Internal Passage Agitators for Additive Powder Removal
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Solution Overview
Problem
Current methods for removing conglomerated powder from internal passages of additively manufactured components, such as gas turbine components, are inefficient, as they often fail to directly and rapidly clear the powder from complex geometries.
Innovation Solution
Incorporating multiple spherical agitators within the internal passages of the components during additive manufacturing, which are then vibrated at a natural frequency to break and remove the semi-sintered powder bonds, facilitating the mechanical working out of the powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional removal methods (accelerated media blast, mechanical scraping, ultrasonic vibration) are used to remove conglomerated powder from internal passages, then some powder removal is achieved, but the removal efficiency remains low and the process is time-consuming
Solution Approach 1:
The patent applies mechanical vibration by attaching agitators to the internal passages and vibrating the entire component at a particular known natural frequency of the agitators. This resonance-based vibration mechanically breaks up the semi-sintered conglomerated powder bonds, enabling rapid and direct removal of powder from complex internal geometries that were previously difficult to access
Solution Approach 2:
The agitators are additively manufactured as integral parts of the component itself, meaning the component contains its own built-in vibration mechanisms. The component serves itself by using its own structure (agitators) to remove the powder that accumulated during manufacturing, eliminating the need for separate external removal equipment
2Ease of operation
If repeated accelerated media blast and mechanical scraping are used to remove powder, then some surface powder is removed, but powder trapped within internal passages remains difficult to remove
Solution Approach 1:
The agitators are nested within the internal passages of the component, with each agitator positioned inside a specific passage. This nested configuration allows the vibration mechanism to be directly embedded within the hard-to-reach internal geometries, enabling effective powder removal from within the passages rather than just from external surfaces
Solution Approach 2:
By vibrating the component at the natural frequency of the nested agitators, mechanical vibration directly作用于 the powder within internal passages, breaking up semi-sintered bonds and enabling complete removal from complex geometries that were previously inaccessible to conventional removal methods
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables direct and rapid removal of conglomerated powder from internal passages, improving the efficiency of the additive manufacturing process by enhancing the flowability and drainage of the powder.
Implementation Method 1
vibrating the component to a natural frequency which will excite the agitators such that the agitators vibrate with a force that will breaking conglomerated powder bonds surrounding each of the multiple of agitators
Implementation Method 2
vibrating a component at a particular known natural frequency of a multiple of agitators within a non-line of sight internal passage of an additively manufactured component
Data Source
AI summary
A component includes an additively manufactured component with an internal passage; and an additively manufactured elongated member within the internal passage. A method of additively manufacturing a component including additively manufacturing a component with an internal passage; and additively manufacturing an elongated member within the internal passage concurrent with additively manufacturing the component.