Self-Supporting AM Passages With Varying Cross-Sections
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Solution Overview
Problem
Current additive manufacturing techniques are limited in printing passages at angles greater than 45° from the build direction, particularly for complex geometries like curvilinear cooling passages in turbomachines, which often require complex supports or re-routing, restricting the creation of non-linear passages with varying cross-sectional shapes.
Innovation Solution
The development of an additively manufactured object with a passage that includes a first portion aligned less than 45° from the build direction and a second portion aligned greater than 45°, featuring a self-supporting top surface with edges no greater than 45° from the build direction, allowing for the creation of passages with varying cross-sectional shapes along a non-linear length, enabling printing regardless of build direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If passages are printed at angles greater than 45° from the build direction, then manufacturing flexibility and passage geometry complexity are improved, but manufacturing reliability deteriorates due to inability to support overhanging structures
Solution Approach 1:
The passage is divided into multiple segments with different cross-sectional shapes along its length. Each segment is designed with specific geometric characteristics that enable self-support during printing. The passage transitions from a first cross-sectional shape to a second cross-sectional shape, allowing different portions to be printed at different orientations without requiring external supports.
Solution Approach 2:
Different portions of the passage have different cross-sectional geometries optimized for their specific printing orientation. The first portion has a cross-sectional shape suitable for printing at certain angles, while the second portion has a different cross-sectional shape suitable for printing at greater angles from the build direction. This local variation in geometry enables reliable printing throughout the entire passage.
2Adaptability or versatility
If complex support structures are added to print passages at greater angles, then passage geometry flexibility is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The solution extracts and eliminates the need for external support structures by incorporating self-supporting geometric features directly into the passage walls. The passage geometry itself provides the necessary support during printing, removing the separate support structure component entirely and simplifying the overall manufacturing process.
Solution Approach 2:
The passage structure is designed to be self-supporting during the printing process. The geometric features of the passage walls provide inherent support for overhanging sections, allowing the structure to support itself without external aids. This self-service capability eliminates the need for separate support materials and post-processing removal steps.
3Reliability
If passages are re-routed to avoid unprintable orientations, then manufacturing reliability is maintained, but passage geometry flexibility and cooling efficiency deteriorate
Solution Approach 1:
The passage cross-sectional geometry dynamically adapts along its length to accommodate changing printing orientations. As the passage transitions through different angles relative to the build direction, the cross-sectional shape changes to maintain self-supporting characteristics. This dynamic geometric adaptation allows the passage to follow complex curvilinear paths without being constrained by fixed orientation limitations.
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 solution enables the additive manufacturing of complex passages without the need for supports and re-routing, allowing for the creation of curvilinear passages with varying cross-sectional shapes, enhancing the manufacturing flexibility and efficiency in producing objects like hot gas path components for turbomachines.
Implementation Method 1
The melting may be performed by a high powered melting beam, such as a 100 Watt ytterbium laser, to fully weld (melt) the metal powder to form a solid metal.
Implementation Method 2
In metal powder additive manufacturing techniques, such as direct metal laser melting (DMLM) (also referred to as selective laser melting (SLM)), metal powder layers are sequentially melted together to form the object.
Data Source
AI summary
A passage incorporated into an additively manufactured object, the object and a related method are disclosed. The object has an additive manufacture build direction. The passage includes: a first portion aligned along an axis oriented less than approximately 45° from the build direction; and a second portion aligned along an axis oriented greater than approximately 45° from the build direction, the second portion including at least one self-supporting top surface portion including at least one edge aligned no greater than approximately 45° from the build direction. The passage having varying cross-sectional shape along a non-linear length accommodates additive manufacture regardless of build direction.