SUPPORT STRUCTURE FOR LINEAR FRICTION WELDING

A method and apparatus for fixturing an airfoil stub during linear friction welding are described. Critical clamping support structures are manufactured by a direct digital manufacturing process such as direct metal laser sintering to minimize time and expense of the process. 1. A method of attaching an airfoil to an airfoil stub of an integrally bladed rotor , the method comprising:forming first and second alloy clamping support structures produced by a direct digital manufacturing process;positioning the first clamping support structure in contact with a leading edge region of the airfoil stub;positioning the second clamping support structure in contact with a trailing edge region of the airfoil stub;applying clamping force to the first and second clamping support structures;contacting the airfoil stub with the airfoil; andoscillating the airfoil with respect to the airfoil stub to frictionally weld the airfoil to the stub.2. The method of claim 1 , wherein the first clamping support structure includes a first base and a first collar and wherein the second clamping support structure includes a second base and a second collar.3. The method of claim 2 , wherein the first collar has a receptacle with an inner surface contour about identical to an outer surface contour of the leading edge region of the airfoil stub and the second collar has a receptacle with an inner surface contour about identical to an outer surface contour of the trailing edge region of the airfoil stub.4. The method of claim 3 , wherein the first and second collars comprise a metal alloy substantially identical to a metal alloy that forms the airfoil stub.5. The method of claim 4 , wherein the first and second bases are formed of a metal alloy the same as or different from the metal alloy of the first and second collars.6. The method of claim 3 , wherein the first and second bases do not contact the airfoil stub.7. The method of claim 1 , wherein the first and second clamping support structures ...

Method of Manufacturing Complex Shaped Component

A method of forming a complex shaped part includes the steps of forming a polymer core by an additive manufacturing process. A metal is plated about surfaces of the polymer core, and the polymer core is removed, leaving hollows within a plate core. Metal powder is deposited within the hollows. An integral blade rotor is also disclosed. 1. A method of forming a complex shaped part including the steps of:(a) forming a polymer core by an additive manufacturing process;(b) plating a metal about surfaces of said polymer core;(c) removing said polymer core leaving hollows within a plating core; and(d) depositing metal powder within said hollows.2. The method as set forth in claim 1 , wherein a consolidation step occurs after the depositing of the metal powder into the hollows.3. The method as set forth in claim 2 , wherein the consolidation process is a hot isostatic pressurization process.4. The method as set forth in claim 1 , wherein said plating metal is a nickel based material.5. The method as set forth in claim 4 , wherein said metal powder is also a nickel based material.6. The method as set forth in claim 1 , wherein said complex shaped component is an integrally bladed rotor claim 1 , and said integrally bladed rotor having a hub and radially outwardly extending airfoils with said hollows being formed in both said hub and said airfoils.7. The method as set forth in claim 1 , wherein said plating occurs utilizing electroplating.8. The method as set forth in claim 1 , wherein said polymer core is removed in a furnace.9. The method of claim 8 , wherein said polymer core is melted claim 8 , disintegrated or evaporated in said furnace.10. The method as set forth in claim 1 , wherein said additive manufacturing process includes one of selective lithography analysis claim 1 , selective laser sintering claim 1 , fusion deposition of material or laminated object manufacturing.11. The method of wherein a computer model of the complex shaped component is utilized to control ...

ABRADABLE SEAL INCLUDING AN ABRADABILITY CHARACTERISTIC THAT VARIES BY LOCALITY

An abradable seal for a gas turbine engine includes a seal body that has a seal side and a non-seal side. The seal body includes an abradability characteristic that varies by locality. 1. An abradable seal for a gas turbine engine , comprising:a seal body having a seal side and a non-seal side, the seal body including an abradability characteristic that varies by locality.2. The abradable seal as recited in claim 1 , wherein the abradability characteristic is selected from the group consisting of a graded composition claim 1 , a graded porosity claim 1 , a non-uniform geometric cell structure and combinations thereof.3. The abradable seal as recited in claim 1 , wherein the abradability characteristic is a graded composition.4. The abradable seal as recited in claim 1 , wherein the abradability characteristic is a graded porosity.5. The abradable seal as recited in claim 1 , wherein the abradability characteristic is a non-uniform geometric cell structure.6. The abradable seal as recited in claim 1 , wherein the abradability characteristic is a graded composition that varies in an amount of nickel between the seal side and the non-seal side.7. The abradable seal as recited in claim 1 , wherein the abradability characteristic is a graded porosity that varies in a percentage of porosity from a relatively low porosity at the non-seal side to a relatively high porosity at the seal side.8. The abradable seal as recited in claim 7 , wherein the relatively low porosity is 0-5% and the relatively high porosity is 40-60%.9. The abradable seal as recited in claim 1 , wherein the abradability characteristic is a non-uniform geometric cell structure including a cell center-to-center dimension that varies by locality.10. The abradable seal as recited in claim 1 , wherein the seal body includes a plurality of cells defined between cell walls claim 1 , the cell walls being made of a first material claim 1 , and cell cores in the cells claim 1 , the cell cores being made of a ...

WORK PIECE HAVING SELF-SUPPORTING GUSSET AND METHOD RELATED THERETO

A structure includes a first body section that has a wall that spans in a vertical direction. The wall has a relatively thin thickness with respect to a length and a width of the wall. A second body section is arranged next to, but spaced apart from, the first body section. A gusset connects the first body section and the second body section. The gusset extends obliquely from the wall of the first body section with respect to the vertical direction such that the gusset is self-supporting. The first body section has a geometry that corresponds to an end-use component exclusive of the gusset. 1. A structure comprising:a first body section including a wall spanning in a vertical direction and having a relatively thin thickness with respect a length and a width of the wall;a second body section next to, but spaced apart from, the first body section; anda gusset connecting the first body section and the second body section, the gusset extending obliquely from the wall of the first body section with respect to the vertical direction such that the gusset is self-supporting, and the first body section having a geometry corresponding to an end-use component exclusive of the gusset.2. The structure as recited in claim 1 , wherein the first body section is an airfoil.3. The structure as recited in claim 1 , where the first body section and the second body section are airfoils.4. The structure as recited in claim 1 , wherein the gusset extends at an angle of 45°±5° with respect to the vertical direction.5. The structure as recited in claim 1 , wherein the gusset extends at an angle of no greater than 70° with respect to the vertical direction.6. The structure as recited in claim 1 , wherein the gusset includes a first section and a second section oriented perpendicularly to the first section.7. The structure as recited in claim 6 , wherein the first section is directly connected to the first body section and the second section is directly connected to the second body section.8. ...

TURBINE ENGINE AND TURBINE ENGINE COMPONENT WITH COOLING PEDESTALS

A turbine engine component includes a surface to be cooled by a flow of cooling air and a plurality of pedestals projecting from the surface to be cooled. At least one of the pedestals includes a pedestal surface oriented such that a ray normal to the pedestal surface and directed away from the pedestal surface intersects a line defined by an intersection between the surface to be cooled and the pedestal. 1. A turbine engine component comprising:a surface to be cooled by a flow of cooling air; anda plurality of pedestals projecting from the surface to be cooled, at least one of the pedestals including a pedestal surface oriented such that a ray normal to the pedestal surface and directed away from the pedestal surface intersects a line defined by an intersection between the surface to be cooled and the pedestal.2. The component of claim 1 , wherein the plurality of pedestals and the surface to be cooled are formed as a single piece.3. The component of claim 2 , wherein the plurality of pedestals and the surface to be cooled are formed of a high-temperature metal.4. The component of claim 1 , wherein the plurality of pedestals and the surface to be cooled are formed by direct digital manufacturing technology from metal alloy powder.5. The component of claim 4 , wherein the direct digital manufacturing technology includes at least one of direct metal laser sintering claim 4 , electron beam sintering claim 4 , and selected laser sintering.6. The component of claim 5 , wherein the direct digital manufacturing technology includes direct metal laser sintering.7. The component of claim 1 , wherein the pedestal is symmetrical about a pedestal axis perpendicular the surface to be cooled.8. The component of claim 7 , wherein sections of the pedestal perpendicular to the pedestal axis are one of ellipses and parallelograms.9. The component of claim 1 , wherein each pedestal of the plurality of pedestals projecting from the surface to be cooled includes a pedestal surface ...

BUILD PLATFORMS FOR ADDITIVE MANUFACTURING

An additive manufacturing apparatus is disclosed which includes a movable platform. The movable platform has a plurality of fasteners and an upper surface, and at least one indexing feature. An upper surface of a movable platform is coupled with an indexing device such that movement of either one corresponds to movement of the other. The indexing device is capable of receiving a compatible indexing device from a manufacturing 1. A method of manufacturing an object , the method comprising:attaching a movable platform to an additive manufacturing apparatus;indexing the relative position of the movable platform to the additive manufacturing apparatus;additively manufacturing a support structure on the movable platform with the additive manufacturing apparatus;additively manufacturing an object on the support structure with the additive manufacturing apparatus;transferring the movable platform, the support structure, and the object to a subtractive manufacturing apparatus;indexing the relative position of the movable platform to the subtractive manufacturing apparatus;subtractively manufacturing the object; andseparating the object from the movable platform.2. The method of wherein the additive manufacturing apparatus is one of the group consisting of:a direct metal laser sintering apparatus;a selective laser sintering apparatus;a laser engineered net shaping apparatus; andan electron beam melting apparatus.3. The method of claim 1 , wherein the support structure is a honeycomb mesh.4. The method of claim 1 , wherein separating the object from the movable platform includes cutting the object from the support structure and cutting the support structure from the movable platform.5. The method of claim 1 , wherein indexing the relative position of the movable platform to the additive manufacturing apparatus includes indexing a surface of the movable platform on which the object will be manufactured.6. The method of claim 5 , wherein indexing the relative position of the ...

Additive manufacturing using partially sintered layers

The invention relates to an additive manufacturing apparatus and method. According to the invention, an additive manufacturing apparatus includes a material supply system. The material supply system delivers layers of partially sintered pulverant material to an additive manufacturing device. 1. An additive manufacturing apparatus comprising:a supply system for delivering a layer of a partially sintered pulverant material to an additive manufacturing station; anda selective heating system that is capable of directing a focused radiation beam onto the layer at the station to sinter selected regions of the based upon data that defines a slice of an object to be manufactured.2. The additive manufacturing apparatus of claim 1 , wherein the supply system includes two rollers claim 1 , at least one of which is heated.3. The additive manufacturing apparatus of claim 1 , and further comprising a hopper capable of delivering the pulverant material to the supply system.4. The additive manufacturing apparatus of claim 1 , wherein the pulverant material may include more than one distinct material.5. The additive manufacturing apparatus of claim 1 , wherein the layer is a fully-dense claim 1 , pre-fabricated sheet of sintered pulverant material.6. The additive manufacturing apparatus of claim 1 , and further comprising a guiding system that is capable of transferring the layer from the supply system to the station.7. The additive manufacturing apparatus of claim 1 , wherein the guiding system is heated.8. The additive manufacturing apparatus of claim 1 , wherein the focused radiation beam is a laser.9. The additive manufacturing apparatus of claim 1 , wherein the pulverant material is a high temperature superalloy.10. The additive manufacturing apparatus of claim 8 , wherein the laser is a CO2 laser.11. The additive manufacturing apparatus of claim 1 , wherein the focused radiation beam is an electron beam.12. The additive manufacturing apparatus of claim 8 , further comprising a ...

Work piece having self-supporting gusset and method related thereto

A powder-derived, non-finished work piece includes a first body section that has a wall that spans in a vertical direction. The wall has a relatively thin thickness with respect to a length and a width of the wall. A second body section is arranged next to, but spaced apart from, the first body section. A gusset connects the first body section and the second body section. The gusset extends obliquely from the wall of the first body section with respect to the vertical direction such that the gusset is self-supporting. The first body section has a geometry that corresponds to an end-use component exclusive of the gusset.

USAGE OF A WITNESS MARK TO DISTINGUISH SUPPORT STRUCTURE FROM PART

A component includes a support structure made with an additive manufacturing process with a first end and a second end, and an object made with an additive manufacturing process with a first end and a second end, where the first end of the object is attached to the second end of the support structure. A cross-sectional area of the first end of the object is larger than a cross-sectional area of the second end of the support structure. A method of making an object, the method includes manufacturing a support structure with an additive manufacturing process. An object is manufactured on top of and connected to the support structure with an additive manufacturing process, wherein there is a witness mark created between the support structure and the object. The witness mark is identified. The object is separated from the support structure along the witness mark. 1. A component comprising:a support structure made with an additive manufacturing process with a first end and a second end; andan object made with an additive manufacturing process with a first end and a second end, where the first end of the object is attached to the second end of the support structure;wherein a cross-sectional area of the first end of the object is larger than a cross-sectional area of the second end of the support structure.2. The component of claim 1 , wherein the object can be separated from the support structure after manufacturing.3. The component of claim 2 , wherein the support structure is a sacrificial part that can be discarded.4. The component of claim 1 , wherein the support structure is capable of support a plurality of objects.5. The component of claim 1 , wherein the object is an airfoil.6. The component of claim 1 , wherein the support structure has a uniform angle of support to minimize shrinkage stresses on the object during manufacturing.7. An additively manufactured component comprising:an object with a proximate end and a distal end, wherein the proximate end is attached ...

Method of and apparatus for attaching by linear friction welding an airfoil to an airfoil stub using clamping supports

A method and apparatus for fixturing an airfoil stub (14) during linear friction welding are described. Critical clamping support structures (32, 42) are manufactured by a direct digital manufacturing process such as direct metal laser sintering to minimize time and expense of the process.

Turbine engine and turbine engine component with improved cooling pedestals

Usage of a witness mark to distinguish support structure from part

A component includes a support structure made with an additive manufacturing process with a first end and a second end, and an object made with an additive manufacturing process with a first end and a second end, where the first end of the object is attached to the second end of the support structure. A cross-sectional area of the first end of the object is larger than a cross-sectional area of the second end of the support structure. A method of making an object, the method includes manufacturing a support structure with an additive manufacturing process. An object is manufactured on top of and connected to the support structure with an additive manufacturing process, wherein there is a witness mark created between the support structure and the object. The witness mark is identified. The object is separated from the support structure along the witness mark.

Work piece having self-supporting gusset and method related thereto

A powder-derived, non-finished work piece includes a first body section that has a wall that spans in a vertical direction. The wall has a relatively thin thickness with respect to a length and a width of the wall. A second body section is arranged next to, but spaced apart from, the first body section. A gusset connects the first body section and the second body section. The gusset extends obliquely from the wall of the first body section with respect to the vertical direction such that the gusset is self-supporting. The first body section has a geometry that corresponds to an end-use component exclusive of the gusset.