Hamilton Sundstrand Corporation

Raytheon Technologies Corporation

Rtx Corporation

Collins Engine Nozzles, Inc.

Other

Delavan Inc.

David W Morganson

Lawrence A Binek

Brendan T Gustafson

Diana Giulietti

Brian A Fisher

Jesse R Boyer

Tommy Skiba

Amit Surana

Michael Walter Bennett

Rebecca L Runkle

Jason J Purdy

Tom Skiba

Eric M Raffia

Jason Purdy

Eklou E Hiheglo

An additively manufactured attritable engine includes a compressor section, a combustion section, a turbine section, and an engine case wall, which surrounds the compressor section, the combustion section, and the turbine section. The engine case wall includes a first cavity embedded in the engine case wall that defines an injector that is in fluid communication with the combustion section. The engine case wall includes at least one second cavity embedded within the engine case wall and defines at least one cooling channel that is in thermal communication through the engine case wall with the injector.

Cooling fuel injector system for an attritable engine

A system for additive manufacturing includes a build chamber including a sidewall and a build plate cooperating to define a build volume, wherein the build chamber is configured to house a part and unfused feedstock powder during a build. An energy source is mounted for movement relative to the build chamber, wherein the energy source is configured to selectively sinter the feedstock powder. A recoater is mounted for movement relative to the build chamber, wherein the recoater is configured to deposit successive layers of the feedstock powder for sintering to the part. A rotational actuator is in operable communication with the build chamber and the recoater configured to rotate the build chamber relative to the recoater.

Rotating relative recoater and part orientation

In accordance with at least one aspect of this disclosure, a method can include selectively sintering at least a portion of a part and one or more indexing features onto a build plate disposed in a build area of a feedstock powder bed, determining an actual orientation of the part and the build plate relative to a recoater prior to recoating, storing the actual orientation of the part and the build plate relative to the recoater, comparing the actual orientation of the part and the build plate relative to the recoater with a predicted orientation, and recoating the build area with feedstock powder if the actual orientation of the part and the build plate relative to the recoater matches the predicted orientation to achieve a predetermined build quality for a respective layer of the part.

A method of manufacturing an additively manufactured component may comprise operating an additive manufacturing machine to form a first structure including an elongate portion having a blind design surface, operating the additive manufacturing machine to form a removal tool proximate the blind design surface, wherein the blind design surface and the removal tool are at least partially enclosed by and in contact with a support material, and translating the removal tool along the blind design surface to separate a portion of the support material from the blind design surface.

Systems and methods for support material removal

A system for depowdering additively manufactured parts includes a deflection plate, a hammer device mounted to a first side of the deflection plate, and a mounting plate operatively connected to a second side of the deflection plate relative to the hammer device, the mounting plate being configured for rotation relative to the deflection plate.

Two-axis depowdering

A unitized build assembly for a gas turbine engine includes an exhaust duct, a hot section with a locking structure and including a combustor and turbine section. The hot section at least partially circumferentially surrounds the exhaust duct. The build assembly includes a compressor section with an interface structure and is proximal to the hot section. The hot section at least partially circumferentially surrounds at least part of the compressor section and the locking structure is configured to engage the interface structure to limit movement of the hot section relative to the compressor section.

Unitized manufacturing of a gas turbine engine

Disclosed is a system for depowdering a workpiece formed from a reactive powder by an additive manufacturing process. The system includes a powder removal enclosure, an inert gas source, a sealed ultrasonic transducer, an oxygen sensor, and a controller coupled to the sealed ultrasonic transducer and the oxygen sensor. The controller is configured to perform a plurality of operations including monitoring the oxygen sensor to observe an oxygen level within the powder removal enclosure as an inert gas from the inert gas source displaces a gas environment within the powder removal enclosure, and applying electrical power to the sealed ultrasonic transducer within the powder removal enclosure to ultrasonically remove a residual amount of the reactive powder from the workpiece based on determining that the oxygen level within the powder removal enclosure is below a minimum oxygen level threshold.

Powder removal from a printed workpiece

A powder removal fixture includes a mounting arm extending along and rotatable about a mounting arm axis, at least one pneumatic knocker mounted to the mounting arm via a strike plate, and configured to impact the strike plate, and a build plate attachment mechanism disposed on the mount bar, and configured to receive a build plate having an at least partially formed component.

High amplitude pneumatic impact for powder removal in additive manufacturing

A system includes an enclosed laser powder bed fusion (LPBF) containment volume. A powder drain is included below the containment volume configured to receive powder dropping from the containment volume by force of gravity. A valve below the powder drain is configured to allow passage with the valve in an open state of unfused powder from the drain into a powder collection volume separated from the containment volume by the valve, and prevent passage of powder from the drain into the collection volume with the valve in a closed state. A source of wetting agent is in fluid communication with the powder collection volume for capturing powder in the collection volume by wetting the powder. A moisture trap is operatively connected to the drain above the valve and is configured to capture moisture to prevent moisture from the collection volume migrating into the containment volume.

Powder removal

A method for inspecting a component made using an additive manufacturing process, the component having an internal conduit, is disclosed. In various embodiments, the method includes the steps of: attaching a fluid-blocking header to the component, the fluid-blocking header having an internal conformal surface configured to mate with an external conformal surface of the component; introducing a plugging media into the internal conduit; activating the fluid-blocking header to freeze the plugging media in a vicinity of the fluid-blocking header; pressurizing the internal conduit of the component; and analyzing a fluid flow characteristic at an outlet of the component to assess an occurrence of a blockage within the internal conduit.

Apparatus and method for testing additively manufactured engine components

An additively manufactured attritable engine includes a compressor section, a combustion section, a turbine section, and an engine case wall, which surrounds the compressor section, the combustion section, and the turbine section. The engine case wall includes a first cavity embedded in the engine case wall that defines an injector that is in fluid communication with the combustion section. The engine case wall includes a second cavity embedded within the engine case wall and defines a fuel feed passage that is in thermal communication through the exterior surface of the engine case wall.

Fuel feed passages for an attritable engine

A method of manufacturing a turbine vane within an engine case includes additively manufacturing a combustor liner within an engine case, additively manufacturing a support structure attached to the combustor liner at a radially distal position, and additively manufacturing the turbine vane attached to the support structure at an inwardly adjacent position to the radially distal position.

Support structure for a turbine vane of a gas turbine engine

A gas knife system for an additive manufacturing system can include one or more gas delivery members configured to move relative to a build area of the additive manufacturing system, and an inlet conduit configured to supply gas to the one or more gas delivery members while the one or more gas delivery members are moved relative to the build area. The system can also include one or more gas collection members configured to move relative to the build area of the additive manufacturing system, and an outlet conduit configured collect gas from the one or more gas collection members while the one or more gas collection members move relative to the build area.

Air knife systems

An additive manufacturing device includes a build platform. A recoater is operatively connected to the build platform to move relative to the build platform to coat unfused powder onto a build on the build platform. The recoater includes a recoater mount defining a length-wise receptacle therein, and a recoater blade seated in the receptacle. A blade reel system is operatively connected to the recoater to replace the recoater blade in the receptacle during a build on the build platform.

Growing community of inventors

Marlborough, CT, United States of America

David W Morganson