Method for removing a support structure for components manufactured by pressurized jet.

Abstract

A method (190) for manufacturing a vaned turbomachinery component (100) is provided, the method including the steps of providing a base portion (115), additively fabricating a plurality of vanes (150) and a plurality of support structures on the base portion (115), the plurality of support structures having a predetermined breaking point (125), additively fabricating an upper portion (140) supported by the plurality of support structures on the plurality of support structures and the vanes (150), whereby the vanes are sandwiched between the base portion (115) and the upper portion (140), and applying a pressurized jet (360) to the plurality of support structures, thereby breaking the plurality of support structures at the predetermined breaking points to remove the plurality of support structures.

Description

Technical Field

[0001] The present disclosure relates at least in part to the field of manufacturing vane components using additive manufacturing. More specifically, the present disclosure relates to the finishing of the manufacturing process of vane components.

Background Art

[0002] Additive Manufacturing (AM), also known as 3D printing, rapid prototyping, or freeform fabrication, is a process of continuously joining materials to an object in usually multiple layers to produce a final component according to 3D model data, in contrast to subtractive manufacturing methodologies such as machining. Additive manufacturing using metal powders is a relatively new technology and a growing industrial field. This has become a process suitable not only for conventional prototyping but also for the manufacture of complex metal net shape parts. Additive manufacturing enables new options for design, prototyping, and even continuous production in all kinds of industries such as aerospace, energy, automotive, medical, tooling, consumer goods, etc.

[0003] Several techniques can be used for additive manufacturing, such as powder bed technology for example. Generally, in each machine, a component (also called the final article or object) is made or formed by continuously manufacturing layers of sintered or melted material from raw materials that are fine powders. Generally, the powders include metal powders, ceramic powders, or a combination of metal powders and ceramic powders. By applying energy with a highly convergent laser beam or electron beam, the powders are locally heated strongly, and the single fine particles in the powders locally melt and stick together or form local melting pools. During the production of metal components in a powder bed melting process, generally, each element of the desired metal component needs to be supported by elements of the previous layer and the entire object in progress needs to be supported during production. Therefore, it is common to create the first layer on a build plate that does not belong to the final component, and the build plate is removed after finishing the component.

[0004] Generally, components are fabricated directly onto the build plate. Generally, support structures are used to stabilize the overhang areas of components. To facilitate the removal of articles from the build plate after the AM manufacturing process is complete, articles may be fabricated entirely or partially on support structures located between the build plate and the first (and therefore lowest) layer of articles or components.

[0005] Since support structures are not part of the actual components being manufactured, they must be removed after the AM process is complete. The removal process can be time-consuming and labor-intensive, thus being a cost factor and limiting the production rate of parts per unit of time. The effort required for the removal procedure generally depends on the size, complexity, and design of the individual manufacturing components, as well as the number and size of the supports, and the strength and ductility of the materials.

[0006] For example, French Patent Publication No. 3064519 describes jet cutting of cellular sacrificial portions of a blank material.

[0007] As another example, International Publication No. 2019021389 describes the hydraulic removal of a support inside a cavity of a 3D printed object.

[0008] In particular, the removal of support structures can be extremely difficult for components that include complex parts or sections that are difficult to access. For example, support structures may need to be removed manually using tools such as screwdrivers, tongs, hammers, hand milling cutters, and hand grinders. This is time-consuming, costly, and critical to quality. As a result, the manual removal of support structures represents a bottleneck in the manufacturing process of the component. [Prior art documents] [Patent Documents]

[0009] [Patent Document 1] French Patent Publication No. 3064519 [Patent Document 2] International Publication No. 2019021389 [Overview of the project] [Problems that the invention aims to solve]

[0010] Therefore, improvements in manufacturing through additive manufacturing are necessary. [Means for solving the problem]

[0011] According to one embodiment, a method for manufacturing a vaned component of a turbomachinery is provided. The method includes the steps of: providing a base portion; and additionally manufacturing a plurality of vanes and a plurality of support structures on the base portion, wherein the plurality of support structures have predetermined failure points. The method further includes the steps of: additionally manufacturing an upper portion supported by the plurality of support structures on the plurality of support structures and vanes, thereby sandwiching the vanes between the base portion and the upper portion; and applying a pressurized jet to the plurality of support structures, thereby destroying predetermined failure points of the plurality of support structures and removing the plurality of support structures.

[0012] In a further embodiment, an apparatus for manufacturing vaned components of a turbomachinery is provided. The apparatus includes a first chamber containing an additive manufacturing apparatus for additively manufacturing vaned components of a turbomachinery having a plurality of support structures; a second chamber containing at least one pressurized jet device for supplying a pressurized jet to remove the plurality of support structures; and a controller configured to perform the method according to the embodiments described herein.

[0013] The embodiments also relate to apparatus for carrying out the disclosed methods, including apparatus components for performing each of the described method embodiments. These method embodiments can be performed by any combination of hardware components, a computer programmed with appropriate software, or in any other way. Furthermore, the embodiments provided herein also relate to methods for operating the described apparatus, including method embodiments for performing all functions of the apparatus.

[0014] To allow for a detailed understanding of the above-mentioned features of the present invention, a more detailed description of the embodiments of the present invention, which are summarized in general terms above, can be referenced by the embodiments. The accompanying drawings are described below with respect to embodiments of the present disclosure. [Brief explanation of the drawing]

[0015] [Figure 1] A flowchart shows a method for manufacturing a vaned component according to the embodiments described herein. [Figure 2A] A schematic cross-sectional view of a vaned component according to the embodiments described herein is shown. [Figure 2B] A schematic three-dimensional perspective view of a vaned component according to the embodiments described herein is shown. [Figure 3A] A schematic side view of a vaned component according to the embodiments described herein is shown. [Figure 3B] A schematic side view of a vaned component according to the embodiments described herein is shown. [Figure 3C] A schematic side view of a vaned component according to the embodiments described herein is shown. [Figure 4A] A schematic top view of a vaned component according to the embodiments described herein is shown. [Figure 4B] A schematic side view of a support structure according to an embodiment described herein is shown. [Figure 5A]Shows a schematic three-dimensional perspective view of a vane component according to an embodiment described herein. [Figure 5B] Shows a schematic three-dimensional perspective view of a vane component according to an embodiment described herein. [Figure 6A] Shows a schematic side view of an apparatus according to an embodiment described herein. [Figure 6B] Shows a schematic side view of an apparatus according to an embodiment described herein. [Figure 7A] Shows a schematic side view of an apparatus according to an embodiment described herein. [Figure 7B] Shows a schematic side view of an apparatus according to an embodiment described herein.

Mode for Carrying Out the Invention

[0016] Hereinafter, various embodiments of the present disclosure will be referred to in detail, and one or more examples thereof are shown in each drawing. In the scope of the following description of the drawings, the same reference numerals refer to the same components. Generally, only the differences regarding individual embodiments are described. Each example is provided for the purpose of explaining the present disclosure and is not intended to limit the present disclosure. Furthermore, features illustrated or described as part of one embodiment can be used on or in combination with other embodiments, resulting in yet another embodiment. This specification intends to include such modifications and variations.

[0017] In the scope of the following description of the drawings, the same reference numerals refer to the same components. Generally, only the differences regarding individual embodiments are described. When a plurality of identical elements or parts appear in the figure, not all parts are given reference numerals in order to simplify the appearance.

[0018] The systems and methods described herein are not limited to the specific embodiments described herein. Rather, the components of the systems and / or method steps can be used separately and independently of other components and / or steps described herein. Rather, exemplary embodiments can be implemented and used in connection with many other applications.

[0019] Certain features of various embodiments of the present invention may be shown in some drawings and not in others, for convenience only. In accordance with the principles of the present invention, any feature in one drawing may be referenced and / or claimed in combination with any feature in any other drawing.

[0020] Manufacturing of general concepts and vane components This disclosure relates to the manufacture of vaned components for turbomachinery. Such components may include structures or elements with complex parts that are not easily accessible, and are therefore difficult to manufacture by conventional methods. For example, casting, forming, milling, and subsequent finishing of components can be time-consuming and have drawbacks in terms of precision and accessibility. Therefore, there is a need for other techniques for the manufacture of such complex turbomachinery components.

[0021] In detail, the vanes of turbomachinery components are difficult to manufacture because, compared to other elements of the component, the vanes may contain cavities between them, making them hard to access parts. Therefore, it is advantageous to manufacture at least the vaned turbomachinery components by additive manufacturing (AM) to provide accurate and precise part shapes.

[0022] When components are manufactured additively, the overhangs (protruding portions) of the components need to be supported by so-called support structures. These support structures are important because they can maintain the overhangs in place. After the additive manufacturing process, the support structures must be removed. For complex shapes, this is usually done manually using tools, resulting in high costs and low repeatability.

[0023] Therefore, improving the removal of support structures is advantageous. This is particularly relevant to vaned components of turbomachinery, because these components include structural elements that are difficult to manufacture and / or reach, resulting in specific challenges with respect to support structures and their removal.

[0024] A method 190 for manufacturing a vaned component of a turbomachinery is provided according to an embodiment that can be combined with any other embodiment described herein. The method includes the step of providing a base portion (step 191 in Figure 1). The base portion may be part of a vaned component. Further parts of the vaned component may be formed or arranged on the base portion. Thus, the base portion can be understood as the foundation of a vaned component, which can serve as a starting point for further manufacturing processes. The base portion may define a vaned gas flow region. For example, the vaned gas flow region may be adapted to receive the working gas flow supplied to the manufactured vaned component (i.e., to the ultimately manufactured component of the turbocharger) during the operation of the turbocharger.

[0025] A base portion according to an embodiment described herein is illustrated in Figure 2A. The base portion 115 can be mounted on a build plate 110 and removed thereafter after the vaned component has been manufactured. The base portion 115 can be mounted on a base support structure 123 on the build plate 110. The base support structure 123 can be manufactured by additive manufacturing. The base support structure may include bar-shaped or grid-shaped structures. This allows the vaned component to be easily removed from the build plate after its manufacture.

[0026] The base portion 115 can be manufactured by additive manufacturing as described above and as shown in Figure 2A. In an alternative embodiment, the base portion 115 can be pre-machined. According to embodiments that can be combined with any other embodiments described herein, the base portion 115 can be manufactured by any known manufacturing method, including molding, milling, etc. For example, the base portion 115 can be a pre-machined base ring, for example, an annular portion machined by turning.

[0027] According to the embodiment, the base portion 115 can be an annular structure. However, it should be understood that the base portion 115 can also be other shapes such as rectangles, parallelograms, or ellipses. Furthermore, the base portion can include multiple shapes at once; that is, the base portion can include an annular or circular portion as a base structure, and additional notches, protrusions, etc.

[0028] According to embodiments that can be combined with any other embodiments described herein, the method further includes the step of additionally manufacturing a plurality of vanes 150 and a plurality of support structures on top of the base portion (step 192 in Figure 1). The plurality of vanes may include a variety of vane numbers depending on the component being manufactured. For example, when manufacturing a nozzle ring, a plurality of vanes may be additionally manufactured on top of the base portion. In embodiments, the number of vanes may be at least 5, preferably at least 10, and more preferably at least 15. On the other hand, the number of vanes may be up to 100, preferably up to 60, and more preferably up to 30. Multiple flow paths may be provided between the vanes. Specifically, one flow path in the final vaned component may be provided between each vane. The “final vaned component” or “manufactured vaned component” is understood as the vaned component after the support structures have been removed and / or the vaned component in a state where it can be used in a turbocharger. The flow paths can receive the working gas flow in the manufactured vaned component. In other words, the working gas flow can flow through multiple channels as the manufactured vaned component performs its intended purpose in the turbocharger and / or turbocharger component. Multiple support structures can extend into multiple channels. For example, multiple support structures can traverse multiple channels or a single channel. The support structure can traverse the channel from the upper portion to the base portion, or vice versa.

[0029] According to embodiments that can be combined with any other embodiments described herein, the plurality of support structures may include a first support structure 124 and a second support structure 122. The plurality of support structures may include various numbers of first and / or second support structures. Various first support structures 124 may be provided between each of the vanes 150, for example, by additive manufacturing. The first support structure 124 may be provided between the base portion and the upper portion 140 of the vaned component, i.e., the first support structure 124 may be sandwiched between the upper portion 140 and the base portion 115. Here, in Figure 4A, a single first support structure 124 is shown between the vanes 150, but more generally, a set of support structures may be provided, where the set may be one or more support structures. The first support structure 124 may extend into multiple channels. For example, the first support structure may traverse multiple channels or one channel. The first support structure can traverse the flow path from the upper portion to the base portion or vice versa.

[0030] As used herein, the terms “support structure” or “support(s)” are intended to mean a section of a component that is (additionally) manufactured, intended to stabilize an overhang region of the component. Support structures are manufactured in a continuous layer with the component. “Overhang” is typically used to describe a surface of a component (under manufacture) where the normal vector points downward, while the angle between the plane of the surface and the build plate (parallel to the ground) is typically less than about 45 degrees. The singular “support structure” or “support(s)” is typically intended to mean a single continuous or cohesive region that supports a particular face or portion of a component being manufactured, while the plural “support structure” typically means multiple regions, usually spatially separated, used during the manufacturing of a component. Supports reinforce a portion or part of a component that has already been manufactured against deformation caused by internal stresses that occur during the process. Supports are typically largely removed after the manufacturing process.

[0031] According to embodiments that can be combined with any other embodiments described herein, the method further includes the step of additionally manufacturing an upper portion supported by a plurality of support structures and vanes, thereby sandwiching the vanes between the base portion and the upper portion (step 192 in Figure 1). Advantageously, the support structures can support the upper portion. For example, the upper portion can include overhangs, such as projections, supported by the support structures. Thus, the manufacturing of the upper portion, in particular the additional manufacturing of the upper portion of the components, can be carried out easily.

[0032] According to embodiments that can be combined with any other embodiments described herein, the method may further include the step of additionally fabricating a second support structure 122 on top of the build plate 110. The second support structure 122 may be provided between the build plate 110 and the upper portion 140, that is, the second support structure 122 may be sandwiched between the upper portion 140 and the build plate 110. In other words, the first support structure 124 may support the upper portion against the base portion. The second support structure may support the upper portion 140 against the build plate 110. As illustrated in the cross-sectional view of the vaned component 100 in Figure 2A, the first support structure 124 and the second support structure 122 may be provided on the radial side of the vane 150. The radial side may include a radially inward-facing side 130 and a radially outward-facing side 120. The first support structure 124 and / or the second support structure 122 may be provided on the radially inward-facing side 130 and / or the radially outward-facing side 120. Additionally or alternatively, a continuous support structure may be provided on the radially inward-facing side 130.

[0033] Advantageously, support structures can hold overhangs or gaps between parts of a component during manufacturing. Support structures can be provided between different parts of a component, more specifically between sequentially formed parts, i.e., between sections manufactured one after the other and / or stacked. As an example, after forming a base portion 115 on a build plate 110, a vane 150 can be formed by additive manufacturing. An upper portion 140 can be formed on the vane by additive manufacturing. Multiple support structures can be formed by additive manufacturing between these two portions, i.e., between the vane and the upper portion. It should be understood that the vane and the multiple support structures can be formed simultaneously. Furthermore, it should be understood that a second support structure 122 can be formed simultaneously with the vane and the first support structure 124. The upper portion can be formed last.

[0034] According to embodiments that can be combined with any other embodiments described herein, a plurality of support structures have predetermined failure points. Each of the support structures may have one or more predetermined failure points, and more specifically, each of the support structures may have two predetermined failure points. Each of the plurality of support structures may include at least two predetermined failure points on opposite sides in the vertical direction of the support structure. For example, a support structure may have a predetermined failure point 125 at the top and one predetermined failure point 125 at the bottom, as illustrated in Figure 4B and further described below.

[0035] As used throughout this disclosure, the term “predetermined fracture point” should be understood as a defined section or geometric region of a support structure in which the molten material of the support structure is generally fabricated to be significantly more brittle than the material of the component itself or other sections of the support structure. In other words, a predetermined fracture point can be understood as a defined portion of the support structure that is designed to be separated from the component and / or other parts of the support structure, i.e., is prone to fracture when pressure is applied to the support structure. This can be achieved, for example, by influencing the laser parameters so that the material of the support structure can be fused with lower density, lower toughness, higher porosity, etc., than the material of the component or other sections of the support structure itself. Additionally or alternatively, this can also be achieved by forming a tapered portion (e.g., conical) in the support structure, such that the tip of the tapered portion forms the predetermined fracture point. The predetermined fracture point can also be formed between the main portion and the overhang of the support structure and / or where the support structure intersects with the overhang.

[0036] Pressure can be applied to remove the support structure. Advantageously, a support structure including a predetermined failure point can be configured such that the force for removing the support structure is applied over the entire area of ​​the support structure. In other words, the force for removing the support structure, for example, pressure in the form of a pressurized jet, does not need to be applied directly to the predetermined failure point. Thus, the support structure according to the embodiment can be removed integrally from the manufactured component. This means that the support structure is removed as a whole or as a predetermined set of subsections, but its shape remains substantially or completely intact, with the exception that it can be bent, and only the predetermined failure point adjacent to the component is broken or partially broken. Thus, a person skilled in the art will understand that by using a support structure having a predetermined failure point, the support structure can be removed as a whole. Thus, the support structure can be removed without relying on jet cutting of the material and can be pushed away from the vaned component by the force applied to the support structure. In a generally preferred embodiment, removal of the support structure can be achieved by deformation-induced failure (as opposed to removal of the material by jet cutting, and therefore, in one embodiment, removal of the support structure is not achieved by jet cutting). When pressure is applied to the support structure, the material at a predetermined fracture point can yield and break, allowing the support structure to be removed.

[0037] The method may further include the removal of the vaned component from the build plate 110. Figure 2B illustrates the vaned component 100 after the (additional) manufacturing of the component parts is completed and before the vaned component is removed from the build plate. Removal of the vaned component from the build plate may include removal by pressurized jet, manual removal with hand tools, and / or removal by machining.

[0038] According to the embodiment, the second support structure 122 can surround the vaned component and be removed first. The second support structure can be located on the radially inward-facing side 130 and / or the radially outward-facing side 120. The second support structure can be manually removed from the vaned component using hand tools such as a screwdriver, tongs, hammer, hand milling cutter, or hand grinder. Additionally or alternatively, the second support structure can be removed by machining or by applying a pressurized jet as further described below.

[0039] According to embodiments that can be combined with any other embodiments described herein, the second support structure 122 may be a segmented, angled transverse support bar. The support bars may be arranged adjacent to one another in the circumferential direction around the vaned component. Each of the second support structures may include a segment projecting radially at its lower end, i.e., a segment extending radially away from the vaned component. The radially projecting segment may be a segment projecting radially inward or a segment projecting radially outward. Furthermore, there may be second support structures having a segment projecting radially inward and second support structures having a segment projecting radially outward. Thus, the second support structures are easily accessible and can be removed from the vaned component. The second support structures can be pulled away from the vaned component by applying tensile force and / or bending moment to the radially projecting segment, and thus can be removed from the upper portion 140 and the vaned component 100. Therefore, the second support structure can be removed manually using hand tools, using a pressurized jet as further described below, and / or by machining.

[0040] Figure 3A illustrates a vaned component with a portion of the second support structure 122 removed. As can be seen from Figure 3A, when the second support structure is removed, the base portion 115, the vanes 150, and the first support structure 124 are exposed directly below. Instead of the second support structure, a continuous support structure 133 can be provided on the radially inward-facing side, which can be removed manually, for example, using a hand tool, in a similar manner to the second support structure 124.

[0041] According to embodiments that can be combined with any other embodiments described herein, the first support structure 124 may be grid-like or bar-like, positioned between the vanes 150. The first support structure 124 may be positioned at an angle corresponding to the angle of the vanes 150 with respect to the circumference of the vaned component.

[0042] Figure 3B shows a vaned component removed from the build plate. For example, a vaned component can be manually removed from the build plate by, for example, destroying the base support structure beneath the base portion 115 of the vaned component. It should be understood that multiple support structures, namely the first and second support structures, can be removed from the vaned component before or after the vaned component is removed from the build plate. For example, when using a device for removing multiple support structures, it may be advantageous to leave the vaned component attached to the build plate for the removal process, as the build plate can be conveniently fixed to the base of the device used to remove the support.

[0043] According to embodiments that can be combined with any other embodiments described herein, the method further includes the step of applying a pressurized jet to a plurality of support structures to break predetermined failure points of the plurality of support structures and remove the plurality of support structures (step 194 in Figure 1). In Figure 3B, the pressurized jet is indicated by arrow 360. In other words, a pressurized jet can be applied to remove the plurality of support structures from the vaned components.

[0044] Advantageously, applying a pressurized jet to multiple support structures can be adapted to the specific vaned component being manufactured, meaning that poorly accessible support structures required for the proper manufacture of the vaned component can be effectively removed at a lower cost and in a shorter time compared to the methods described in the Art.

[0045] According to embodiments that can be combined with any other embodiments described herein, the pressurized jet can be applied to the second support structure 122 and / or the first support structure. Any description of the application of the pressurized jet herein can be applied to the second support structure and the first support structure unless expressly otherwise described.

[0046] According to embodiments that can be combined with any other embodiments described herein, the pressurized jet can be applied by periodically changing the pressure of the pressurized jet to generate a pulsed pressurized jet. Advantageously, multiple support structures can be repeatedly targeted, and the material at a predetermined failure point, i.e., a predetermined failure point, can yield over time where the pressurized jet is applied to the support structure. This can also advantageously reduce the overall application time by wearing down the joint between the support structure and the vaned component.

[0047] According to embodiments that can be combined with any other embodiments described herein, the pressurized jet may be a pressurized fluid jet. For example, it may be a pressurized liquid jet, and more specifically, a pressurized water jet. It should be understood that any other compressible fluid may be used. According to embodiments, the pressurized jet may include abrasive particles and / or one or more additives, one or more of which are selected from the group consisting of additives for affecting viscosity, additives for affecting the persistence of the fluid jet, and rust inhibitors, and / or combinations thereof. Advantageously, the jet may be adapted to the material of the support structure and may be particularly strengthened.

[0048] According to embodiments that can be combined with any other embodiments described herein, a pressurized jet, more particularly a pressurized fluid jet, can be applied at volumetric flow rates between 1 liter / min and 50 liters / min, more particularly between 15 liters / min and 35 liters / min, and more specifically at a volumetric flow rate of 25 liters / min. The volumetric flow rate can be selected depending on the material to be removed.

[0049] According to embodiments that can be combined with any other embodiments described herein, the pressurized jet can be applied at a jet velocity between 150 m / s and less than 1000 m / s, more specifically between 200 m / s and less than 950 m / s. The jet velocity can be selected depending on the material of the multiple support structures.

[0050] The table below shows examples of specific jet velocities depending on the materials of multiple support structures. [Table 1] In the table above, materials are defined by a known material numbering system according to their respective DIN / ISO / ASTM standards, and the pressure difference is the overpressure of the fluid inside the nozzle (the difference between the fluid pressure before exiting the nozzle and atmospheric pressure). Therefore, from this table, it can be seen that the preferred pressure difference for the jet is at least 150 bar, preferably at least 200 bar, and a maximum of 5000 bar, preferably a maximum of 4500 bar. Furthermore, the preferred jet velocity is at least 100 m / s, preferably at least 200 m / s, and a maximum of approximately 1000 m / s.

[0051] According to embodiments that can be combined with any other embodiments described herein, the pressurized jet can be applied manually, automatically, and / or adaptively controlled by a robot. For example, the pressurized jet can be applied using a handheld nozzle. Furthermore, the pressurized jet can be applied by apparatus according to embodiments described herein.

[0052] According to embodiments that can be combined with any other embodiments described herein, the manufactured vaned component may be circular in shape. Figure 3C illustrates a vaned component after all the support structures, i.e., the first and second support structures, have been removed after the parts of the vaned component, i.e., the base portion, vanes, multiple support structures, and upper portion, have been manufactured (additionally). Thus, Figures 3A to 3C show the progress of the vaned component during the manufacturing method according to the embodiments described herein, in particular during the steps of the support structure removal process.

[0053] A vaned component can define an axis that can extend essentially vertically. The axis can be the axis of a circle, that is, the axis can extend essentially vertically through the center of the circle of the vaned component. A vaned component can extend essentially vertically around the axis of a circular shape. As used herein, the term “essentially vertical” can be understood as a direction perpendicular to the horizontal, i.e., a direction extending at an angle of 90° from the horizontal. However, “essentially vertical” should also be understood to include directions within ±30° of the vertical, i.e., angles between 60° and 120° with respect to the horizontal. For example, vaned components can be turbine wheels, nozzle rings, compressor wheels, and compressor diffusers.

[0054] According to the embodiment, the vaned component may include a base portion 115 and an upper portion 140. The base portion 115 and the upper portion 140 may have an annular geometry. The annular geometry may be arranged essentially around a vertical axis. The vaned component may include a diameter and a radius, the radius being essentially constant in each horizontal direction from the vertical axis. In other words, the base portion 115 and the upper portion 140 may be annular and concentric around an axis and spaced apart from each other in the axial direction. As an example, the base portion and the upper portion may form the lower and upper boundaries of a nozzle ring.

[0055] According to embodiments that can be combined with any other embodiments described herein, the base portion 115 and / or upper portion 140 may include notches and / or projections. The projections may extend radially from the base portion and / or upper portion. For example, the notches and / or projections may extend inward, i.e., essentially toward the vertical axis, and / or the notches and / or projections may extend outward, i.e., essentially away from the vertical axis. The upper portion may extend more outward and / or inward than the base portion, or vice versa. Thus, an overhang can be formed. The projections may be considered as overhangs of the vaned components.

[0056] According to embodiments that can be combined with any other embodiments described herein, the vaned component may include one or more vanes 150. The vanes may be located between the base portion and the upper portion of the vaned component, that is, the vanes may be sandwiched between the base portion 115 and the upper portion 140 of the vaned component. The vane portion 150 may be inclined circumferentially of the vaned component, as illustrated in Figures 3C and 4A. In other words, the vanes may be located circumferentially and may extend from the lower portion to the upper portion. The vanes 150 may be constructed to allow liquid flow to be applied.

[0057] According to embodiments that can be combined with any other embodiments described in the specification, vaned components or parts of vaned components may be additionally manufactured from any one of the following: steel powder, titanium powder, titanium alloy powder, nickel-based alloy powder (e.g., Inconel®), aluminum powder, aluminum alloy powder, and combinations thereof. In particular, vanes, support structures, and upper parts may be additionally manufactured.

[0058] Returning to the removal of multiple support structures, according to embodiments that can be combined with any other embodiments described herein, each set of vanes 150 and the first support structure 124 can be arranged in an alternating manner along the circumferential direction indicated by arrow 4, as illustrated in the schematic top view of Figure 4A. This allows the vanes to be arranged in an alternating circumferential order next to each set of the first support structure(s), and vice versa. In other words, each set of the first support structure(s) is sandwiched circumferentially between two vanes. Thus, effective support of the overhanging upper portion can be ensured, particularly in the space between the vanes where access is difficult. In Figure 4A, the first support structure(s) are arranged circumferentially between the vanes with a radius overlapping the vanes. In other embodiments, unlike those shown in Figure 4A, (some) of the first support structures(s) can be arranged radially displaced from the vanes (radially inward and / or outward). Thus, support for the upper portion can be enhanced.

[0059] According to embodiments that can be combined with any other embodiments described herein, the jet can be applied to multiple support structures. The jet can be pressurized. The jet can be a jet of particles and / or liquid, for example, a water jet. The jet is preferably applied essentially horizontally (with a primary horizontal component and a negligible vertical component).

[0060] The jet can be applied radially (inward and / or outward) or from a predetermined (non-zero) angle relative to the radial direction. The application angle may depend on each support structure being removed. As an example, as shown by arrow 6 in Figure 4A, the application angle can be essentially perpendicular to the main surface of the support structure (e.g., the elongation direction of the horizontal cross-section of the main part) (up to a maximum of 30° or a tolerance of up to 15°). Depending on the arrangement of the vanes 150, the application angle of the pressurized jet can be adjusted to be essentially parallel to the vanes or relative to the main direction of the gap between the vanes, so that at least a portion of the jet can cross the gap, which is minimally obstructed by the vanes, and push the support structure out of the gap.

[0061] In the embodiment, the pressurized fluid jet can be applied to the first support structure at an angle to the radial direction, i.e., with a circumferential component, preferably with an angle / circumferential component, such that the direction of the jet corresponds to the fluid flow direction defined by the vane. The fluid flow direction can be defined by the vane angle at the end of the vane to which the jet is applied. Thus, the circumferential component can be in the same quadrant as the circumferential direction indicated by arrow 6, and preferably parallel with a tolerance of up to 30°.

[0062] According to embodiments that can be combined with any other embodiments described herein, the pressurized jet can be applied to multiple support structures by periodically readjusting the direction of the jet to the multiple support structures in order to strike different target points on the multiple support structures. Thus, the position at which the pressurized jet can strike one support structure can be modified so that each support structure can be removed more efficiently.

[0063] As illustrated in Figure 4B, the support structure includes a predetermined failure point 125. Each of the multiple support structures may include at least two predetermined failure points on opposite sides of the support structure in the vertical direction. Each of the multiple support structures may have an upper, lower, and main part 126. The upper may be provided or formed adjacent to the upper part 140 of the vaned component, while the lower may be provided or formed adjacent to the base part 115 of the vaned component. The main part may be provided vertically in sequence between the upper and lower parts. The main part may be located between predetermined failure points. It should also be understood that predetermined failure points can be provided as failure points of the main part. In other words, the main part of the support structure may include various predetermined failure points distributed on the main part of the support structure, for example.

[0064] Vaned components can define an axis (essentially perpendicular). The main part can be bar-shaped or grid-shaped with a horizontal cross-section, the horizontal cross-section being elongated with an extension axis essentially perpendicular to the direction in which the jet is applied. In other words, the elongated cross-section can define a main surface (parallel to the axis) and / or a pair of inward and outward surfaces for receiving jets from a direction having a radial component that can be essentially perpendicular to the main surface / surface. In other words, the main part of the support structure can define a plane that is oriented, targeted by a pressurized jet, and extends essentially perpendicular to the direction in which the jet is applied.

[0065] According to embodiments that can be combined with any other embodiments described herein, the pressurized jet can be applied in a radial component, preferably periodically and alternately in a radial component between a radially inward-directed component and a radially outward-directed component.

[0066] According to embodiments that can be combined with any other embodiments described herein, a pressurized jet can be applied to the support structure to impact the main portion 126 of the support structure, and the impact on the main portion causes the failure of predetermined failure points 125 located between the main portion and the upper and / or lower part of the support structure. Thus, the support structure can be pushed away by the pressurized jet and efficiently removed from the vaned components.

[0067] According to embodiments that can be combined with any other embodiments described herein, the support structure may include an outer side and an inner side. The outer side of the support structure can be understood as a side of the support structure that aligns with the side facing the pressurized jet, i.e., the side facing radially outward or the side facing radially inward of the vaned component. The inner side of the support structure can be understood as a side of the support structure that faces the vanes of the vaned component. Since the support structure, in particular the first support structure 124, can be positioned on the side facing radially outward and the side facing radially inward of the vaned component, the inner side of the support structure can face each vane from two opposing sides. Arrangements of multiple support structures, i.e., arrangements of the first support structures 526, 536 and the second support structures 528, 538, are further shown in Figures 5A and 5B.

[0068] According to embodiments that can be combined with any other embodiments described herein, the pressurized jet can be applied to multiple support structures by alternately applying the pressurized jet to the outer and inner sides of the multiple support structures, thereby targeting the multiple support structures alternately on their outer and inner sides. Advantageously, targeting the support structures from different sides can further enhance the fracture at a given fracture point and the yielding of the material at that fracture point. Thus, the overall application time can be reduced and the support structures can be removed efficiently.

[0069] According to embodiments illustrated in Figures 5A and 5B and which can be combined with any other embodiments described herein, the multiple support structures can include a variety of shapes. As illustrated in Figure 5A, the first support structure 526 can include a tree-like structure; that is, the main part of the first support structure can be relatively narrow and expand with respect to the upper part of the support structure. The upper part can include a branched structure, each branch can include a predetermined failure point. A pressurized jet can be applied to the narrow part and / or branched part of the main part. According to embodiments, the second support structure 528 can also include the narrow and branched structure described above.

[0070] According to embodiments that can be combined with any other embodiments described herein, the support structures may include support angles. For example, the support structures may be formed on vaned components at a specific angle with respect to the normal direction defined by the build plate (orthogonal to the build plate), thereby providing easier access to the support structures. The support angles may range between 10° and 45°, and more specifically between 20° and 35°.

[0071] Advantageously, the branched structure allows for even easier removal of the support structure because there is less material that can yield and break more easily, even if the predetermined failure points are distributed over a wider area.

[0072] According to embodiments that can be combined with any other embodiments described herein, an apparatus 600 for manufacturing vaned components of turbomachinery is provided, with illustrative reference to Figures 6A and 6B. The apparatus 600 comprises a first chamber 672 including an additive manufacturing apparatus 670 for additive manufacturing vaned components of turbomachinery.

[0073] According to embodiments that can be combined with any other embodiments described herein, the additive manufacturing apparatus 670 may be configured to perform a powder bed melting process, such as a 3D printer. The additive manufacturing apparatus may be controlled by a controller 672 so that various parameters can be set depending on the component to be manufactured. For example, different 3D geometries for various components can be input to a computer system connected to the controller 674. The controller can adjust and modify the manufacturing conditions according to the design plan, i.e., according to the component to be manufactured. Furthermore, several parameters such as the layer thickness of the single layer to be fused, laser parameters, and temperature can be controlled to obtain the desired component. According to embodiments, the controller 674 may be configured to perform a method according to any of the embodiments described herein, i.e., the controller may be configured to send commands to perform a method according to any of the embodiments described herein.

[0074] It should be understood that blank material that can be further processed by additive manufacturing techniques can be inserted into the first chamber 672. For example, the base portion can be inserted into the first chamber in order to additively manufacture further parts of a vaned component, such as vanes, support structures and / or upper portions, onto the base portion of the vaned component. According to embodiments described herein, the first chamber 672 may include a build plate for providing support to the vaned component to be (further) processed in the first chamber.

[0075] According to embodiments described herein, the vaned component 100 can be transferred from a first chamber to a second chamber 680. The second chamber can be configured to remove a plurality of support structures from the vaned component 100. The vaned component can be transferred to the second chamber with or without the build plate used during additive manufacturing in the first chamber.

[0076] According to embodiments that can be combined with any other embodiments described herein, as illustrated in Figure 6B, the apparatus comprises a second chamber 680 including at least one pressurized jet device 682 for supplying a pressurized jet to remove a plurality of support structures. The second chamber 680 may include a high-pressure pump 681 for generating the pressurized jet. For example, the high-pressure pump may be a liquid high-pressure pump for generating a pressurized liquid jet.

[0077] According to the embodiment, a high-pressure pump can be connected to a pressurized jet device 682 by a high-pressure line 683 for supplying a fluid or liquid jet to the pressurized jet device. The pressurized jet device may include one or more nozzles for applying a jet toward a manufactured vaned component, i.e., toward a plurality of support structures, in order to remove the support structures. A second chamber may further include a table 685 for supporting the vaned component 100 during the removal of the plurality of support structures. The table 685 may be rotatable (indicated by an arrow in Figure 6B), and by moving the pressurized jet device and / or rotating the table, various application angles of the pressurized jet toward the vaned component, i.e., toward the plurality of support structures, can be obtained.

[0078] According to embodiments described herein, the second chamber may further include a collection container 684 for collecting the removed support structure (material) and / or the fluid / liquid of the pressurized jet. The collection container may further include a drain pipe for facilitating cleaning of the apparatus.

[0079] As shown in other drawings, it should be understood that the apparatus may include first and second chambers that are directly and spatially close to each other. Transfer of vaned components between chambers can be done in an automated manner. Furthermore, the first and second chambers can be separated from each other. In such cases, vaned components can be transferred manually between chambers.

[0080] According to embodiments that can be combined with any other embodiments described herein, the apparatus may include a detection device for automatically detecting the position of each of the first and / or second support structures, and the multiple support structures may be removed in an automated manner. The detection device may be located in a second chamber. The detection device may be a camera, laser, barcode scanner, infrared camera, etc. The detection device may be configured to selectively direct the pressurized fluid jet towards a determined position, i.e., the detection device may be connected to a controller, which may use the received data to control the pressurized jet device accordingly.

[0081] According to embodiments that can be combined with any other embodiments described herein, commands sent from the controller can activate and / or deactivate components of the apparatus for manufacturing vaned components according to any embodiment described herein. Additionally or alternatively, commands sent from the controller can adjust any of the components of the apparatus for manufacturing vaned components according to any of the embodiments described herein. For example, the controller can adjust the rotation of the table 685, the movement of the pressurized jet, and / or the movement of the detection device by sending commands. Thus, the controller can send commands to adjust the operation of the apparatus, i.e., the operation of the components of the apparatus for manufacturing vaned components, and / or instruct the user to take further steps. Any of the components and / or apparatus described herein can be controlled by the controller.

[0082] According to the embodiments, different embodiments of the second chambers 680, 680' are shown exemplary with reference to Figures 7A and 7B. The second chambers can include all the features described above. As can be seen from Figure 7A, one pressurized jet device 682 may be provided. The pressurized jet device may include one high-pressure nozzle for directing the pressurized jet toward the vaned components, i.e., toward the multiple support structures. The pressurized jet device may be provided on the side facing radially outward or radially inward of the vaned components. Thus, different settings of the pressurized jet can be performed as described according to the embodiments described herein. For example, a specific target point on the support structure may be targeted. Furthermore, the pressurized jet device may be configured to change its position relative to the vaned components. That is, the pressurized jet device may be provided on the side facing radially outward and / or radially inward, depending on the direction in which the pressurized jet will be applied to remove the support structure. The position of the pressurized jet device can also be selected depending on the support structure to be removed, that is, if either the first or second support structure is to be removed.

[0083] Additionally or alternatively, the second chamber 680' may include two or more pressurized jet devices. For example, the second chamber may include two pressurized jet devices, a first pressurized jet device 682 and a second pressurized jet device 682'. Each device may be positioned on one radial side of the vaned component 100; that is, the first pressurized jet device may be located on the side facing the radially outward direction of the vaned component, and the second pressurized jet device may be located on the side facing the radially inward direction of the vaned component. Thus, multiple applications of pressurized jets can be enabled. For example, multiple support structures may be targeted with pressurized jets from both radial sides simultaneously or alternately, as described according to the embodiments herein.

[0084] In light of the foregoing, it should be understood that embodiments of this disclosure provide beneficial methods and apparatus for manufacturing vaned components of turbomachinery that are improved with respect to the application of additive manufacturing and the removal of support structures compared to the prior art. Furthermore, embodiments described herein provide beneficially more efficient removal and time-efficient manufacturing of additively manufactured components compared to conventional methods and apparatus.

[0085] While the foregoing is directed toward embodiments of the present disclosure, other and further embodiments of the present disclosure can be conceived without departing from its basic scope, which is defined by the following claims.

Claims

1. A method (190) for manufacturing a vane component (100) of a turbomachinery, A step of providing a base portion (115), wherein the base portion is part of the vaned component and serves as a starting point for manufacturing the vaned component. A step of additionally manufacturing a plurality of vanes (150) and a plurality of support structures on the base portion (115), wherein the plurality of support structures have predetermined failure points (125), A step of additionally manufacturing an upper portion (140) supported by the plurality of support structures on the plurality of support structures and the vane (150), wherein the vane is sandwiched between the base portion (115) and the upper portion (140), A step of applying a pressurized jet (360) to the plurality of support structures, thereby breaking the predetermined failure points of the plurality of support structures and removing the plurality of support structures, Includes, Method (190), wherein the pressurized jet (360) is applied to the support structure to impact the main part (126) of the support structure, and the impact on the main part results in the failure of a predetermined failure point (125) located between the main part and the upper part of the support structure.

2. The method according to claim 1 (190), wherein the plurality of support structures comprises a first support structure (124) and a second support structure (122), and the first support structure (124) is additionally manufactured on the base portion (115) so as to be sandwiched between the upper portion (140) and the base portion (115).

3. The second support structure (122) is provided on the build plate (110), and the method is as follows: The method of claim 2 (190), further comprising the step of additionally manufacturing the second support structure (122) on the build plate (110) such that the second support structure is sandwiched between the build plate (110) and the upper portion (140).

4. The method according to claim 2 or 3 (190), wherein the second support structure (122) is manually removed from the vane-equipped component.

5. The method according to any one of claims 1 to 4 (190), wherein the step of applying the pressurized jet (360) to the plurality of support structures includes the step of alternately applying the pressurized jet to the outer side and the inner side of the plurality of support structures, thereby alternately targeting the plurality of support structures with the outer side and the inner side.

6. The method according to any one of claims 1 to 5 (190), wherein the step of applying the pressurized jet (360) includes the step of periodically changing the pressure of the pressurized jet to generate a pulsed pressurized jet.

7. The method according to any one of claims 1 to 6 (190), wherein the step of applying the pressurized jet (360) includes the step of periodically readjusting the direction of the jet to the plurality of support structures in order to strike different target points in the plurality of support structures.

8. The method according to any one of claims 1 to 7 (190), wherein the vane-equipped component defines a vertical axis, and the support structure has a main portion (126) having a horizontal cross-section, the horizontal cross-section being elongated and having an extension axis perpendicular to the direction in which the jet is applied.

9. The method according to any one of claims 1 to 8 (190), wherein the step of applying the pressurized jet (360) includes the step of applying the pressurized fluid jet at a volumetric flow rate between 1 liter / min and 50 liters / min.

10. The method according to any one of claims 1 to 9 (190), wherein the step of applying the pressurized jet (360) includes the step of applying the pressurized jet at a jet velocity between 150 m / s and 1000 m / s.

11. The method according to claim 10 (190), wherein the jet velocity is selected according to the material of the plurality of support structures.

12. The method according to any one of claims 1 to 11 (190), wherein the vaned component (100) is at least one selected from the group consisting of a casing, a turbine wheel, a nozzle ring, a compressor wheel, and a compressor diffuser.

13. The method (190) according to any one of claims 1 to 12, wherein the step of applying the pressurized jet (360) to the plurality of support structures includes one selected from the group consisting of a step of manually applying the pressurized jet, a step of automatically applying it, and a step of applying it under robotic control.

14. The method according to any one of claims 1 to 13 (190), wherein the pressurized jet (360) is a pressurized fluid jet, and more specifically, the pressurized jet is a pressurized water jet.

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