General Electric Company

Ge Infrastructure Technology, LLC

Sathyanarayanan Raghavan

Ananda Barua

Changjie Sun

Neelesh Nandkumar Sarawate

Arunkumar Natarajan

Vadim Bromberg

Prabhjot Singh

Arvind Rangarajan

Ken Ivcar Salas Nobrega

Kenneth Martin Lewis

Zachary John Snider

Larry Steven Rosenzweig

Dean Michael Robinson

Daniel Jason Erno

Brendon James Leary

Arun Karthi Subramaniyan

Jinjie Shi

Raymond Floyd Martell

Evan John Dozier

Gautam Suresh Naik

Claire Fridtjof Lang

Yu Mukherjee

Joseph Block

Meghan J Borz

An additively manufactured heat exchanger assembly formed of a lattice structure with a plurality of shell structure unit cells. The plurality of shell structure unit cells each include at least one junction and a plurality of connectors coupled to the junction. The junction and the plurality of connectors form an integral surface. The heat exchanger assembly further includes a fluid boundary wall defined within the lattice structure to define an active heat exchanger portion. The active heat exchanger portion includes at least one working fluid contained within the fluid boundary wall. Further, at least one of the plurality of shell structure unit cells extends through and beyond the fluid boundary wall. Further, the shell structure unit cells may be isotropic.

Heat exchanger assembly formed of a lattice structure with a plurality of shell structure unit cells

Turbine shroud

An industrial asset item definition data store may contain at least one electronic record defining the industrial asset item. An automated support structure creation platform may include a support structure optimization computer processor. The automated support structure optimization computer processor may be adapted to automatically create support structure geometry data associated with an additive printing process for the industrial asset item. The creation may be performed via an iterative loop between a build process simulation engine and a topology optimization engine.

Optimizing support structures for additive manufacturing

A method, medium, and system to receive a specification defining a model of a part to be produced by an additive manufacturing (AM) process; execute an AM simulation on the model of the part to determine a prediction of thermal distortions to the part; execute a topology optimization (TO) to create TO supports that counteract the predicted thermal distortions; generate at least one rule-based support based on a geometry of the part to interface with the part at one or more regions other than the TO supports; combining the TO supports and the at least one rule-based support to generate a set of hybrid supports; save a record of the set of hybrid supports; and transmit the record of the set of hybrid supports to an AM controller to control an AM system to generate a support structure for an AM production of the part.

Hybrid support structures for additively printed parts

A method and system to receive a specification defining a model of a part to be produced by an additive manufacturing (AM) process; define a design space to enclose the part and a support structure for the part, the support structure to support the part and printed with the part during the AM process; execute an iterative topology optimization(TO) based at least in part on the specification for the part and the defined design space, to generate a TO support structure that counteracts predicted gravity-based distortions during the AM process; save a record of the generated TO support structure; and transmit the record of the TO support structure to an AM controller, the AM controller to control an AM system to generate an instance of the part and the TO support structure based on the record.

Optimized support design for sintering parts with complex features

A method, medium, and system to execute an additive manufacturing (AM) simulation on a model of a part; determine, based on the AM simulation, a prediction of a temperature and displacement distribution in the part at a particular time in the AM process; apply the predicted temperature and displacement distributions in the part as a boundary conditions on a support design space to determine a temperature distribution throughout the support design space; and execute a thermal-structural topology optimization based on the determined temperature and displacement distributions throughout the support design space to determine a distribution of material in the design space for a thermal support structure to interface with the part that optimally reduces a thermal gradient in the part with a minimum of material and results in the generation of an optimized AM support structure.

Multiphysics automated support generation for additively manufactured components

A method includes assembling a setter assembly onto a binder-jet printed part, wherein the setter assembly includes a base, a top setter, a bottom setter positioned between the base and the top setter, and a support pin extending between the base and the top setter having a terminus that abuts an inward facing surface of the top setter, such that at least portion of the binder-jet printed part is nested between the top setter and the bottom setter. The method includes heating the binder-jet printed part and the setter assembly to debind or sinter the binder-jet printed part, wherein a length of the support pin decreases in response to the heating to move the top setter toward the base.

Setter assembly for additive manufacturing

A binder jet printed article includes a part having a top portion, a bottom portion, and an overhang extending from the top portion and a support structure formed around the part that may block deformation of the part during post-printing thermal processing. The support structure includes a skid positioned adjacent to the bottom portion that may support the part, a first plurality of support features disposed along an outer perimeter of the skid, and a second plurality of support features disposed on the top portion of the printed part. The first and second plurality of support features form a lattice around the printed part such that the printed part is nested within the support structure.

Method and system for additive manufacturing

A turbine shroud for turbine systems may include a unitary body including a support portion coupled directly to a turbine casing of the turbine system, and forward hook(s) and aft hook(s) formed integral with the support portion. The unitary body may also include an intermediate portion formed integral with and extending from the support portion. The intermediate portion may include a non-linear segment extending from the support portion, and a forward segment formed integral with the non-linear segment. The forward segment of the intermediate portion may be positioned axially upstream of the forward hook(s). Additionally the unitary body may include a seal portion formed integral with the intermediate portion, opposite the support portion. The seal portion may include a forward end formed integral with the intermediate portion. The forward end may be positioned axially upstream of the forward hook(s).

Unitary body turbine shroud for turbine systems

A setter assembly for use in additive manufacturing a binder-jet part includes a base, a first setter component having a first setter portion and a second setter portion that may be removably coupled to the first setter portion and a plurality of protrusions disposed on and extending away from a surface of the base. The plurality of protrusions may align the base with the first setter component and enable coupling of the first setter component to the base. The setter assembly also includes a second setter component positioned between the base and the first setter component. The second setter component is disposed on the surface and the first setter component, the second setter component, and the base can be assembled onto a printed part such that at least a portion of the printed part is nested between the first setter component and the second setter component.

An airfoil for use in a turbomachine includes a pressure sidewall and a suction sidewall coupled to the pressure sidewall. The suction sidewall and the pressure sidewall define a leading edge and a trailing edge, the leading edge and the trailing edge define a chord distance. The airfoil includes a tip portion extending between the pressure sidewall and the suction sidewall. The tip portion includes a planar section and a recessed section. The recessed section extends adjacent to the planar section such that a thickness of the planar section is less than a thickness of the airfoil. The recessed section is offset a predetermined distance from the leading edge and the trailing edge along the chord distance.

Airfoil tip geometry to reduce blade wear in gas turbine engines

Coating systems for components of a gas turbine engine, such as a compressor blade tip, are provided. The coating system can include an abradable material disposed along the compressor blade tip and may be used with a bare compressor casing. The abradable coating is softer than the compressor casing and can reduce the overall rub ratio thereby increasing the lifetime of the compressor blade and casing. Methods are also provided for applying the coating system onto a compressor blade.

Abradable coating composition for compressor blade and methods for forming the same

Coating systems for components of a gas turbine engine, such as a compressor blade tip, are provided. The coating system can include a ceramic material disposed along the compressor blade tip and may be used with a bare compressor casing. The ceramic coating is harder than the bare compressor casing and can reduce the rub ratio thereby increasing the lifetime of the compressor blades. Methods are also provided for applying the coating system onto a compressor blade.

Ceramic coating compositions for compressor blade and methods for forming the same

An airfoil for use in a turbomachine includes a pressure sidewall and a suction sidewall coupled to the pressure sidewall. The suction sidewall and the pressure sidewall define a leading edge and an opposite trailing edge. The leading edge and the trailing edge define a chord distance. The airfoil further includes a root portion, and a tip portion. The tip portion extends between the pressure sidewall and the suction sidewall such that the tip portion is substantially perpendicular to each sidewall. The tip portion includes at least one planar section and at least one oblique section that forms a recess within the tip portion. The at least one oblique section extends from the at least one planar section towards the root portion along the chord distance. The tip portion is configured to reduce airfoil wear during contact with a surrounding casing.

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Ballston Lake, NY, United States of America

Sathyanarayanan Raghavan