REFINED FEATURES

TECHNICAL FIELD

The present invention relates generally to additive manufactured metal parts,

5 and more specifically to a turbine airfoil formed by a metal additive manufacturing process with a film cooling hole.

GOVERNMENT LICENSE RIGHTS

None.

10

BACKGROUND

In a gas turbine engine, airfoils exposed to the highest gas stream flow must be cooled to prevent damage. Turbine airfoils that require cooling air flow are typically formed using an investment casting process with a ceramic core that represents the

15 internal cooling features. The size and shape of these internal features are limited by the strength of the ceramic material that forms the core. During the casting process, liquid metal is poured into a mold that secures the ceramic core. Small features on the ceramic core can easily break due to the heavy liquid metal passing through. Thus, casting yields for complex airfoil internal cooling features can be quite low (that is, a

20 large number of casted parts are defective), and the cost to produce these airfoils are therefore relatively expensive.

The new metal additive manufacturing process is being used to form complex parts such as turbine airfoils with internal cooling features where the entire part is printed by a metal printing process such as direct metal laser sintering (DMLS).

25 However, small features such as film cooling holes that are printed are formed with a very large tolerance. The degree of accuracy to resolve holes and features is limited by the size of the laser melt pool, the size of the powder particles, and the geometry being formed. Defects in passages can cause restrictions in flow or surface stress concentrations that will limit the part life. In the case of a relatively small film cooling

30 hole, additive manufactured holes can have surface defects that create roughness or blockage that restrict the flow and create additional pressure drop. FIG. 1 shows a side view of a small film cooling hole printed using the metal additive manufacturing process of the prior art. FIG. 2 shows a front view of the printed film cooling hole of FIG. 1 with a wide variation in tolerance or relatively large surface defects.

SUMMARY

A part such as an air cooled turbine airfoil with a film cooling hole, where the part is formed by a metal additive manufacturing process with an oversized feature such as a hole, and where the oversized feature is formed with a normal size by inserting a preform having the normal size to the part and secured to the part, and where the preform is removed such that the normal size feature is left in the part.

The part can be an air cooled turbine airfoil and the feature is a film cooling hole. The airfoil is formed from the metal additive manufacturing process with an oversized hole. A preform made from a refractory material is secured in the oversized hole using a braze or weld material that also fills the gap between the oversized hole and the preform. The preform has a shape of the normal size film cooling hole. The refractory alloy preform is removed, such as by exposure to oxygen at temperatures where the refractory alloy sublimates, and the normal sized film cooling hole is thus formed in the wall.

The hole can be a spiral or helical shaped hole, a curved hole, a hole with a diffusion opening, a slot for a seal, and even a threaded hole for a fastener.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:

FIG. 1 shows a cross-section side view of a film cooling hole formed using a metal additive manufacturing process of the prior art;

FIG. 2 shows a front view of the printed film cooling hole of FIG. 1 with a large variation in the hole surface;

FIG. 3 shows a cross-section side view of a film cooling hole formed using the metal additive manufacturing process of the present invention with a refractory alloy hole replica in place; FIG. 4 shows a cross-section side view of the film cooling hole of the present invention with the refractory hole replica removed;

FIG. 5 shows an embodiment of the present invention in which a double conical shaped preform is used;

FIG. 6 shows an embodiment of the present invention in which a diffusion hole shaped preform is used;

FIG. 7 shows an embodiment of the present invention in which a helical shaped preform is used;

FIG. 8 shows an embodiment of the present invention in which a curved shaped preform is used;

FIG. 9 shows an embodiment of the present invention in which a slot shaped preform is used; and

FIG. 10 shows an embodiment of the present invention in which a threaded shaped preform is used.

DETAILED DESCRIPTION

The present invention is an apparatus and a process to form a metal additive manufactured (3D printed) part with a feature having a detail that cannot be formed by the metal printing process alone. FIGS. 1 and 2 show a part with a hole, such as that in a turbine airfoil having a film cooling air hole in which the part and the hole are formed as a single piece using the metal printing process. The hole varies widely in the tolerance and surface finish due to limitations in the metal additive manufacturing process. With the metal printing process of the present invention, however, the features such as the film cooling hole can be formed with fine details like that produced in the prior art metal casting process. Defects such as splatter can adhere unwanted particles to the desired printed geometry such as a smooth wall surface or hole.

FIG. 3 shows a first embodiment of the present invention in which a film cooling hole is formed in a part such as a turbine airfoil wall. The part in which the hole is to be formed can be cast or printed in which the hole is formed oversized. In FIG. 3, the manufactured part (for example, a turbine airfoil wall) 11 is formed with an oversized hole. A preform 12 having a finished shape of the feature to be formed, such as in this case the film cooling hole, is secured in place within the oversized hole such as by a braze or a weld material 13. The preform 12 is formed from a refractory material that can be easily removed after the braze or weld material 13 has been formed around the preform 12. The braze or welding would be performed in a reducing gas (reactive gas that removes free oxygen), an inert gas, or vacuum environment so as to prevent the oxidation of the refractory alloy. The refractory material can be alloys of molybdenum, tungsten, niobium, or other materials that can be easily removed by methods such as by sublimation to leave a hole having the desired shape. The material may include non-refractory material, but the object of the preform material is that substantially all of the perform material can be removed by rapid oxidation/sublimation at moderate elevated temperatures so that a refined hole is left in the part of wall 11 without any surface defects like those found in the metal additive manufacturing process alone. FIG. 4 shows the preform 12 removed and the resulting finished film cooling hole 14 formed within the airfoil wall 11. The film cooling hole 14 has a much lower tolerance than the prior art film cooling hole of figures 1 and 2 because of the use of the preform 12. The resulting hole is referred to as being a normal sized hole.

FIG. 5 shows an embodiment of the present invention where a double conical shaped hole can be formed using a preform 21 having this finished shape that is secured into the oversized hole by a braze or weld material 13 formed in the wall or part 11.

Figure 6 shows an embodiment of the present invention where the perform 22, and therefore the hole formed, has a diffusion cooling hole shape.

Figure 7 shows an embodiment of the present invention where the perform 23, and therefore the hole formed, has a helical cooling hole shape.

Figure 8 shows an embodiment of the present invention where the perform 24, and therefore the hole formed, has a curved cooling hole shape.

Figure 9 shows an embodiment of the present invention where the wall of the manufactured part 11 defines a slot shape and the perform 25 has a shape matching the slot shape (that is, the perform 25 is sized and configured to be at least partially received within the slot shape) such that the hole formed has a slot shape. Figure 10 shows an embodiment of the present invention where the perform 26, and therefore the hole formed, has a threaded shape such that a screw or bolt can be inserted and rotated therein.

The apparatus and process of the present invention utilizes an additive manufactured part 11 created with an oversized hole in which a refractory material having a desired finished shape (the preform 22) is inserted and the gap(s) between the preform 22 and the manufactured part 11 filled by welding or braze filler material. In one embodiment of the present invention, the braze alloy is used to create the refined hole feature. A refractory material 22 sized to the desired shape of the final hole is inserted into the oversized hole in the part 11 and the gap filled with the braze alloy or weld material. In another embodiment, the refractory hole preform 22 could have the braze alloy pre-applied to the replica or preform before it is inserted into the part 11.

The brazing thermal cycle would be performed in an insert gas environment, vacuum, or reducing gas environment, each to prevent the oxidation of the refractory alloy. Post braze, the braze furnace could be backfilled with air to allow the refractory alloy to oxidize (sublimate) leaving the clear hole as the result interface of the removed refractory and the braze filler.

The apparatus and process of the present invention can be used to produce a variety of features such as slots, channels, recesses, cooling holes, or other features that cannot be printed with the desired low tolerance. The surface finish within the final refined part with the hole refinement process applied would be reflective or the initial refractory form.

Features such as tapered cooling holes, could be produced to allow for acceleration, diffusion, or metering of the cooling air flow through the axial length of the hole. Curved holes or helical shaped holes can also be produced with the high tolerance finish.

The apparatus and process of the present invention is applicable to additive manufactured parts and additionally to conventional manufactured parts such as machined from bar or plate stock, casting (investment cast, sand cast, centrifugal cast), and machined forgings. A part can be formed unfinished using a casting process (for example) and then finished using the metal printing process with the preform of the present invention. Refurbishment of the parts such as gas turbine parts, hot gas path parts, blades, vanes, heat shields could be restored and improved by the use of this process. Features could include slots, holes, threads, and recesses.

The preform can be made from a ceramic material instead of a refractory material, and where the ceramic preform can be removed by chemical leaching to produce the desired feature such as a hole. In this embodiment, an oversized feature such as a hole is still formed, but the preform is not a refractory material but a ceramic material.

In one embodiment, a process for forming a hole in a part formed by a metal additive manufacturing process comprises the steps of: forming a part with an oversized hole using a metal additive manufacturing process; inserting a preform having a shape of a normal sized hole into the oversized hole of the part; securing the preform in the oversized hole with a material that fills a gap between the oversized hole and the preform; and removing the preform so that the normal sized hole is formed in the part.

In one aspect of the embodiment, the part is a turbine airfoil; and the normal sized hole is a film cooling hole.

In one aspect of the embodiment, the preform is formed of a refractory material that can be removed by exposure to oxygen.

In one aspect of the embodiment, the process further comprises the step of: securing the preform to the oversized hole with a braze material or a weld material.

In one aspect of the embodiment, the normal sized hole is one of a helical shaped hole, a curved hole, a slot for a seal, and a threaded hole for a fastener.

In one aspect of the embodiment, the part is a turbine airfoil; and the normal sized hole is a film cooling hole with a diffusion opening.

In one aspect of the embodiment, the metal additive manufacturing process is a direct metal laser sintering process or an electron beam melting process.

In one aspect of the embodiment, the preform is formed substantially from at least one of Molybdenum, Tungsten, and Niobium.

In one aspect of the embodiment, an air cooled turbine airfoil is provided that comprises a plurality of film cooling holes. In this embodiment, the plurality of film cooling holes are made by a process for forming a hole in a part formed by a metal additive manufacturing process comprises the steps of: forming a part with an oversized hole using a metal additive manufacturing process; inserting a preform having a shape of a normal sized hole into the oversized hole of the part; securing the preform in the oversized hole with a material that fills a gap between the oversized hole and the preform; and removing the preform so that the normal sized hole is formed in the part.

In one embodiment, a part is formed by a metal additive manufacturing process, the part including a hole having a surface with a low tolerance that cannot be formed from the metal additive manufacturing process by itself, the part comprising: a wall having an oversized hole formed from a metal additive manufacturing process; a preform having a shape of a normal sized hole; the preform being formed from a refractory material that can be removed by exposure to oxygen; and at least one of a braze material and a weld material filling a gap between the oversized hole and the preform to secure the preform to the oversized hole, exposure of the preform to oxygen removing the preform from the oversized hole and leaving the normal sized hole within the wall.

In one aspect of the embodiment, after exposure of the preform to oxygen such that the preform is removed, the part is an air cooled turbine airfoil; and the hole is a film cooling hole.

In one aspect of the embodiment, the normal sized hole is one of a helical shaped hole, a curved hole, a slot for a seal, and a threaded hole for a fastener.

In one aspect of the embodiment, the preform is formed substantially from at least one of Molybdenum, Tungsten, and Niobium.

In one aspect of the embodiment, the part is a turbine airfoil; and the normal sized hole is a film cooling hole with a diffusion opening.

In one aspect of the embodiment, the preform is removable by exposure to oxygen.

In one embodiment, a process of forming an air cooled turbine airfoil from a metal additive manufacturing process is provided, the process of forming the air cooled turbine airfoil comprising the steps of: forming an air cooled turbine airfoil with a plurality of film cooling holes from an additive manufacturing process in which the film cooling holes are formed oversized; inserting a preform having a shape of a non-oversized film cooling hole into each of the oversized film cooling holes; securing the preform to each of the oversized film cooling holes with a material having a melting temperature of at least as high as the material of which the air cooled turbine airfoil is made from; and removing the preform from each of the oversize film cooling holes to leave non-oversized film cooling holes in the air cooled turbine airfoil.

In one aspect of the embodiment, the process further comprises the step of: securing the preform to the oversized hole with at least one of a braze material and a weld material.

In one aspect of the embodiment, the preform is formed of a refractory material that can be removed by exposure to oxygen.

In one aspect of the embodiment,

It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. A variety of modifications and variations are possible in light of the above teachings without departing from the scope and spirit of the invention, which is limited only by the following claims.