturing processing. For example, a turbine rotor blade can include cooling passages, i.e., various internal cooling circuits that vent to the outer surface of the component through openings on the surface of the component. The cooling passages can be provided to cool the internal structures in which they are present and / or to form a cooling film across the outer surface of the component.

[0005] To protect the openings, various mechanisms are used. In some cases, a removable material such as a plug is provided in or on the opening, for example, to prevent the opening from being filled when a coating is applied thereon. The removable material blocks the coating from entering the opening, but since the removable material and / or the coating thereon must ultimately be removed, it increases the manufacturing time and complexity. For example, each opening has to have the blocking material removed, which can be time-consuming. Further, the coating is typically applied over the blocking material but needs to be removed from over the blocking material to expose the blocking material and / or the opening. Since the coating cross-links over the blocking material, removal of the coating can cause extensive cracking in the remaining portion of the coating, for example, in the TBC, rendering the part unusable or requiring extensive additional processing. Removal of the blocking material after the peening process can be particularly difficult if the blocking material adheres to the part material by the process. Other approaches use permanent shielding features to protect the openings. In the latter case, the complexity of the part increases and the performance of the part can be sacrificed to accommodate the shielding.

Summary of the Invention

[0006] A first aspect of the present disclosure provides a mask for an additive manufacturing part that includes a plurality of apertures spaced apart on a surface of the part. The mask includes an attachment ligament configured to be integrally coupled to the part between the plurality of apertures in a cantilevered manner, a first cover member integrally coupled to the attachment ligament and including a first proximal end and a first distal end that at least partially extends over a first portion of the plurality of apertures, wherein the first distal end of the first cover member is separated from the part by a first spacing, a second cover member integrally coupled to the attachment ligament and including a second proximal end and a second distal end that at least partially extends over a second portion of the plurality of apertures, wherein the second distal end of the second cover member is separated from the part by a second spacing, and a removal member extending from each of the first and second cover members. The attachment ligament is the only connection to the part.

[0007] A second aspect of the present disclosure provides a part that includes a plurality of apertures spaced apart on its surface, an attachment ligament configured to be integrally coupled to the part in a cantilevered manner between a first plurality of apertures and a second plurality of apertures, a first cover member integrally coupled to the attachment ligament and including a first proximal end and a first distal end that at least partially extends over a first portion of the plurality of apertures, wherein the first distal end of the first cover member is separated from the part by a first spacing, a second cover member integrally coupled to the attachment ligament and including a second proximal end and a second distal end that at least partially extends over a second portion of the plurality of apertures, wherein the second distal end of the second cover member is separated from the part by a second spacing, and a mask that includes a removal member extending from each of the first and second cover members. The attachment ligament is the only connection to the part, and the part, the attachment ligament, the first and second cover members, and the removal member provide an additive manufacturing (AM) structure that includes a plurality of integral material layers.

[0008] A third aspect of the present disclosure provides a mask for an additively manufactured part, the part including a plurality of openings in a surface thereof, the mask comprising: an attachment ligament configured to integrally couple to the part in a cantilevered manner adjacent a first of the plurality of openings; and a cover member including a proximal end integrally coupled to the attachment ligament and a distal end extending at least partially over the plurality of openings, the distal end of the cover member being separated from the part by a first distance, the attachment ligament being the only connection to the part.

[0009] A fourth aspect of the present disclosure includes an additively manufactured (AM) structure comprising: a part including a plurality of openings on a surface thereof; attachment ligaments configured to be cantilevered to integrally couple to the part adjacent a first of the plurality of openings; a cover member including a proximal end integrally coupled to the attachment ligaments and a distal end extending at least partially over the plurality of openings, the distal end of the cover member being separated from the part by a first spacing; and a mask including a release member extending from the cover member, wherein the attachment ligaments are the only connections to the part, and the part, attachment ligaments, cover member, and release member comprise multiple layers of integral material.

[0010] The exemplary aspects of the present disclosure are designed to solve the problems described herein and / or other problems not discussed.

[0011] 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]

[0012] [Figure 1] 1A-1C are perspective views of several masks for additively manufactured parts according to embodiments of the present disclosure; [Figure 2] FIG. 1 is an enlarged cross-sectional view of a mask according to an embodiment of the present disclosure. [Figure 3]FIG. 1 is an enlarged cross-sectional view of a coated mask according to an embodiment of the present disclosure. [Figure 4] FIG. 1 is an enlarged cross-sectional view of a mask having a coating and a space-filling material according to an embodiment of the present disclosure. [Figure 5] FIG. 10 is an enlarged cross-sectional view of a mask having alternative attachment ligaments according to an embodiment of the present disclosure. [Figure 6] FIG. 10 is an enlarged cross-sectional view of a mask having another alternative attachment ligament according to an embodiment of the present disclosure. [Figure 7] 10A-10C are perspective views of several masks illustrating variations in attachment ligaments according to embodiments of the present disclosure. [Figure 8] 1A-1C are perspective views of several masks illustrating segmented cover members and removal members according to embodiments of the present disclosure. [Figure 9] FIG. 9 is a cross-sectional view taken along line 9-9 of FIG. 8. [Figure 10] FIG. 10 is a cross-sectional view of a mask according to an alternative embodiment of the present disclosure. [Figure 11] FIG. 10 is a cross-sectional view of a mask according to yet another alternative embodiment of the present disclosure. [Figure 12] FIG. 10 is a cross-sectional view of a mask according to another embodiment of the present disclosure. [Figure 13] 1A-1C are perspective views of several masks for additively manufactured parts according to embodiments of the present disclosure; [Figure 14] FIG. 14 is an enlarged cross-sectional view of the mask of FIG. 13 in a relaxed position according to an embodiment of the present disclosure. [Figure 15] FIG. 10 is an enlarged cross-sectional view of a mask with a tool thereon, according to an embodiment of the present disclosure. [Figure 16] FIG. 1 is an enlarged cross-sectional view of a coated mask according to an embodiment of the present disclosure. [Figure 17] FIG. 14 is an enlarged cross-sectional view of the mask of FIG. 13 in a bent position according to an embodiment of the present disclosure. [Figure 18] 10A-10C are perspective views of several masks illustrating variations in attachment ligaments according to embodiments of the present disclosure. [Figure 19]10A-10C are cross-sectional views of masks including alternative features according to embodiments of the present disclosure. [Figure 20] 10A-10C are cross-sectional views of masks including alternative features according to embodiments of the present disclosure. [Figure 21] 10A-10C are cross-sectional views of masks including alternative features according to embodiments of the present disclosure. [Figure 22] 10A-10C are cross-sectional views of masks including alternative features according to embodiments of the present disclosure. [Figure 23] 10A-10C are cross-sectional views of masks including alternative features according to embodiments of the present disclosure. [Figure 24] 10A-10C are cross-sectional views of masks including alternative features according to embodiments of the present disclosure. [Figure 25] 10A-10C are cross-sectional views of masks including alternative features according to embodiments of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0013] It should be noted that the drawings of the present disclosure are not necessarily to scale. The drawings are intended to depict only typical aspects of the present disclosure and therefore should not be considered limiting of the scope of the present disclosure. In the drawings, like numbers represent like elements between the drawings.

[0014] As an initial matter, a clear explanation of the state of the art requires the selection of specific terminology when referring to and describing relevant machine components. Wherever possible, common industry terminology is used and utilized consistent with 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 recognize that in many cases, a particular component may be referred to using several different or overlapping terms. What may be described herein as a single component may include and be referred to in other contexts as consisting of multiple components. Alternatively, what may be described herein as comprising multiple components may be referred to elsewhere as a single component.

[0015] It is often necessary to describe components that are located at different linear positions relative to a certain location. The term "distal" refers to a location or part of an object that is farther away than a "proximal" location or part of the same object. For example, the distal end of an object is farther away from the proximal end of the same object. Thus, these terms provide a general positioning relative to one another. In addition, as described below, some descriptive terms may be used regularly in this specification. The terms "first," "second," and "third" may be used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of the individual components.

[0016] The terminology used herein is merely for the purpose of describing particular 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 expressly stated otherwise. 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-stated event or circumstance may or may not occur, and the description is meant to include instances in which the event occurs and instances in which it does not occur.

[0017] When an element or layer is referred to as "on," "engaged," "connected," or "coupled" to another element or layer, it can be directly on, engaged, connected, or coupled to the other element or layer, or intervening elements or layers may be present. Conversely, when an element is referred to as "directly on," "directly engaged," "directly connected," or "directly coupled" to another element or layer, there may not be intervening elements or layers. Other terms used to describe relationships between elements should be interpreted similarly (e.g., "between" versus "directly between," "adjacent to" versus "directly adjacent to," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0018] As described above, the present disclosure provides a mask for an additively manufactured part including a first plurality of openings and a second plurality of spaced-apart openings on a surface of the part. The mask can include attachment ligaments configured to be fabricated with the part and integrally coupled to the part between the first and second plurality of openings in a cantilevered manner. The mask can be removed from the part by breaking the attachment ligaments. In one embodiment, the first and second cover members include proximal ends integrally coupled to the attachment ligaments and distal ends that extend at least partially over the respective plurality of openings. In another embodiment, a single cover member is integrally coupled to the attachment ligaments and extends at least partially over the plurality of openings. Certain embodiments may include a release member to facilitate easy removal of the mask from the part. In either case, the attachment ligaments are the only connection to the part. The mask may be generally umbrella-shaped or L-shaped in cross section.

[0019] 1-12, a mask 100 for an additively manufactured part 102 is shown in accordance with certain embodiments of the present disclosure. FIG. 1 illustrates a perspective view of a mask 100 for an additively manufactured part 102 (hereinafter, "part 102") in accordance with certain embodiments of the present disclosure. The mask 100 and part 102 may be formed using any suitable additive manufacturing technique for the part material and may collectively comprise an additively manufactured (AM) structure 103 (FIG. 2 only). Additive manufacturing (AM) encompasses a wide variety of processes that produce components by the successive layering of material rather than material removal. As such, additive manufacturing can form complex geometric shapes without the use of any type of tooling, molds, or fixtures, and with little or no material waste. Instead of machining a component from a solid billet of material, most of which is removed and discarded, additive manufacturing uses only the material needed to form the component. Additive manufacturing techniques typically involve obtaining three-dimensional computer-aided design (CAD) files of the components to be formed, e.g., part 102 and mask 100, electronically slicing the components into layers, e.g., 18-102 micrometers thick, and creating a file with two-dimensional images of each layer, including vectors, images, or coordinates. This file may then be loaded into a preparation software system that interprets the files so that the components, e.g., mask 100 and part 102, can be constructed by different types of additive manufacturing systems. Additive manufacturing forms such as 3D printing, rapid prototyping (RP), and direct digital manufacturing (DDM) selectively dispense layers of material, e.g., plastic or ceramic, to form components, e.g., by depositing layer after layer. In contrast, metal powder additive manufacturing techniques, such as direct metal laser melting (DMLM) (also known as selective laser melting (SLM)), sequentially fuse layers of metal powder together to form parts. More specifically, fine metal powder layers are uniformly dispensed using an applicator on a metal powder bed, which are then sequentially melted.Each applicator is in the form of a lip, brush, blade, or roller made of metal, plastic, material, carbon fiber, or rubber, and includes an applicator element that evenly spreads metal powder over a build platform. The metal powder bed can be moved along a vertical axis. The process is performed within a processing chamber having an accurately controlled atmosphere. Once each layer is formed, each two-dimensional slice of the geometric shape of the component can be fused by selectively melting the metal powder. Melting can be performed by a high-power melting beam such as a 100-watt ytterbium laser, which completely welds (melts) the metal powder to form solid metal. The melting beam moves in the X-Y direction using a scanning mirror and has sufficient intensity to completely weld (melt) the metal powder to form solid metal. The metal powder bed may be lowered for each subsequent two-dimensional layer, and the process may be repeated until the component is completely formed. In one non-limiting example, mask 100 and component 102 may be formed by DMLM or SLM for metal components, or 3D printing for ceramic components.

[0020] In the embodiment of FIG. 1, component 102 includes a plurality of openings 106 in surface 110 of component 102. The plurality of openings 106 can include any number of openings generally grouped in a row. Component 102 may include any currently known or later-developed industrial component. In one non-limiting example, component 102 can include a turbine rotor blade that includes various internal cooling circuits that vent through cooling passages to the outer surface of the component, e.g., surface 110. The cooling passages can be provided to cool the internal structure in which they are present and / or to form a cooling film across surface 110 of component 102. Although not necessarily required, as shown in the example of FIG. 1, openings 106 may be positioned on pedestal 112 in surface 110 of the component that extends from another surface 114 of the component.

[0021] The openings 106 may have any cross-sectional shape at the surface 110, e.g., circular, oval, polygonal (e.g., square, rectangular, trapezoidal), diffuser-shaped, etc., and may extend into the part 102 in any direction relative to the surface 110. Multiple openings 106 are positioned on the surface 110 of the part 102 over a distance, e.g., in a row. Multiple openings 106 may also be spaced apart across the surface 110, e.g., equidistantly or non-equidistantly. Four sets of openings 106 are shown in FIG. 1 , each with an associated mask 100. Any number of masks 100, e.g., less than four or more than four masks, may be used.

[0022] 2 illustrates an enlarged cross-sectional view of the mask 100 of FIG. 1 in accordance with certain embodiments of the present disclosure. The mask 100 includes attachment ligaments 120 configured to integrally couple to the part 102 between selected openings 106 in a cantilevered manner, i.e., it is a protruding member coupled to the part 102 at only one end. The attachment ligaments 120 are the only connection to the part 102. As described below, the attachment ligaments 120 couple the mask 100 to the part 102 in a manner that allows for easy removal of the mask 100 from the part 102. Note that due to limitations of certain additive manufacturing techniques, the mask 100 and the part 102 may not necessarily be formed in the same orientation as shown.

[0023] The mask 100 also includes a first cover member 130 including a first proximal end 132 integrally coupled to the attachment ligament 120 and a first distal end 134 at least partially extending over a first portion of the plurality of openings 106, and a second cover member 140 including a second proximal end 142 integrally coupled to the attachment ligament 120 and a second distal end 144 at least partially extending over a second portion of the plurality of openings 106. The first and second cover members 130, 140 at least partially extend over the plurality of openings 106 along the entire distance over which the openings extend. That is, all of the openings 106 are at least partially covered by the respective cover members 130, 140. "At least partially covered" indicates that some exposure of the openings 106 is permitted. For example, the first distal end 134 of the first cover member 130 is separated from the component 102 by a first distance D1, and the second distal end 144 of the second cover member 140 is separated from the component 102 by a second distance D2. Accordingly, some distances D1, D2 that expose the openings 106 are provided by the cover members 130, 140.

[0024] The intervals D1, D2 provide several advantages. In certain embodiments, as shown in FIG. 2, the first and second intervals D1, D2 have dimensions configured to prevent peening material 146, such as metal shot, ice, pellets, sand, etc., from passing through. In this case, the diameter D3 of the peening material 146 can be checked, and the intervals D1, D2 are sized to be sufficiently smaller than the diameter D3 to prevent the peening material 146 from entering the intervals D1, D2. In this way, the cover members 130, 140 can prevent damage to the opening 106 that may occur from the impact of the peening material 146 in some cases. In certain embodiments, as shown in FIG. 3, the first and second intervals D1, D2 have dimensions configured to prevent the coating 148 applied on the respective cover members 130, 140 from bridging from the respective cover members 130, 140 to the component 102. That is, there is a gap 149 in the coating 148. The intervals D1, D2 may be sized based on, for example, among other factors, the material of the coating 148, the application format, and the expected thickness. As shown, the coating 148 coats the component 102 and the mask 100, but cannot enter the intervals D1, D2 and thus does not coat or fill the opening 106. Further, the coating 148 cannot connect across the intervals D1, D2, leaving a gap 149. In this way, when the mask 100 is removed, the coating 148 does not need to break to remove the mask, and cracks may be caused at the location where the coating 148 extends over the component 102. That is, no force is applied to the coating 148 on the component 102, and thus there is no possibility of cracking of the coating 148 on the component 102. The dimensions of the intervals D1, D2 may vary depending on the peening material 146 and / or the coating 148, but in one non-limiting example, the first and second intervals D1, D2 may each be 0.88 millimeters (mm) to 1.4 mm (0.035 to 0.055 inches).This size range prevents, for example, a coating 148 having a thickness of 1.40 mm to 1.52 mm from bridging from the cover members 130, 140 to the component 102, and prevents a 1.5 mm metal shot from remaining within the spacing D1, D2 and impacting the opening 106. Other sizes are also possible.

[0025] 4, in certain embodiments, a space-filling material 150 can be positioned between at least one of the first and second cover members 130, 140 and the surface 110. The space-filling material 150 can at least partially fill the space beneath the cover members 130, 140 and the gaps D1, D2. The space-filling material 150 can include any material capable of filling the space without unnecessarily overfilling the opening 106 and should be easily removable. The space-filling material 150 may include, but is not limited to, filaments including a water-soluble polymer or other eutectic salt.

[0026] Mask 100 may also include a removal member 152 extending from each of the first and second cover members 130, 140, i.e., generally from the cover members 130, 140. The removal member 152 can include any structure that can be engaged and manipulated to remove the mask 100 from the component 102 by breaking the attachment ligament 120. The removal member 152 can include, for example, a square end that can be gripped by a tool (not shown), such as a channel lock pliers, an adjustable wrench, etc. In addition to or alternatively, as shown in FIG. 7, the removal member 152 can include a tool receiving feature 154 configured to receive a tool (not shown), such as, but not limited to, a pry bar, a screwdriver, a channel lock pliers, an adjustable wrench, etc. The tool receiving feature 154 can have any shape and / or size that prevents it from being filled by the coating 148 (FIG. 3). In any case, the removal member 152 can apply a force to break the attachment ligament 120 using a tool or manually, thus enabling the removal of the mask 100. The removal member 152 can have any desired vertical height from the cover members 130, 140.

[0027] Regarding the attachment ligament 120 further, as shown in FIGS. 2 and 3, the attachment ligament 120 has a minimum width W that enables easy removal from the component 102 and thus removal of the mask 100. FIG. 2 shows the attachment ligament 120 intersecting at an angle substantially perpendicular to the component 102. In FIG. 2, the width W is substantially uniform, but this is not necessary in all cases as it may be advantageous for the attachment ligament 120 to taper or narrow to facilitate breakage. For example, FIG. 3 shows an attachment ligament 120 having a lower portion 126 integrally coupled to the component 102 and having a first (minimum) width W1, and an upper portion 128 above the lower portion 126 and having a second width W2 wider than the first width W1. The smaller the width W1, the easier it is to break the attachment ligament 120 and the less of the remainder that requires machining removal on the component 102. FIGS. 5 and 6 show enlarged cross-sectional views of attachment ligaments 120 having various widths according to other embodiments. FIGS. 5 and 6 show that the cover members 130, 140 can have their lower surfaces 156 formed in any desired manner to form the desired minimum width W of the attachment ligament 120. In one non-limiting example, the attachment ligament 120 can have a minimum width W in the range of 0.01 millimeter (mm) to 0.50 mm (0.01 to 0.02 inches). The minimum width W can vary depending on a number of factors including, but not limited to, the component and mask materials, the size of the component 102, the size of the opening 106, the desired force for removal, the tools expected to be used, the predicted combined width Wc (FIG. 2) of the cover members 130, 140, etc. Note that the combined width Wc of the cover members 130, 140 may be, in one non-limiting example, 3.81 mm to 4.32 mm (0.15 to 0.17 inches).

[0028] The attachment ligaments 120 can also take a variety of structural forms. While shown generally perpendicular to the component 102, some non-perpendicular angles may be used. In certain embodiments, as shown in FIG. 1, the attachment ligaments 120 may extend the entire length of the mask 100, including a single length of cover members 130, 140. Alternatively, as shown in various configurations in FIG. 7, the attachment ligaments 120 can be integrally coupled to the component 102 at connection points spaced apart along the distance covered by the cover members 130, 140. Any configuration of spaced apart attachment ligaments 120 can be used. 7, mask 100A has attachment ligaments 120 that are generally randomly spaced and of varying lengths; mask 100B has attachment ligaments 120 that are also generally randomly spaced and of varying lengths but spaced differently than mask 100A; mask 100C has attachment ligaments 120 that are uniformly long and equidistantly spaced apart except for end attachment ligaments 120E; and mask 100D has pairs of attachment ligaments 120 that are uniformly long and equidistantly spaced apart. In certain embodiments, attachment ligaments 120 are integrally coupled to component 102 along 25% to 60% of the distance covered by cover members 130, 140. In further embodiments, attachment ligaments 120 are integrally coupled to component 102 along 25% to 35% of the distance covered by cover members 130, 140. Any desired spacing and length of attachment ligaments 120 can be used to achieve the desired removal action, e.g., desired force, tool, etc., and desired attachment ligaments 120 remaining on part 120 after removal of mask 100. Remaining portions of attachment ligaments 120 can be removed by machining, e.g., grinding.

[0029] Referring to FIGS. 8 and 9, in other embodiments, the first and second cover members 130, 140 and the removable member 152 may be segmented into a plurality of cover member and removable member segments 156 along the distance covered by the cover members 130, 140. Here, a gap 158 (FIG. 9) may be formed in the cover members 130, 140 and the removable member 152 along the length of the mask 100. As shown in FIG. 9, along a cross-sectional view taken along line 9-9 of FIG. 8, the segment 156 may be connected to the lower ends of adjacent cover members 130, 140 so as to maintain the support of the mask 100. Each of the plurality of cover member and removable member segments 156 is individually separable from the component 102 by breaking respective portions of the attachment ligaments 120. The segmentation allows for easier and selective removal of segments of the mask 100.

[0030] Returning to FIG. 2, the cover members 130, 140 are shown as having a convex outer surface 164 facing outward from the component 102 and a concave inner surface (lower surface) 156 facing the component 102. In this case, the cover members 130, 140 having the removal member 152 can have a mushroom-shaped cross-section. As shown in FIGS. 1-9, in these embodiments, the mask 100 has a somewhat umbrella-shaped cross-section. However, the cover members 130, 140 may have any shape desirable for protecting the opening 106 in the manner described herein that enables additive manufacturing with the component 102. FIGS. 10-12 show cross-sectional views of some non-exhaustive examples of alternative shapes. FIG. 10 shows a more conical-shaped mask, FIG. 11 shows a more drooping umbrella-shaped or mushroom-shaped mask, and FIG. 12 shows a more cross-shaped mask. Other shapes may be possible and are considered to be within the scope of the present disclosure. The outer surface of the mask 100, e.g., surface 164 (FIG. 2) or the outer surface of the removal member 152, may be configured to couple with the coating 148 (FIG. 3) with a rougher surface in a different manner than the component 102, e.g., for better retention. The figures show cover members of the same shape on both sides of the attachment ligament 120, i.e., symmetric cover members 130, 140, but the cover members of different shapes shown herein may be used asymmetrically, e.g., using the cover member 130 of FIG. 2 together with the cover member 140 of FIG. 12. Any combination of the cover members 130, 140 of different shapes shown herein may be used asymmetrically.

[0031] The mask 100 may be made of the same material as the component 102. Consequently, the material may depend on the application of the component. In one embodiment, the mask 100 and the component 102 may be made of a metal, which may include a pure metal or an alloy. In one example, when the component 102 is a turbine blade, the metal may include substantially any non-reactive metal powder, i.e., a non-explosive or non-conductive powder, such as, but not limited to, a cobalt-chromium-molybdenum (CoCrMo) alloy, stainless steel, an austenitic nickel-chromium-based alloy such as nickel-chromium-molybdenum-niobium alloy (NiCrMoNb) (e.g., Inconel 625 or Inconel 718), a nickel-chromium-iron-molybdenum alloy (NiCrFeMo) (e.g., Hastelloy® X available from Haynes International), or a nickel-chromium-cobalt-molybdenum alloy (NiCrCoMo) (e.g., Haynes 282 available from Haynes International). In another example, the metal may be, for example, tool steel (e.g., H13), titanium alloy (e.g., Ti6Al4V), stainless steel (e.g., 316L), cobalt-chromium alloy (e.g., CoCrMo), and aluminum alloy (e.g., AlSi 10 The mask 100 may comprise substantially any metal, including, but not limited to, titanium (Mg), titanium dioxide (TiO 3), titanium carbide (TiO 4), titanium carbide (TiO 5), titanium carbide (TiO 6), titanium carbide (TiO 7), titanium carbide (TiO 8), titanium carbide (TiO 9), titanium carbide (TiO 10), titanium carbide (TiO 1 ...

[0032] 13-18, a mask 200 for an additively manufactured part 102 according to another embodiment of the present disclosure is shown. The mask 200 and the part 102 may be formed using any suitable additive manufacturing technique for the part material and may collectively comprise an AM structure 203 (FIG. 14 only). In this embodiment, the part 102 may include a (single) plurality of openings 204 in its surface 110. That is, while multiple openings may be covered by the mask 200, in this embodiment, only a single group of openings 204 in a single line is provided. The part 102 may include any now-known or later-developed industrial part. In one non-limiting example, the part 102 may include a turbine rotor blade including various internal cooling circuits that ventilate the exterior surface of the part, e.g., the surface 110, through cooling passages. The cooling passages may be provided to cool the internal structures within which they reside and / or to form a cooling film across the surface 110 of the part 102. Although not required, as shown in the example of FIG. 13 , the openings 204 may be positioned in seats 112 in the surface 110 of the part that extend from another surface 114 of the part. The openings 204 may have any cross-sectional shape at the surface 110, e.g., circular, oval, polygonal (e.g., square, rectangular, trapezoidal), diffuser-shaped, etc., and may extend into the part 102 in any direction relative to the surface 110. Multiple openings 204 are positioned in the surface 110 of the part 102 across a distance, e.g., generally in a row. The openings 204 may also be spaced apart across the surface 110, e.g., equidistantly or non-equidistantly. While two masks 200 are shown in FIG. 13 , any number of masks 200, e.g., less than two or more than two, may be used.

[0033] Figures 14 and 15 show enlarged cross-sectional views of the mask 200 according to certain embodiments of the present disclosure. Figure 14 is along line 15-15 of Figure 13, and Figure 15 is along line 16-16 of Figure 13. The mask 200 includes an attachment ligament 220 configured to be integrally coupled to the component 102 adjacent to the plurality of openings 204 in a cantilevered manner, i.e., it is a projecting member coupled to the component 102 only at one end thereof. The attachment ligament 220 is the only permanent connection to the component 102. As will be described later, the attachment ligament 220 couples the mask 200 to the component 102 such that it is possible to easily remove the mask 200 from the component 102.

[0034] The mask 200 also includes a cover member 230 including a proximal end 232 integrally coupled to the attachment ligament 220 and a distal end 234 that at least partially extends over the plurality of openings 204. The distal end 234 may have any cross-sectional shape, for example, generally triangular as shown. The cover member 230 at least partially extends over the plurality of openings 204 along the entire distance that the openings extend. That is, all of the openings 204 are at least partially covered by the cover member 230. The cover member 230 and the attachment ligament 220 provide the mask 200 with a somewhat L-shaped or 7-shaped cross-section.

[0035] As previously mentioned, "at least partially covered" indicates that some exposure of the opening 204 is permitted. For example, as shown in FIG. 14 , the distal end 234 of the cover member 230 is separated from the component 102 by a distance D4. Thus, some distance D4 exposing the opening 204 is provided by the cover member 230. Distance D4, like distances D1 and D2 in the previous figures, offers several advantages. In certain embodiments, as shown in FIG. 14 , distance D4 has a dimension configured to prevent the passage of peening material 246, such as metal shot, ice, pellets, sand, and the like. In this case, a diameter D5 of the peening material 246 can be identified, and distance D4 is sized to be sufficiently smaller than diameter D5 to prevent the peening material 246 from entering distance D4. In this manner, the cover member 230 can prevent damage to the opening 204 that may result from impact with the peening material 246. In certain embodiments, as shown in FIG. 16 , the distance D4 has a dimension configured to prevent the coating 248 applied over the cover member 230 from bridging from the cover member 230 to the component 102 at the distal end 234. The distance D4 may be sized based on, for example, the material, application format, and expected thickness of the coating 248, among other factors. As shown, the coating 248 coats the component 102 and the mask 200 but cannot enter the distance D4 and therefore does not coat or fill the opening 204. The cover member 230 prevents the coating 248 from reaching the opening 204, leaving a gap 249. Furthermore, the coating 248 cannot connect across the distance D4. In this way, when the mask 200 is removed, the coating 248 on the component 102 is not affected. No force is applied to the coating 248 on the component 102, and therefore there is no possibility of cracking the coating 248 on the component 102. The dimensions of the spacing D4 may vary depending on the peening material 246 and / or coating 248, but in one non-limiting example, the spacing D4 may be 0.88 millimeters (mm) to 1.4 mm (0.035 to 0.055 inches).This dimension range, for example, prevents a coating 248 having a thickness of 1.40 mm to 1.52 mm from bridging from the cover member 230 to the component 102, and prevents a 1.5 mm metal shot from remaining within the distance D4 and impacting the opening 204. Other dimensions may also be possible.

[0036] Mask 200 may also include a removal member 252 extending from the cover member 230. The removal member 252 can include any structure that can be engaged and manipulated to remove the mask 200 from the component 102 by breaking the attachment ligament. The removal member 252 can include, for example, a square end that can be gripped by a tool (not shown), such as a channel lock pliers, an adjustable wrench, etc. In addition to or alternatively, as shown in FIG. 13, the removal member 252 can include a tool receiving feature 254 configured to receive a tool 268 (shown only in FIG. 15), such as, but not limited to, a pry bar, a screwdriver, a channel lock pliers, an adjustable wrench, etc. The tool receiving feature 254 may have any size and / or shape that prevents it from being filled by the coating 248. In a particular embodiment, as best shown in FIG. 14, in contrast to the cover members 130, 140 of FIGS. 1-12, the cover member 230 can also include a force receiving surface 270 that is at a distance D6 (shown only in FIG. 14) from the removal member 252. The force F (up and down) applied by the tool 268 positioned at the tool receiving feature 254 of the removal member 252 applies a lever force LF (clockwise or counterclockwise, respectively) to remove the attachment ligament 220 from the component 102. In either case, the removal member 252 can be operated to apply a force to break the attachment ligament 220 either by a tool or manually, thus enabling the removal of the mask 200. The removal member 252 can have any desired vertical height from the cover member 230. For example, as shown in FIG. 14, the removal member 252 may be positioned above the proximal end 232 of the cover member 230, or, for example, as shown in FIG. 15, between the proximal end 232 and the distal end 234 of the cover member 230, for example, spaced near the proximal end 232, allowing a force to be directly applied to the attachment ligament 220 during removal.

[0037] As shown in FIG. 13 and in cross section in FIG. 14 , the mask 200 may optionally include at least one pair of pivotal restraint members 274 extending from the distal end 234 of the cover member 230. While FIG. 13 shows three pivotal restraint members 274 extending from the distal end 234 of each mask 200, any number, including four or more, may be used. As shown in FIG. 14 , each pivotal restraint member 274 extends from the distal end 234 to a distance D7 from the component 102, i.e., the surface 110, in the first, relaxed position of the cover member 230. That is, each pivotal restraint member 274 may have its own distal end 276 spaced from the component 110 by the distance D7. The distance D7 between the pivotal restraint member 274 and the component 102 is less than the distance D4 between the distal end 234 of the cover member 230 and the component 102. In one non-limiting example, the spacing D7 may be approximately 0.1 millimeters (mm) (0.004 inches). As shown in FIG. 17, due to the cantilevered nature of the mask 200, the mask 200 can pivot under certain circumstances, such as during coating and / or peening processes. In this configuration, the pivoting constraint member 274 can move to approach and / or contact the part 102 in a second pivot position where a bending moment force B ( FIG. 17 ) is applied to at least one of the attachment ligaments 220, the cover member 230, and the removal member 252. Thus, the pivoting constraint member 274 withstands any temporary forces applied during processing that are not intended to remove the mask 200. Once the bending moment force B is removed, the mask 200 can return to the relaxed position, for example, as shown in FIG. 14, and the spacing D7 returns between the pivoting constraint member 274 and the part 102. FIG. 16 shows the mask 200 without the pivoting constraint member.

[0038] Further with regard to the attachment ligaments 220, as shown in FIG. 14, the attachment ligaments 220 have a minimum width W3 that allows for easy detachment from the component 102 and, therefore, removal of the mask 200. While FIG. 14 shows the attachment ligaments 220 meeting the component 102 at a substantially perpendicular angle, other angles may be possible. The attachment ligaments 220 may also be tapered or narrowed to facilitate breakage. For example, in FIG. 14, the attachment ligaments 220 may have a lower portion 226 integrally joined to the component 102 and having a first (minimum) width W3, and an upper portion 228 above the lower portion 226 and having a second width W4 that is wider than the first width W3. The attachment ligaments 220 may also have varying widths, as described with respect to FIGS. 5 and 6, or a generally uniform width as in FIG. 2. In one non-limiting example, attachment ligament 220 can have a minimum width W3 in the range of 0.01 millimeters (mm) to 0.50 mm (0.01 to 0.02 inches). The minimum width W3 can vary depending on numerous factors, including, but not limited to, the part and mask material, the size of part 102, the size of opening 204, the desired force for removal, the tool expected to be used, and the expected width Wcm of cover member 230 (FIG. 14). Note that the cover member width Wcm of cover member 230, in one non-limiting example, can be 5.33 mm to 6.35 mm (0.21 to 0.25 inches).

[0039] The attachment ligaments 220 can also take various structural forms. In certain embodiments, as shown in FIG. 13, the attachment ligament 120 may extend over the entire length of the mask 200 including a single length of cover member 230. Alternatively, similar to those shown in the various forms of FIG. 7, the attachment ligaments 220 can be integrally coupled to the component 102 at connection points spaced along the distance covered by the cover member 230. Any configuration of the spaced-apart attachment ligaments 220 can be used. In the non-limiting example of FIG. 18, the mask 200A has attachment ligaments 220 generally randomly spaced at various lengths, the mask 200B also has attachment ligaments 220 generally randomly spaced at various lengths but spaced at different intervals than the mask 200A, the mask 200C has attachment ligaments 220 spaced equidistantly at a uniform length except for the end attachment ligament 220E, and the mask 200D has pairs of attachment ligaments 220 spaced equidistantly at a uniform length. In certain embodiments, the attachment ligaments 220 are integrally coupled to the component 102 along 25% to 60% of the distance covered by the cover member 230. In a further embodiment, the attachment ligaments 220 are integrally coupled to the component 102 along 25% to 35% of the distance covered by the cover member 230. Using any desired spacing and length of the attachment ligaments 220, a desired removal action, e.g., a desired force, tool, etc., and the desired attachment ligaments 220 remaining on the component 220 after removal of the mask 200 can be achieved. The remaining portion of the attachment ligaments 220 can be removed by machining, e.g., grinding.

[0040] Regarding the cover member 230 further, as shown in FIG. 14 for example, the cover member 230 can include a pair of square corners 280, 282. The square corners 280, 282 are on both sides of the attachment ligament 220. In this way, when grasped by a tool such as a hand or pliers, the mask 200 can be easily removed by breaking the attachment ligament 220.

[0041] FIGS. 19-25 show cross-sectional views of various alternative embodiments similar to the mask 200. In these embodiments, as shown in FIG. 19 for example, the mask 300 includes an attachment ligament 220 and a cover member 230. The proximal end 232 of the cover member 230 is coupled to the attachment ligament 220. The cover member 230 and its distal end 234 extend over the opening 204, and the distal end 234 has a spacing D8 from the component 102, i.e., the surface 110. The spacing D8 can be similar to the spacing D4 (FIG. 14). An optional pivoting restraint member 274 may extend from the distal end 234 in each embodiment, but may not be shown for clarity.

[0042] FIGS. 19-21 show cross-sectional views of a mask 300 similar to the mask 200 (FIGS. 12-18) including a removal member 252 and various alternative structures. FIG. 19 shows a mask 300 having a distal end 234 with a generally polygonal (e.g., rectangular) cross-sectional shape. FIG. 20 shows a mask 300 having a distal end 234 including a flange 384 extending away from the attachment ligament 220. FIG. 21 is similar to FIG. 20, but shows a mask 300 including a removal member 352 having a notch 386 for receiving a tool (not shown) and disposed with a spacing between the proximal end 232 and the distal end 234 of the cover member 230.

[0043] Figures 22 to 25 show cross-sectional views of the mask 300 with the removable member 352 (Figs. 19 to 21) omitted. Fig. 22 shows the mask 300 with the removable member 352 (Figs. 19 to 21) omitted and the attachment ligament 220 being linear. Fig. 23 is similar to Fig. 22 but shows the mask 300 including a distal end 234 having a flange 384 extending away from the attachment ligament 220. Figs. 24 and 25 show the mask 300 with the quadrilateral corners 280, 282 (Fig. 22) omitted. In Fig. 24, the cover member 230 is rounded, and in Fig. 25, the cover member 230 includes parallel side surfaces 388, 390 for gripping by a hand or a tool (not shown), such as pliers. In Fig. 25, the attachment ligament 220 is integrally coupled to the component 102 and has a lower portion 326 having a first (minimum) width W5 and an upper portion 328 above the lower portion 326 and having a second width W6 wider than the first width W5. The distal end 234 of Fig. 25 has a pointed end 392.

[0044] Any of the alternative features shown in Figs. 19 to 25 can be mixed and adapted to create alternative embodiments within the scope of the present disclosure.

[0045] The masks 200, 300 may be made of the same material as the component 102. The masks 200, 300 and the component 102 can be made of any of the materials listed herein for the mask 100 and the component 102. The masks 200, 300 and the component 102 may be made by additive manufacturing, such as DMLM or SLM for metal parts, or 3D printing for ceramic parts. In this case, the component 102, the attachment ligament 220, the cover member 230, and the removable member 252 (and any alternative features described herein) include a plurality of integral material layers.

[0046] Embodiments of the present disclosure are described using the masks 100, 200, 300 additively manufactured using the component 102, but it will be readily appreciated that the masks 100, 200, 300 can be formed separately by additive manufacturing or other techniques and coupled to the component 102, for example, by welding.

[0047] Embodiments of the present disclosure provide a mask for an additive manufactured part that protects an opening in a surface of a part during other processes such as coating and peening. The masks described herein can be used to additively manufacture a part, for example, to eliminate the need to manually laboriously mask the opening using taping or a weld-on structure. The mask also better protects the opening from processes that can damage the opening, such as peening, and eliminates the need for costly cleaning from the opening.

[0048] As used herein throughout the specification and claims, the language representing approximation can be applied to modify any quantitative expression that can vary within a tolerable degree without causing a change in the relevant basic function. Thus, values modified by terms such as “about,” “approximately,” and “substantially” are not limited to the precisely stated value. In at least some instances, the language representing approximation can correspond to the accuracy of the instrument for measuring the value. Here, as well as throughout the specification and claims, range limitations can be combined and / or replaced, and such ranges are identified and include all sub-ranges subsumed therein, unless the context and language specifically dictate otherwise. “About” applied to a particular value of a range applies to both end values and can indicate + / - 10% of the stated value, unless particularly dependent on the accuracy of the instrument for measuring the value.

[0049] The corresponding structure, material, acts, and equivalents of all means-plus-function or step-plus-function elements in the following claims are intended to encompass any structure, material, 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 precise form disclosed. 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 embodiments were 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 suited to the particular uses envisioned. [Explanation of symbols]

[0050] 100 masks 100A Mask 100B Mask 100C Mask 100D mask 102 Additively Manufactured Parts 103 Additive Manufacturing (AM) Structures 106 Opening 110 Surface 112 Pedestal 114 Surface 120 Mounting Ligament 120E End Mounting Ligament 126 Lower part, first part, second part 128 Upper part 130 first cover member 132 first proximal end 134 first distal end 140 second cover member 142 second proximal end 144 second distal end 146 Peening Materials 148 Coating 149 Gap 150 Space-filling materials 152 Removal member 154 Tool receiving feature 156 Lower surface, cover member and removal member segment, concave inner surface 158 Gap 164 Convex outer surface, surface 200 Mask 200A Mask 200B Mask 200C Mask 200D Mask 203 AM structure 204 Opening 220 Attachment ligament 220E End attachment ligament 226 Lower portion 228 Upper portion 230 Cover member 232 Proximal end 234 Distal end 246 Peening material 248 Coating 249 Gap 252 Removal member 254 Tool receiving feature 268 Tool 270 Force-receiving surface 274 Pivoting restraint member 276 Distal end 280 Quadrilateral corner 282 Quadrilateral corner 300 Mask 326 Lower portion 328 Upper portion 352 Removal member 384 Flange 386 Notch 388 Side surface 390 Side surface 392 Sharpened end 9-9 line 15-15 line 16-16 line D1 First interval D2 Second interval D3 Diameter D4 Interval D5 Diameter D6 Distance D7 Interval D8 Interval F Force W Minimum Width W1 First (Minimum) Width W2 Second Width W3 First (Minimum) Width W4 Second Width W5 First (Minimum) Width W6 Second Width Wc Collective Width Wcm Cover Member Width BM Bending Moment Force LF Lever Force LF

Claims

1. A mask (100) for a component (102) comprising a plurality of apertures (106) spaced apart on a surface (110) of an additive manufactured component (102), the mask (100) comprising: An attachment ligament (120) configured to integrally couple to the component (102) between the plurality of apertures (106) in a cantilevered shape and extending in a first direction away from the plurality of apertures (106); A first cover member (130) including a first proximal end (132) integrally coupled to the attachment ligament (120) and a first distal end (134) at least partially extending over a first portion (106A) of the plurality of apertures (106) in the first direction, wherein the first distal end (134) of the first cover member (130) is separated from the component (102) in the first direction by a first spacing (D1); A second cover member (140) including a second proximal end (142) integrally coupled to the attachment ligament (120) and a second distal end (144) at least partially extending over a second portion (106B) of the plurality of apertures (106), wherein the second distal end (144) of the second cover member (140) is separated from the component (102) in the first direction by a second spacing (D2); And removal members (152) extending in the first direction from each of the first and second cover members (130, 140); Comprising; The first distal end (134) is further from the attachment ligament than the first proximal end (132) in a second direction perpendicular to the first direction; The second distal end (144) is further from the attachment ligament than the second proximal end (142) in the second direction; The plurality of apertures (106) are spaced apart in a third direction perpendicular to the first and second directions; The attachment ligament (120) is the only connection to the surface (110) of the component (102); Mask (100).

2. The mask (100) according to claim 1, wherein the attachment ligament (120) has a minimum width in the second direction in the range of 0.01 millimeters (mm) to 0.50 mm.

3. The plurality of openings (106) are positioned on the surface (110, 114) of the component (102) over a distance in the third direction, and the first and second cover members (130, 140) extend at least partially over the first and second portions (106) of the plurality of openings (106) respectively along the entire distance, the mask (100) according to claim 1.

4. The attachment ligament (120) is integrally coupled to the component (102) at connection points spaced along the distance, the mask (100) according to claim 3.

5. The attachment ligament (120) is integrally coupled to the component (102) along 25% to 60% of the distance, the mask (100) according to claim 4.

6. The first and second cover members (130, 140) and the removal member (152) are segmented into a plurality of cover member (130, 140) and removal member (152) segments (156) along the distance, the mask (100) according to claim 3.

7. Each of the plurality of cover member (130, 140) and removal member (152) segments (156) is individually separable from the component (102) by breaking respective portions of the attachment ligament (120), the mask (100) according to claim 6.

8. The first and second intervals (D1, D2) are from 0.88 millimeter (mm) to 1.4 mm, the mask (100) according to claim 1.

9. The first and second intervals (D1, D2) are dimensioned such that a coating (148) applied on each of the cover members (130, 140) respectively prevents cross - bridging from the cover members (130, 140) to the component (102) and prevents the passage of peening material (146), the mask (100) according to claim 1.

10. The plurality of openings (106) are positioned on a pedestal (112) extending from another surface (110, 114, 156) of the component (102), the mask (100) according to claim 1.

11. The mask (100) according to claim 1, further comprising a space filling material (150) positioned between at least one of the first and second cover members (130, 140) and the surfaces (110, 114, 156) of the component (102).

12. The first and second cover members (130, 140) of the mask (100) according to claim 1 have a convex outer surface (164) facing outward in the first direction from the component (102) and a concave inner surface (156) facing the component (102).

13. The attachment ligament (120) of the mask (100) according to claim 1 is cantilevered between the first and second portions (106) of the plurality of openings (106) so that the mask (100) can be easily removed from the component (102).

14. The removal member (152) of the mask (100) according to claim 1 includes a tool receiving feature (154) configured to receive a tool (268).

15. The component (102), the attachment ligament (120), the first and second cover members (130, 140), and the removal member (152) of the mask (100) according to claim 1 include a plurality of material layers.

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