Metallic Component Support Structure Removal via Oxidation
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Solution Overview
Problem
The removal of support structures from metallic components with complex shapes and internal passages during additive manufacturing for industrial machines like gas turbine engines is time-consuming and expensive, especially for internal passages, as conventional methods are inefficient and generate significant scrap material.
Innovation Solution
A method involving the formation of a support structure with a thin-walled lattice arrangement and internal flow passages, followed by rapid heating in a sealed chamber with an explosive gas mixture to burn off the support structure, allowing for quick and cost-effective removal without damaging the main component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional methods are used to remove support structures from internal passages, then the support structure can be removed, but the process is time-consuming and expensive
Solution Approach 1:
The patent replaces conventional mechanical removal methods (such as drilling, machining, or manual removal) with a chemical/thermal oxidation process. By introducing an oxidizing atmosphere into the sealed chamber containing the component, the support structures are removed through oxidation reactions rather than mechanical means, dramatically reducing removal time and cost while effectively accessing internal passages.
Solution Approach 2:
The patent changes the chemical and thermal parameters of the removal process by controlling the oxidizing atmosphere composition, temperature, and exposure time. By adjusting these parameters, the support structures are selectively oxidized and removed without damaging the main component, achieving rapid and cost-effective removal of even internally located support structures.
2Manufacturing precision
If support structures are designed for additive manufacturing, then complex shapes can be manufactured, but the support structures become waste material requiring removal
Solution Approach 1:
The patent converts the harmful effect of support structures (as waste material requiring removal) into a beneficial process feature. By designing support structures with specific geometries that facilitate oxidizing atmosphere penetration and by controlling the oxidation process parameters, the support structures are selectively removed through oxidation, transforming from unwanted scrap into a controlled material removal process that leaves no harmful residues.
3Productivity
If rapid removal of support structures is achieved through explosive heating, then manufacturing cost is reduced, but high temperatures must be controlled to preserve component integrity
Solution Approach 1:
The patent applies local quality by creating different thermal and chemical environments in different regions of the component. The oxidizing atmosphere and high temperatures are concentrated specifically at the support structure locations through controlled atmosphere introduction and component positioning, while the main component body remains in a more controlled environment. This selective localization allows rapid support structure removal while preserving component integrity.
Solution Approach 2:
The patent employs beforehand cushioning by pre-designing the support structures with specific geometries and properties that make them more susceptible to oxidation than the main component. The support structures are designed with higher surface-area-to-volume ratios, different material compositions, or surface treatments that promote preferential oxidation, cushioning the main component from damage while enabling rapid support structure removal.
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 reduces manufacturing costs and simplifies the support structure removal process by rapidly oxidizing thin-walled support structures at high temperatures, minimizing scrap and preserving the integrity of the metallic component.
Implementation Method 1
igniting the fuel mixture in the chamber to remove one or more of the support walls of the support structure from the metallic component
Implementation Method 2
introducing a fuel mixture into the chamber after sealing the chamber. The method still further includes igniting the fuel mixture in the chamber
Data Source
AI summary
A method for manufacturing a metallic component is disclosed. The method includes forming a metallic component with a support structure using an additive manufacturing process. The support structure includes support walls arranged to form flow passages with a predetermined cross-sectional area. The method also includes placing the metallic component with the support structure into a chamber and sealing the chamber. The method further includes introducing a fuel mixture into the chamber after sealing the chamber. The method still further includes igniting the fuel mixture in the chamber to remove one or more of the support walls of the support structure from the metallic component.