U.S. patent application number 16/507349 was filed with the patent office on 2019-10-31 for composite component having angled braze joint, coupon brazing method and related storage medium.
The applicant listed for this patent is General Electric Company. Invention is credited to Paul Stephen DiMascio, Cem Murat Eminoglu.
Application Number | 20190329344 16/507349 |
Document ID | / |
Family ID | 62386003 |
Filed Date | 2019-10-31 |
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United States Patent
Application |
20190329344 |
Kind Code |
A1 |
Eminoglu; Cem Murat ; et
al. |
October 31, 2019 |
COMPOSITE COMPONENT HAVING ANGLED BRAZE JOINT, COUPON BRAZING
METHOD AND RELATED STORAGE MEDIUM
Abstract
Various aspects include a composite component (also known as a
Shear Enabled Regionally Engineered Facet (SEREF)) and methods of
forming such a component. In some cases, a method includes: forming
a slot in a main body of a metal alloy component, the slot
extending at least partially through a wall of the metal alloy
component, the forming of the slot including forming an angled main
body interface in the wall of the metal alloy component; forming a
coupon for coupling with the slot in the metal alloy component, the
coupon having an angled coupon interface complementing the angled
main body interface; and brazing the coupon to the main body at the
slot to form a composite component.
Inventors: |
Eminoglu; Cem Murat;
(Simpsonville, SC) ; DiMascio; Paul Stephen;
(Greer, SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
General Electric Company |
Schenectady |
NY |
US |
|
|
Family ID: |
62386003 |
Appl. No.: |
16/507349 |
Filed: |
July 10, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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15605294 |
May 25, 2017 |
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16507349 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F05D 2230/237 20130101;
B23K 1/19 20130101; B23P 6/005 20130101; B23K 2101/001 20180801;
B23K 1/0008 20130101; B23K 2103/26 20180801; B23K 20/021 20130101;
B23K 1/0018 20130101; F01D 5/005 20130101; F05D 2250/232
20130101 |
International
Class: |
B23K 1/00 20060101
B23K001/00; F01D 5/00 20060101 F01D005/00; B23K 20/02 20060101
B23K020/02; B23P 6/00 20060101 B23P006/00; B23K 1/19 20060101
B23K001/19 |
Claims
1. A method comprising: forming a slot in a main body of a metal
alloy component, the slot extending at least partially through a
wall of the metal alloy component, the forming of the slot
including forming an angled main body interface in the wall of the
metal alloy component; forming a coupon for coupling with the slot
in the metal alloy component, the coupon having an angled coupon
interface complementing the angled main body interface; and brazing
the coupon to the main body at the slot to form a composite
component.
2. The method of claim 1, wherein the metal alloy component
includes a high-gamma prime alloy or a brittle alloy including:
Rene 125, Rene 80, Rene N5, Rene N4, Rene 108, GTD-111, GTD-444,
Inconel (IN) 738, IN792, MAR-M200, MAR-M247, CMSX-3, CMSX-4,
PWA1480, PWA1483, or PWA1484.
3. The method of claim 1, wherein the metal alloy component is a
previously commissioned component exposed to operation within a
machine.
4. The method of claim 1, wherein the angled main body interface
and the angled coupon interface have an angle between approximately
10 degrees and approximately 45 degrees, as measured from a plane
coincident with an outer surface of the main body.
5. The method of claim 1, wherein the angled main body interface
and the angled coupon interface have an angle between approximately
10 degrees and approximately 25 degrees, as measured from a plane
coincident with an outer surface of the main body.
6. The method of claim 1, wherein the forming of the slot in the
main body includes cutting the metal alloy component, and wherein
forming the coupon includes casting or additively manufacturing the
coupon.
7. The method of claim 1, wherein the main body has an outer
surface, and the coupon has: a larger diameter (LD) spanning the
slot across the outer surface of the main body; and a smaller
diameter (SD) spanning the slot across an inner surface of the main
body, wherein the LD is defined by: LD=((2*Z)/tan .alpha.)+SD
wherein Z=a thickness of the wall and .alpha.=an angle of the
angled main body interface and the angled coupon interface, as
measured relative to a plane coincident with the outer surface of
the main body.
8. The method of claim 1, wherein the angled main body interface
and the angled coupon interface are configured to bear a
predominately shear stress in response to application of tension on
the composite component.
9. The method of claim 1, wherein the composite component includes
a turbomachine component.
10. The method of claim 1, wherein the coupon includes the metal
alloy or a distinct metal alloy from the metal alloy of the metal
alloy component.
11. The method of claim 1, further comprising performing a hot
isostatic pressure (HIP) heat treatment (HT) on the composite
component after the brazing.
12. A method comprising: forming a slot in a main body of a metal
alloy component, the slot extending at least partially through a
wall of the main body, wherein the wall has an inner surface and an
outer surface, the forming of the slot including forming an angled
main body interface in the wall of the main body; forming a coupon
for coupling with the slot in the main body, the coupon having an
angled coupon interface complementing the angled main body
interface, wherein the coupon has: a larger diameter (LD) spanning
the slot across the outer surface of the main body; and a smaller
diameter (SD) spanning the slot across an inner surface of the main
body; and brazing the coupon to the main body at the slot to form a
composite component.
13. The method of claim 12, wherein the LD is defined by:
LD=((2*Z)/tan .alpha.)+SD wherein Z=a thickness of the wall and
.alpha.=an angle of the angled main body interface and the angled
coupon interface, as measured from a plane coincident with the
outer surface of the main body
14. The method of claim 12, wherein the metal alloy component
includes a high-gamma prime alloy or a brittle alloy including:
Rene 125, Rene 80, Rene N5, Rene N4, Rene 108, GTD-111, GTD-444,
Inconel (IN) 738, IN792, MAR-M200, MAR-M247, CMSX-3, CMSX-4,
PWA1480, PWA1483, or PWA1484.
15. The method component of claim 12, wherein the angle a is
between approximately 10 degrees and approximately 45 degrees, as
measured from the plane coincident with the outer surface of the
main body.
16. The method component of claim 12, wherein the angle a is
between approximately 10 degrees and approximately 25 degrees, as
measured from the plane coincident with the outer surface of the
main body.
17. The method component of claim 12, wherein the angled main body
interface and the angled coupon interface are configured to bear a
predominately shear stress in response to application of tension on
the composite component.
18. The method component of claim 12, wherein the composite
component includes a turbomachine component.
19. The method component of claim 12, wherein the coupon includes
the metal alloy or a distinct metal alloy from the metal alloy of
the metal alloy component.
20. A method comprising: forming a slot in a main body of a metal
alloy component, the slot extending at least partially through a
wall of the main body, wherein the wall has an inner surface and an
outer surface, the forming of the slot including forming an angled
main body interface in the wall of the main body; forming a coupon
for coupling with the slot in the main body, the coupon having an
angled coupon interface complementing the angled main body
interface, wherein the coupon has a larger diameter (LD) spanning
the slot across the outer surface of the main body; and a smaller
diameter (SD) spanning the slot across an inner surface of the main
body, wherein the LD is defined by: LD=((2*Z)/tan .alpha.)+SD
wherein Z=a thickness of the wall and .alpha.=an angle of the
angled main body interface and the angled coupon interface, as
measured from a plane coincident with the outer surface of the main
body; and brazing the coupon to the main body at the slot to form a
composite component.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of co-pending U.S. patent
application Ser. No. 15/605,294, filed 25 May 2017, which is
incorporated herein as though fully set forth.
FIELD OF THE INVENTION
[0002] The subject matter disclosed herein relates to manufacturing
and repair of components. More specifically, the subject matter
disclosed herein relates to approaches of manufacturing and/or
repairing components using brazing techniques.
BACKGROUND OF THE INVENTION
[0003] Metal alloys can be particularly useful in industrial
applications. For example, metal alloys are commonly used to form
components within industrial machinery subjected to high
temperatures, pressures and/or stresses over extended periods.
Systems such as turbomachines, dynamoelectric machines, fuel flow
systems, aviation systems, etc. employ metal alloys in their parts.
During the lifespan of these systems, components may require
maintenance and/or repair, which may present particular challenges
in the case of metal alloys. For example, brittle metal alloys or
high-gamma prime alloys can be structurally compromised when
subject to particular types of heat treatment such as welding. This
can make repair and maintenance of components formed from these
alloys particularly challenging. Additionally, forming composite
parts with these types of alloys can be disadvantageous.
BRIEF DESCRIPTION OF THE INVENTION
[0004] Various aspects of the disclosure include a composite
component and methods of forming such a component. In a first
aspect, a method includes: forming a slot in a main body of a metal
alloy component, the slot extending at least partially through a
wall of the metal alloy component, the forming of the slot
including forming an angled main body interface in the wall of the
metal alloy component; forming a coupon for coupling with the slot
in the metal alloy component, the coupon having an angled coupon
interface complementing the angled main body interface; and brazing
the coupon to the main body at the slot to form a composite
component.
[0005] A second aspect of the disclosure includes a composite
component having: a metal alloy component including a main body,
the main body having: a wall having an inner surface and an outer
surface; and a slot extending at least partially through the wall,
the slot including an angled main body interface in the wall; a
coupon coupled with the slot, the coupon having an angled coupon
interface complementing the angled main body interface, wherein the
coupon has a larger diameter (LD) spanning the slot across the
outer surface of the main body; and a smaller diameter (SD)
spanning the slot across an inner surface of the main body, wherein
the LD is defined by: LD=((2*Z)/tan .alpha.)+SD, wherein Z=a
thickness of the wall and .alpha.=an angle of the angled main body
interface and the angled coupon interface, as measured from a plane
coincident with the outer surface of the main body; and a braze
joint coupling the coupon to the main body at the slot.
[0006] A third aspect of the disclosure includes a non-transitory
computer readable storage medium storing code representative of at
least a portion of a composite component, the at least a portion of
the composite component physically generated upon execution of the
code by a computerized additive manufacturing system, the code
including: code representing at least the portion of the composite
component, the composite component including: a metal alloy
component including a main body, the main body having: a wall
having an inner surface and an outer surface; and a slot extending
at least partially through the wall, the slot including an angled
main body interface in the wall; a coupon coupled with the slot,
the coupon having an angled coupon interface complementing the
angled main body interface, wherein the coupon has a larger
diameter (LD) spanning the slot across the outer surface of the
main body; and a smaller diameter (SD) spanning the slot across an
inner surface of the main body, wherein the LD is defined by:
LD=((2*Z)/tan .alpha.)+SD wherein Z=a thickness of the wall and
.alpha.=an angle of the angled main body interface and the angled
coupon interface, as measured from a plane coincident with the
outer surface of the main body; and a braze joint coupling the
coupon to the main body at the slot.
[0007] A fourth aspect of the disclosure includes a method
including: forming a slot in a main body of a metal alloy
component, the slot extending at least partially through a wall of
the main body, wherein the wall has an inner surface and an outer
surface, the forming of the slot including forming an angled main
body interface in the wall of the main body; forming a coupon for
coupling with the slot in the main body, the coupon having an
angled coupon interface complementing the angled main body
interface, wherein the coupon has: a larger diameter (LD) spanning
the slot across the outer surface of the main body; and a smaller
diameter (SD) spanning the slot across an inner surface of the main
body; and brazing the coupon to the main body at the slot to form a
composite component.
[0008] A fifth aspect of the disclosure includes a method
including: forming a slot in a main body of a metal alloy
component, the slot extending at least partially through a wall of
the main body, wherein the wall has an inner surface and an outer
surface, the forming of the slot including forming an angled main
body interface in the wall of the main body; forming a coupon for
coupling with the slot in the main body, the coupon having an
angled coupon interface complementing the angled main body
interface, wherein the coupon has a larger diameter (LD) spanning
the slot across the outer surface of the main body; and a smaller
diameter (SD) spanning the slot across an inner surface of the main
body, wherein the LD is defined by: LD=((2*Z)/tan .alpha.)+SD,
wherein Z=a thickness of the wall and .alpha.=an angle of the
angled main body interface and the angled coupon interface, as
measured from a plane coincident with the outer surface of the main
body; and brazing the coupon to the main body at the slot to form a
composite component.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] These and other features of this disclosure will be more
readily understood from the following detailed description of the
various aspects of the disclosure taken in conjunction with the
accompanying drawings that depict various embodiments of the
disclosure, in which:
[0010] FIG. 1 is a schematic depiction of separated portions of a
composite component according to various embodiments of the
disclosure.
[0011] FIG. 2 is a schematic depiction of an assembled composite
component according to various embodiments of the disclosure.
[0012] FIG. 3 is a flow diagram illustrating processes in forming a
composite component according to various embodiments of the
disclosure.
[0013] FIG. 4 shows a metal alloy component prior to a process
performed according to various embodiments of the disclosure.
[0014] FIG. 5 shows the metal alloy component of FIG. 4 after
forming a slot according to various embodiments of the
disclosure.
[0015] FIG. 6 is a schematic depiction of separated portions of a
composite component according to various embodiments of the
disclosure.
[0016] FIG. 7 shows a distinct schematic view of a portion of the
composite component of FIG. 6.
[0017] FIG. 8 is a schematic depiction of an assembled composite
component according to various embodiments of the disclosure.
[0018] FIG. 9 shows a block diagram of an additive manufacturing
process including a non-transitory computer readable storage medium
storing code representative of one or more portions of the
composite component of FIG. 2 according to embodiments of the
disclosure.
[0019] It is noted that the drawings of the disclosure are not
necessarily to scale. The drawings are intended to depict only
typical aspects of the disclosure, and therefore should not be
considered as limiting the scope of the disclosure. In the
drawings, like numbering represents like elements between the
drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The subject matter disclosed herein relates to manufacturing
and/or repair. More specifically, the subject matter disclosed
herein relates to approaches for forming composite components
including metal alloys, also known as Shear Enabled Regionally
Engineered Facets (SEREF).
[0021] In contrast to conventional approaches, various aspects of
the disclosure include a composite metal component, and methods of
forming such a component. In various embodiments, the composite
metal component has a main body and a coupon filling a slot in the
main body, and the interface between the main body and the coupon
is an angled braze joint. The angled interface between the main
body and the coupon, as opposed to a substantially normal interface
in conventional composite components, can transfer the tensile
stress applied at that interface to predominately shear stress. The
composition of metal alloys, in particular, high-gamma prime alloys
or other brittle alloys, gives these materials significantly
greater shearing strength than tensile strength. As such, these
composite components may be stronger than conventional composite
components formed with normal braze joints between a main body and
a coupon.
[0022] In some particular cases, the angle of the interface between
the main body and the coupon is approximately 10-25 degrees
(measured from surface plane), but could be up to 50 or 60 degrees
in some cases. In other embodiments, the angle of the interface
between the main body and the coupon is approximately 25-35
degrees, and in other cases it is between approximately 35-45
degrees. In various embodiments, the angle of the interface between
the main body and the coupon is defined by an equation which
accounts for the surface area of the interface, the angle of the
interface, and the thickness of the wall of the main body and the
coupon proximate the joint.
[0023] In various embodiments, the composite component can include
a refurbished component, e.g., where the main body is an original
part having gone through field use and the coupon is a replacement
portion of the component. In other cases, the composite component
can include two original parts (either having gone through field
use, or not) joined at an interface, and in other cases, the
composite component can include two replacement parts joined at an
interface.
[0024] In the following description, reference is made to the
accompanying drawings that form a part thereof, and in which is
shown by way of illustration specific embodiments in which the
present teachings may be practiced. These embodiments are described
in sufficient detail to enable those skilled in the art to practice
the present teachings and it is to be understood that other
embodiments may be utilized and that changes may be made without
departing from the scope of the present teachings. The following
description is, therefore, merely illustrative.
[0025] FIG. 1 shows a schematic depiction of a metal alloy
component 10 and a coupon 20 for coupling with metal alloy
component 10. FIG. 2 shows metal alloy component 10 and coupon 20
coupled to form a composite component 30. Also shown in FIG. 2 is a
braze joint 40 (portions shown), coupling metal alloy component 10
and coupon 20 at an interface (further described herein). It is
understood that braze joint 40 can extend across an entirety of the
interface between metal alloy component 10 and coupon 20, or in
some cases, may extend only partially across that interface.
[0026] With reference to FIGS. 1 and 2, composite component 30 can
include metal alloy component 10, which has a main body 50 formed
of a metal alloy. In some case, the metal alloy can include a
brazeable alloy, such as a high-gamma prime alloy or a brittle
alloy. In various embodiments, alloys having a gamma prime
percentage greater than 40% can be well suited for approaches
according to various embodiments of the disclosure, as these alloys
can present challenges in welding. Examples are gamma prime
(.gamma.') precipitation-strengthened nickel-base superalloys,
particular examples of which can include Rene 125, Rene 80, Rene
N5, Rene N4, Rene 108, GTD-111.TM., GTD-444.TM., Inconel (IN)738,
IN792, MAR-M200, MAR-M247, CMSX-3, CMSX-4, PWA1480, PWA1483, and
PWA1484. Each of these alloys has a relatively high gamma prime
(principally Ni3(Al, Ti)) content as a result of containing
significant amounts of aluminum and/or titanium. As noted herein,
these metal alloys can be particularly susceptible to structural
weakening under particular heat treatments such as welding, and may
also be susceptible to failure or undesirable wear under tensile
stress. As such, the configuration of composite component 30 may
help to transfer tensile stress to shear stress proximate braze
joint 40. In some embodiments, coupon 20 includes the same metal
alloy as metal alloy component 10, or a distinct metal alloy. In
some cases, the coupon 20 can include a metal alloy which is more
ductile than the alloy in metal alloy component 10. In various
embodiments, coupon 20 can be formed of (single-crystal, or SD)
Rene N5, (directionally solidified, or DS) Rene 108, and/or (N4) or
(Equiaxed, or EA) Rene 108.
[0027] With continuing reference to FIGS. 1-3, main body 50 can
have a wall 60 with an inner surface 70 and an (opposed) outer
surface 80. In some cases, inner surface 70 and outer surface 80
are merely indicative that these are distinct surfaces proximate
braze joint 40 and coupon 20, as the terms "inner" and "outer" are
not intended to be limiting. Main body 50 can also include a slot
90 extending at least partially through wall 60 (shown extending
entirely through wall 60 in example depiction of FIG. 1). As shown
in FIG. 1, slot 90 can include an angled main body interface (face)
100 in wall 60, described further herein.
[0028] Composite component 30 can also include coupon 20 coupled
with slot 90, where coupon 20 has an angled coupon interface (face)
110 that complements angled main body interface 100. Angled coupon
interface (face) 110 can span between an outer surface 120 and an
inner surface 130 of coupon 20. In various embodiments, the angle
of angled coupon interface 110 is equal or approximately (e.g.,
within margin of measurement error) equal with the angle of angled
main body interface 100, both referred to as angle (.alpha.), as
measured from a plane (P) coincident with outer surface 80 of main
body 50. As shown in FIGS. 1 and 2, coupon 20 can have a taper,
such that it has a larger diameter (LD) spanning slot 90 across
outer surface 80, and a smaller diameter (SD) spanning slot 90
across inner surface 70. In various embodiments LD is defined
by:
LD=((2*Z)/tan .alpha.)+SD (Equation 1)
[0029] Wherein Z=a thickness of wall 60. In some cases, angle
(.alpha.) is between approximately 10 degrees and approximately 60
degrees. However, in other particular embodiments, angle (.alpha.)
is between approximately 10 degrees and approximately 25 degrees.
In other cases, angle (.alpha.) is between approximately 25-35
degrees, and in other cases angle (.alpha.) is between
approximately 35-45 degrees. As noted herein, the angle (.alpha.)
is designed for these particular metal alloys such that proximate
braze joint 40, angled main body interface 100 and angled coupon
interface 110 are configured to bear a predominately shear stress
in response to application of tension on composite component 30. In
some cases, composite component 30 can include a turbomachine
component, such as a combustion component or a gas or steam turbine
component.
[0030] FIG. 3 shows a flow diagram illustrating processes in a
method according to various embodiments. FIGS. 4 and 5 illustrate
some of the processes described with reference to FIG. 3. In
various embodiments, a method can include:
[0031] Process P1: forming slot 90 in main body 50 of a metal alloy
component 10, where slot 90 is formed to extend at least partially
through wall 60 (FIGS. 4 and 5). In various embodiments, forming
slot 90 includes forming angled main body interface 100 in wall 60.
In various embodiments, metal alloy component 10 can include a
previously commissioned component exposed to operation within a
machine, e.g., a turbomachine, dynamoelectric machine or other
machine. In some cases, metal alloy component 10 includes a turbine
bucket, blade or nozzle. It is understood that metal alloy
component 10 can include any machine component, in any of a variety
of industrial or other machines subjected to high temperatures
and/or pressures, e.g., turbomachines, dynamoelectric machines, or
engine systems. In other embodiments, metal alloy component 10 can
include an original equipment component not yet deployed in
operation. In some particular cases, forming slot 90 in main body
50 includes cutting metal alloy component 10, e.g., with a saw or
other machining tool. In other cases, metal alloy component 10 can
be formed as an original component, including slot 90, via
conventional molding, casting, etc., or via additive manufacturing
techniques further described herein.
[0032] Process P2: forming coupon 20 for coupling with slot 90 in
metal alloy component 10, where coupon 20 is formed having angled
coupon interface 110 that complements angled main body interface
100 in metal alloy component 10 (coupon 20 shown in FIG. 1). In
some cases, coupon 20 is formed by casting or other conventional
manufacturing techniques, and in other embodiments, coupon 20 is
formed by additive manufacturing techniques further described
herein. In various embodiments, coupon 20 includes a metal alloy,
e.g., a metal alloy similar to the composition of metal alloy
component 10, or a distinct metal alloy. As noted herein, angled
main body interface 100 and angled coupon interface 110 can be
formed to have angle (a) between approximately 10 degrees and
approximately 45 degrees, as measured from plane (P) coincident
with outer surface 80 of main body 50. It is understood that coupon
20 and slot 90 can be formed to have a range of angles (.alpha.),
larger diameters (LD) and smaller diameters (SD), depending upon
the thickness (Z) of wall 60. In various embodiments, diameters
(LD, SD) will be dictated in part by a portion of metal alloy
component 10 which requires repair. For example, where metal alloy
component 10 is in need of repair, a portion of metal alloy
component 10 is removed (e.g., cut out), and slot 90 is formed to
accommodate coupon 20. In these cases, the dimensions of diameters,
along with thickness (Z) of wall 60, will limit the range of
interface angles (.alpha.).
[0033] Process P3: after forming coupon 20 and slot 90, this
process can include brazing coupon 20 to main body 50 at slot 90 to
form composite component 30 (FIG. 2). In various embodiments,
conventional brazing techniques can be used to form braze joint 40
along angled main body interface 100 and angled coupon interface
110. In various embodiments the brazing temperature may range
between approximately 925 degrees Celsius (C) (approximately 1700
degrees Fahrenheit (F)) and 1260 degrees C. (approximately 2300
degrees F.). In some particular cases, the brazing temperature may
range between approximately 1065 degrees C. (approximately 1950
degrees F.) and approximately 1230 degrees F. (approximately 2250
degrees F.). In some cases, the thickness of the braze joint can be
between approximately 0.0025 millimeters (mm) (approximately 0.1
mils) and approximately 0.05 inches (approximately 2 mils). In some
particular cases, the thickness of the braze joint can be
approximately 0.025 millimeters (mm) (approximately 1 mil) to
approximately 0.1 mm (approximately 4 mils). As noted herein, the
angled main body interface 100 and angled coupon interface 110,
proximate (e.g., contacting or nearly contacting braze joint 40)
are configured to bear a predominately shear stress in response to
application of tension on composite component 30.
[0034] In some particular cases, after forming composite component
30, an additional process can include performing a hot isostatic
pressure (HIP) heat treatment (HT) on composite component 30. This
HIP HT can occur after brazing coupon 20 to main body 50 at slot
90. This HIP HT can include any conventional HIP process known in
the art, including the use of an inert gas (e.g., argon) at an
elevated temperature (e.g., up to approximately 1,400 degrees C.)
and pressure (e.g., up to approximately 300 mega-pascals (MPa)) to
reduce the porosity/increase the density of composite component
30.
[0035] It is understood that the processes described herein can be
performed in any order, and that some processes may be omitted,
without departing from the spirit of the disclosure described
herein.
[0036] While the embodiment of composite component 30 in FIGS. 1
and 2 shows a single coupon 30, it is understood that composite
component 30 can include a plurality of coupons 20 which may
combine to fill slot 90 according to various embodiments of the
disclosure. That is, while a single coupon 20 is shown in FIGS. 1
and 2, it is understood that two or more coupons 20 can be formed
in order to fill slot 90 in composite component 30. In some cases,
a pair of coupons (e.g., similar to coupon 20) can be coupled with
main body 50 at slot 90, e.g., one from each of inner surface 70
and outer surface 80. In these cases, the pair of coupons could
share approximately the same shorter diameter (SD) value, their
longer diameter (LD) value may be slightly different due to the
geometry of composite component 30. These coupons could be coupled
with one another, and/or main body 50, with one or more braze
joints 40.
[0037] In additional embodiments, forming slot 90 in main body 50
can include forming one or more slots 90 from two distinct
directions through wall 60. That is, in various embodiments, one or
more slots 90 may be formed in main body 50 (as described herein)
from one or more surfaces (e.g., inner surface 70, outer surface
80). For example, as shown in the schematic depiction of a metal
alloy component 210 in FIGS. 6 and 7, slots 90 can be formed (as
described herein) from opposing surfaces (e.g., inner surface 70
and outer surface 80), and a plurality of coupons 20 (FIG. 6) can
be formed (as described herein) to couple with slot(s) 90 and form
a composite component 230 (FIG. 8). In some cases, two coupons 20
(FIG. 6) are formed to couple with slots 90 on opposing sides
(e.g., inner surface 70 and outer surface 80) of metal alloy
component 110. Coupons 20 can be coupled with slots 90 as discussed
herein to form another embodiment of a composite component. In
various embodiments, where two slots 90 are formed from opposing
surfaces, those slots 90 may connect to form an aperture 250
through metal alloy component 210, however, in other embodiments,
these slots 90 may remain separated by a portion of wall 60. In
various embodiments, distinct slots 90 can have distinct dimensions
(e.g., as governed by Equation 1), however, in other cases,
distinct slots 90 can be substantially symmetrical with respect to
wall 60. In these embodiments, e.g., with two distinct slots 90
through opposite surfaces 70, 80 of wall 60, the larger diameter
(LD) can be reduced relative to the larger diameter (LD) in
composite component 30, which permits composite component 230 to
have a lesser interface angle (a) (relative to composite component
30), while still being configured to bear a predominately shear
stress in response to application of tension on composite component
230.
[0038] One or more portions of composite component 30 (FIG. 2)
and/or composite component 230 (FIG. 8) may be formed in a number
of ways. In one embodiment, as noted herein, at least a portion of
composite component 30 may be formed by conventional manufacturing
techniques, such as molding, casting, machining (e.g., cutting),
etc. In one embodiment, however, additive manufacturing is
particularly suited for manufacturing at least a portion of
composite component 30 (FIG. 2) and/or composite component 230
(FIG. 8), e.g., metal alloy component 10, metal alloy component 210
and/or coupon 20. As used herein, additive manufacturing (AM) may
include any process of producing an object through the successive
layering of material rather than the removal of material, which is
the case with conventional processes. Additive manufacturing can
create complex geometries without the use of any sort of tools,
molds or fixtures, and with little or no waste material. Instead of
machining components from solid billets of metal (e.g., alloy) or
other material such as plastics and/or polymers, much of which is
cut away and discarded, the only material used in additive
manufacturing is what is required to shape the part. Additive
manufacturing processes may include but are not limited to: 3D
printing, rapid prototyping (RP), direct digital manufacturing
(DDM), selective laser melting (SLM) and direct metal laser melting
(DMLM). In the current setting, DMLM can be beneficial.
[0039] To illustrate an example of an additive manufacturing
process, FIG. 9 shows a schematic/block view of an illustrative
computerized additive manufacturing system 900 for generating an
object 902. In this example, system 900 is arranged for DMLM. It is
understood that the general teachings of the disclosure are equally
applicable to other forms of additive manufacturing. Object 902 is
illustrated as a double walled turbine element; however, it is
understood that the additive manufacturing process can be readily
adapted to manufacture at least a portion of composite component 30
(FIG. 2) and/or composite component 230 (FIG. 8), e.g., metal alloy
component 10, metal alloy component 110 and/or coupon 20. AM system
900 generally includes a computerized additive manufacturing (AM)
control system 904 and an AM printer 906. AM system 900, as will be
described, executes code 920 that includes a set of
computer-executable instructions defining at least a portion of
composite component 30 (FIG. 2) and/or composite component 230
(FIG. 8) to physically generate the object using AM printer 906.
Each AM process may use different raw materials in the form of, for
example, fine-grain powder, liquid (e.g., polymers), sheet, etc., a
stock of which may be held in a chamber 910 of AM printer 906. In
the instant case, at least a portion of composite component 30
(FIG. 2) and/or composite component 230 (FIG. 8) may be made of
metal(s), alloy(s), plastic/polymers or similar materials. As
illustrated, an applicator 912 may create a thin layer of raw
material 914 spread out as the blank canvas from which each
successive slice of the final object will be created. In other
cases, applicator 912 may directly apply or print the next layer
onto a previous layer as defined by code 920, e.g., where the
material is a polymer. In the example shown, a laser or electron
beam 916 fuses particles for each slice, as defined by code 920,
but this may not be necessary where a quick setting liquid
plastic/polymer is employed. Various parts of AM printer 906 may
move to accommodate the addition of each new layer, e.g., a build
platform 918 may lower and/or chamber 910 and/or applicator 912 may
rise after each layer.
[0040] AM control system 904 is shown implemented on computer 930
as computer program code. To this extent, computer 930 is shown
including a memory 932, a processor 934, an input/output (I/O)
interface 936, and a bus 938. Further, computer 930 is shown in
communication with an external I/O device/resource 940 and a
storage system 942. In general, processor 934 executes computer
program code, such as AM control system 904, that is stored in
memory 932 and/or storage system 942 under instructions from code
920 representative of at least a portion of composite component 30
(FIG. 2) and/or composite component 230 (FIG. 8), described herein.
While executing computer program code, processor 934 can read
and/or write data to/from memory 932, storage system 942, I/O
device 940 and/or AM printer 906. Bus 938 provides a communication
link between each of the components in computer 930, and I/O device
940 can comprise any device that enables a user to interact with
computer 940 (e.g., keyboard, pointing device, display, etc.).
Computer 930 is only representative of various possible
combinations of hardware and software. For example, processor 934
may comprise a single processing unit, or be distributed across one
or more processing units in one or more locations, e.g., on a
client and server. Similarly, memory 932 and/or storage system 942
may reside at one or more physical locations. Memory 932 and/or
storage system 942 can comprise any combination of various types of
non-transitory computer readable storage medium including magnetic
media, optical media, random access memory (RAM), read only memory
(ROM), etc. Computer 930 can comprise any type of computing device
such as a network server, a desktop computer, a laptop, a handheld
device, a mobile phone, a pager, a personal data assistant,
etc.
[0041] Additive manufacturing processes begin with a non-transitory
computer readable storage medium (e.g., memory 932, storage system
942, etc.) storing code 920 representative of at least a portion of
composite component 30 (FIG. 2) and/or composite component 230
(FIG. 8). As noted, code 920 includes a set of computer-executable
instructions defining outer electrode that can be used to
physically generate the tip, upon execution of the code by system
900. For example, code 920 may include a precisely defined 3D model
of outer electrode and can be generated from any of a large variety
of well-known computer aided design (CAD) software systems such as
AutoCAD.RTM., TurboCAD.RTM., DesignCAD 3D Max, etc. In this regard,
code 920 can take any now known or later developed file format. For
example, code 920 may be in the Standard Tessellation Language
(STL) which was created for stereolithography CAD programs of 3D
Systems, or an additive manufacturing file (AMF), which is an
American Society of Mechanical Engineers (ASME) standard that is an
extensible markup-language (XML) based format designed to allow any
CAD software to describe the shape and composition of any
three-dimensional object to be fabricated on any AM printer. Code
920 may be translated between different formats, converted into a
set of data signals and transmitted, received as a set of data
signals and converted to code, stored, etc., as necessary. Code 920
may be an input to system 900 and may come from a part designer, an
intellectual property (IP) provider, a design company, the operator
or owner of system 900, or from other sources. In any event, AM
control system 904 executes code 920, dividing at least a portion
of composite component 30 (FIG. 2) and/or composite component 230
(FIG. 8) into a series of thin slices that it assembles using AM
printer 906 in successive layers of liquid, powder, sheet or other
material. In the DMLM example, each layer is melted to the exact
geometry defined by code 920 and fused to the preceding layer.
Subsequently, the portion(s) of composite component 30 (FIG. 2)
and/or composite component 230 (FIG. 8) may be exposed to any
variety of finishing processes, e.g., minor machining, sealing,
polishing, assembly to other part of the igniter tip, etc.
[0042] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to practice the invention, including making and
using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they have structural elements that do not differ
from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal languages of the claims.
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