阅读说明：本技术 包括一体形成的通路、通道和导管的增材制造的部件及其形成方法 (Additive manufactured components including integrally formed passageways, channels, and conduits and methods of forming the same ) 是由 扎卡里·约翰·斯奈德 迈克尔·斯科特·佐登 迈克尔·罗伯特·贝里 于 2020-10-28 设计创作，主要内容包括：本发明题为“包括一体形成的通路、通道和导管的增材制造的部件及其形成方法”。本发明提供了增材制造的部件,该增材制造的部件包括整体式主体。该部件可包括具有部件节段的整体式主体。该部件节段可包括至少部分地延伸穿过部件节段的至少一个通路。该整体式主体还可包括与部件节段一体形成的补充节段。该补充节段可设置在部件节段的通路上,并且可包括至少部分地延伸穿过补充节段的通道。该通道可与部件节段的通路流体连通。另外,整体式主体可包括定位在部件节段和补充节段内的过渡导管。过渡导管可在部件节段的通路与补充节段的通道之间延伸,以流体联接通路和通道。(The invention provides an additive manufactured component including integrally formed passageways, channels and conduits and a method of forming the same. The invention provides an additively manufactured component comprising a monolithic body. The component may include a monolithic body having component segments. The component segment may include at least one passage extending at least partially through the component segment. The monolithic body may also include a supplemental segment integrally formed with the component segment. The supplemental segment may be disposed on the passage of the component segment and may include a channel extending at least partially through the supplemental segment. The channel may be in fluid communication with the passage of the component segment. Additionally, the monolithic body may include a transition duct positioned within the component segment and the supplemental segment. A transition conduit may extend between the passage of the component segment and the channel of the supplemental segment to fluidly couple the passage and the channel.)

1. A component (200), the component comprising:

a monolithic body (102,202,302) comprising:

a component segment (104,204,304), the component segment (104,204,304) comprising:

at least one passage (108) extending at least partially through the component segment (104,204,304), the at least one passage (108) including an opening (110,220B) having a first size;

a supplemental segment (206) integrally formed with the component segment (104,204,304), the supplemental segment (206) disposed on the at least one passage (108) of the component segment (104,204,304) and comprising:

a channel (118,2018B,218A) extending at least partially through the supplemental segment (206), the channel (118,2018B,218A) in fluid communication with the at least one passage (108) of the component segment (104,204, 304); and

a transition conduit (124,224A) positioned within the component segment (104,204,304) and the supplemental segment (206), the transition conduit (124,224A) extending between the at least one passage (108) of the component segment (104,204,304) and the channel (118,2018B,218A) of the supplemental segment (206) to fluidly couple the at least one passage (108) and the channel (118,2018B, 218A).

2. The component (200) of claim 1, wherein the transition duct (124,224A) includes a second dimension that is greater than the first dimension of the opening (110,220B) of the at least one passage (108) of the component segment (104,204, 304).

3. The component (200) of claim 2, wherein the at least one passage (108) comprises:

a first passage (208A) extending at least partially through the component segment (104,204,304), the first passage (208A) including a first opening (220A) having the first size,

wherein the channel (118,2018B,218A) of the supplemental segment (206) is in fluid communication with the first passage (208A); and

a second passage (208,208B) extending at least partially through the component segment (104,204,304), the second passage (208,208B) including a second opening (210B) having a third size.

4. The component (200) of claim 3, wherein the supplemental segment (206) is disposed over the second opening (210B) of the second passageway (208,208B), and the supplemental segment (206) further comprises:

a second channel (218B,318B) extending at least partially through the supplemental segment (206) and in fluid communication with the second passage (208, 208B).

5. The component (200) of claim 4, further comprising:

a second transition conduit (224B,324B) positioned within the component segment (104,204,304) and the supplemental segment (206), the second transition conduit (224B,324B) extending between the second passage (208,208B) of the component segment (104,204,304) and the second channel (218B,318B) of the supplemental segment (206) to fluidly couple the second passage (208,208B) and the second channel (218B,318B),

wherein the second transition duct (224B,324B) includes a substantially uniform fourth dimension that is greater than the third dimension of the second opening (210B) of the second passage (208, 208B).

6. The component (200) of claim 4, wherein the supplemental segment (206) further comprises a manifold (236) in fluid communication with the channel (118,2018B,218A) and the second channel (218B, 318B).

7. The component (200) of claim 3, further comprising:

a second supplemental segment (306B) integrally formed with the component segment (104,204,304) and disposed on the second opening (210B) of the second passageway (208,208B), the second supplemental segment (306B) comprising:

a second channel (218B,318B) extending at least partially through the second supplemental segment (306B) and in fluid communication with the second passageway (208, 208B).

8. The component (200) of claim 7, further comprising:

a second transition conduit (224B,324B) positioned within the component segment (104,204,304) and the second supplemental segment (306B), the second transition conduit (224B,324B) extending between the second passage (208,208B) of the component segment (104,204,304) and the second channel (218B,318B) of the second supplemental segment (306B) to fluidly couple the second passage (208,208B) and the second channel (218B, 318B).

9. The component (200) of claim 2, wherein the transition duct (124,224A) is frustoconical and includes:

a first end (126) positioned directly adjacent to and in direct fluid communication with the opening (110,220B) of the at least one passage (108), the first end (126) having a third dimension that is greater than the first dimension of the opening (110,220B) of the at least one passage (108), an

A second end (128) positioned opposite the first end (126), the second end (128) positioned directly adjacent to and in direct fluid communication with the channel (118,2018B,218A) positioned in the supplemental segment (206),

wherein the second end (128) has the second dimension greater than:

the first dimension of the opening (110,220B) of the at least one passage (108), and

the third dimension of the first end (126) of the transition duct (124, 224A).

10. The component (200) of claim 1, wherein the at least one passage (108) extends at least partially through the component segment (104,204,304) at a non-perpendicular angle relative to a finished surface (20,112,122,222) of the monolithic body (102,202,302), the finished surface (20,112,122,222) of the monolithic body (102,202,302) exposing the at least one passage (108).

11. A method, comprising:

a monolithic body (102,202,302) of an additive-manufactured component (200), the monolithic body (102,202,302) comprising:

a component segment (104,204,304), the component segment (104,204,304) including at least one passage (108) extending at least partially through the component segment (104,204,304), the at least one passage (108) including an opening (110,220B) having a first size;

a supplemental segment (206) integrally formed with the component segment (104,204,304), the supplemental segment (206) disposed on the at least one passage (108) of the component segment (104,204,304) and including a channel (118,2018B,218A) extending at least partially through the supplemental segment (206), the channel (118,2018B,218A) in fluid communication with the at least one passage (108) of the component (200) segment; and

a transition conduit (124,224A) positioned within the component segment (104,204,304) and the supplemental segment (206), the transition conduit (124,224A) extending between the at least one passage (108) of the component segment (104,204,304) and the channel (118,2018B,218A) of the supplemental segment (206) to fluidly couple the at least one passage (108) and the channel (118,2018B, 218A);

performing at least one post-build process on the component (200) including the monolithic body (102,202, 302); and

removing the supplemental segment (206) from the component segment (104,204,304) of the monolithic body (102,202,302) to expose a portion of the transition duct (124,224A) and the at least one passage (108) of the component segment (104,204, 304).

12. The method of claim 11, wherein the transition duct (124,224A) includes a second dimension that is greater than the first dimension of the opening (110,220B) of the at least one passage (108) of the component segment (104,204, 304).

13. The method of claim 12, wherein the transition duct (124,224A) is frustoconical and includes:

a first end (126) positioned directly adjacent to and in direct fluid communication with the opening (110,220B) of the at least one passage (108), the first end (126) having a third dimension that is greater than the first dimension of the opening (110,220B) of the at least one passage (108), an

A second end (128) positioned opposite the first end (126), the second end (128) positioned directly adjacent to and in direct fluid communication with the channel (118,2018B,218A) positioned in the supplemental segment (206),

wherein the second end (128) has the second dimension greater than:

the first dimension of the opening (110,220B) of the at least one passage (108),

the third dimension of the first end (126) of the transition duct (124, 224A).

14. The method of claim 11, wherein removing the supplemental segment (206) from the component segment (104,204,304) of the monolithic body (102,202,302) further comprises:

machining the supplemental segment (206) through the transition duct (124,224A) to define a finished surface (20,112,122,222) of the monolithic body (102,202,302) of the component (200), the finished surface (20,112,122,222) including the portion of the transition duct (124,224A) exposed and the at least one passage (108) of the component segment (104,204, 304).

15. The method of claim 14, wherein additively manufacturing the monolithic body (102,202,302) further comprises:

additive manufacturing the at least one passageway (108) at a non-perpendicular angle relative to the conditioning surface (20,112,122,222) of the monolithic body (102,202, 302).

Background

The present disclosure relates generally to additively manufactured components and, more particularly, to additively manufactured components including integrally formed passageways, channels, and conduits and methods of forming the same.

Components or parts for various machines and mechanical systems may be built using additive manufacturing systems. Additive manufacturing systems may build such components by continuously layering powder materials in predetermined areas and performing material conversion processes, such as sintering or melting, on the powder materials. The material conversion process may change the physical state of the powder material from a granular composition to a solid material to build a part. Components built using additive manufacturing systems have physical properties that are nearly identical to conventional components that are typically made by performing a machining process (e.g., a material removal process) on raw materials. However, due to advantageous processes, components formed using additive manufacturing may include unique features and/or complex geometries that are difficult or impossible to obtain and/or build using conventional machining processes.

However, the ability to easily form unique features and/or complex geometries results in new and/or additional manufacturing difficulties or problems. For example, when conduits or channels are exposed and/or formed to extend to the surface of a component, post-build processing performed on the additively manufactured component may create problems for the intended use of such conduits or channels. That is, when excess build material is removed and/or the surface of the component including the opening of the conduit or channel is resurfaced (e.g., polished/planed), undesirable burrs may form on the surface and/or may extend into the opening. Burrs formed during post-build processes may clog, block, or otherwise plug conduits or channels formed in the component, rendering the feature unusable for its intended purpose. While the flash removal process may be performed on the component to remove the formed flash, the tool used to remove the flash may reshape, reconfigure, and/or otherwise damage the opening and/or a portion of the conduit or channel. This is particularly common where the size or dimensions of the opening or conduit are small, and/or where the conduit or channel does not extend directly perpendicular (e.g., angled conduit) to the surface comprising the opening.

Disclosure of Invention

A first aspect of the present disclosure provides a component comprising a monolithic body comprising: a component segment, the component segment comprising: at least one passage extending at least partially through the component segment, the at least one passage including an opening having a first size; a supplemental segment integrally formed with the component segment, the supplemental segment disposed on at least one pathway of the component segment and comprising: a channel extending at least partially through the supplemental segment, the channel in fluid communication with the at least one passage of the component segment; and a transition duct positioned within the component section and the supplemental section, the transition duct extending between the at least one passage of the component section and the channel of the supplemental section to fluidly couple the at least one passage and the channel.

A second aspect of the disclosure provides a method comprising additively manufacturing a monolithic body of a component, the monolithic body comprising: a component segment including at least one passage extending at least partially through the component segment, the at least one passage including an opening having a first size; a supplemental segment integrally formed with the component segment, the supplemental segment disposed on the at least one passage of the component segment and including a channel extending at least partially therethrough, the channel in fluid communication with the at least one passage of the component segment; and a transition duct positioned within the component section and the supplemental section, the transition duct extending between the at least one passage of the component section and the channel of the supplemental section to fluidly couple the at least one passage and the channel; performing at least one post-build process on a component comprising a monolithic body; and removing the supplemental segment from the component segment of the monolithic body to expose a portion of the transition duct and at least one passage of the component segment.

Exemplary aspects of the present disclosure are designed to solve the problems herein described and/or other problems not discussed.

Drawings

These and other features of the present disclosure will be more readily understood from the following detailed description of the various aspects of the present disclosure taken in conjunction with the accompanying drawings that depict various embodiments of the disclosure, in which:

fig. 1 illustrates an exploded perspective view of a component including a component segment and a supplemental segment according to an embodiment of the present disclosure.

Fig. 2 illustrates a front view of the component of fig. 1 including a component segment and a supplemental segment, according to an embodiment of the present disclosure.

Fig. 3 illustrates a front cross-sectional view of the component of fig. 2 taken along line CS-CS, according to an embodiment of the present disclosure.

Fig. 4 illustrates a front cross-sectional view of the component of fig. 2 with the supplemental segment removed from the component segment, according to an embodiment of the present disclosure.

Fig. 5 illustrates an enlarged view of a portion of the component segment of fig. 4 including burrs, according to an embodiment of the present disclosure.

Fig. 6 illustrates an enlarged view of a portion of the component segment of fig. 4 with burrs removed, according to an embodiment of the present disclosure.

Fig. 7 illustrates a front cross-sectional view of a component including a component segment and a supplemental segment according to additional embodiments of the present disclosure.

Fig. 8 illustrates a front cross-sectional view of the component of fig. 7 with a supplemental segment removed from the component segment, according to additional embodiments of the present disclosure.

Fig. 9 illustrates a front cross-sectional view of a component including a component segment and a supplemental segment according to further embodiments of the present disclosure.

Fig. 10 illustrates a front cross-sectional view of the component of fig. 9 with a supplemental segment removed from the component segment, according to further embodiments of the present disclosure.

Fig. 11 and 12 show front cross-sectional views of a component including a component segment, a supplemental segment, and a plurality of passageways extending therein, according to embodiments of the present disclosure.

Fig. 13 illustrates a front cross-sectional view of a component including a component segment, a supplemental segment, a plurality of passages extending therein, and a manifold, according to an embodiment of the present disclosure.

Fig. 14 illustrates a front view of a component including a component segment and a plurality of supplemental segments, according to an embodiment of the present disclosure.

Fig. 15 illustrates a flow diagram of an example process for forming an additively manufactured component including a component segment and a supplemental segment, according to an embodiment of the present disclosure.

Fig. 16 illustrates a block diagram of an additive manufacturing system and process including a non-transitory computer-readable storage medium storing code representing a component including a component segment and a supplemental segment, according to an embodiment of the disclosure.

It should be noted that the drawings of the present disclosure are not necessarily drawn 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

First, in order to clearly describe the present disclosure, it will be necessary to select certain terms when referring to and describing the relevant machine components within the present disclosure. In so doing, if possible, common industry terminology will be used and employed in a manner consistent with its accepted meaning. Unless otherwise indicated, such terms should be given a broad interpretation consistent with the context of the application and the scope of the appended claims. One of ordinary skill in the art will appreciate that often several different or overlapping terms may be used to refer to a particular component. An object that may be described herein as a single part may comprise multiple components and in another context be referred to as being made up of multiple components. Alternatively, an object that may be described herein as comprising a plurality of components may be referred to elsewhere as a single part.

The following disclosure relates generally to additively manufactured components and, more particularly, to additively manufactured components including integrally formed passageways, channels, and conduits and methods of forming the same.

These and other embodiments are discussed below with reference to fig. 1-16. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only and should not be construed as limiting.

Fig. 1 and 2 show various views of a component 100 including a monolithic body 102. Specifically, fig. 1 shows an exploded perspective view of the component 100 including the monolithic body 102, and fig. 2 shows a front view of the component 100 including the monolithic body 102. The component 100 including the monolithic body 102 may be considered an "intermediate" formed component and/or a component that may be at an intermediate stage of processing. Accordingly, and as discussed herein, the component 100 may undergo additional post-construction processes performed before and/or after the final configuration (e.g., component segment) of the component 100 is available for its intended purpose.

In the non-limiting examples discussed herein, the component 100 may include and/or be formed as a unitary body 102 such that the component 100 is a single, continuous and/or non-disjointed component or part. In the non-limiting example shown in fig. 1-14, because the component 100 includes the monolithic body 102, the turbine shroud 100 may not require joining, coupling, and/or assembling various parts to completely form the component 100. Rather, once a single, continuous and/or non-disjointed monolithic body 102 of component 100 is built, as discussed herein, the monolithic body 102 of component 100 may include all desired features therein that may be used in the final configuration (e.g., component portion) of component 100 in the intended purpose.

In a non-limiting example, the unitary body 102 of the component 100 and the various components and/or features of the component 100 can be formed using any suitable additive manufacturing process and/or method. For example, the component 100 including the monolithic body 102 may be formed by: direct Metal Laser Melting (DMLM) (also known as Selective Laser Melting (SLM)), Direct Metal Laser Sintering (DMLS), Electron Beam Melting (EBM), Stereolithography (SLA), binder jetting, or any other suitable additive manufacturing process. As such, the monolithic body 102 of the component 100 and various components and/or features integrally formed on and/or in the monolithic body 102 of the component 100 may be formed during a single additive manufacturing process and/or method. Additionally, the component 100, and more particularly the monolithic body 102, may be formed from any suitable material that may be subjected to an additive manufacturing process performed by an Additive Manufacturing System (AMS) (see fig. 15). In non-limiting examples, the monolithic body 102 of the component 100 may be formed from thermoplastics, metals, metal alloys, ceramics, glass, and other suitable materials.

As shown in fig. 1 and 2, the monolithic body 102 of the component 100 may include two distinct portions and/or segments. That is, while the monolithic body 102 is formed as a single continuous piece or part, the monolithic body 102 of the component 100 may be formed as two distinct segments. In the non-limiting examples discussed herein, the monolithic body 102 may include a component segment 104 and at least one supplemental segment 106, respectively. As shown in fig. 2, the component segment 104 and the supplemental segment 106 may be integrally formed to form the monolithic body 102 of the component 100. The component segment 104 and the supplemental segment 106 may be integrally formed using a (single) additive manufacturing process and/or AMS (see fig. 15). As discussed herein, the component segment 104 and the supplemental segment 106 may be separated from each other via a (single) additive manufacturing process after formation, and the component segment 104 may then be used for its intended purpose, while the supplemental segment 106 may be discarded. As discussed herein, the component segments 104 of the component 100 may represent "final" configurations, geometries, parts, and/or assemblies manufactured by the AMS that may be used by the component, device, and/or system for an intended purpose.

As a result of being formed from the monolithic body 102, and as discussed herein, the component 100 may include various integrally formed features, components, and/or sections that may provide a desired function and/or operation for a final configuration of the component 100 (e.g., the component segment 104). That is, and because the component 100 includes a monolithic body 102 formed using any suitable (single) additive manufacturing process and/or method, features, components, and/or sections of the component 100 may be integrally formed with the monolithic body 102. The terms "integral feature" or "integrally formed feature" may refer to a feature formed on or in the monolithic body 102, a feature formed from the same material as the monolithic body 102, and/or a feature formed on or in the monolithic body 102 during a (single) additive manufacturing process such that the feature is not manufactured using a different process and/or raw material components that are separately and subsequently constructed, joined, coupled, and/or assembled on or in the monolithic body 102 of the component 100. Additionally, the features formed in the monolithic body 102 of the component 100 may be specific to the operation and/or function of the component segment 104 of the component 100.

As shown in fig. 1 and 2, the component 100 may include at least one feature formed in the monolithic body 102. More specifically, the component 100 may include at least one feature formed at least partially in, on, and/or through a component segment 104 of the monolithic body 102. In the non-limiting example shown in fig. 1 and 2, the feature formed in the monolithic body 102, and more particularly the component segment 104, may be at least one passage 108. The passage 108 may be at least partially formed in and/or may extend at least partially through the component segment 104 of the monolithic body 102. In a non-limiting example, the passage 108 may extend only partially through the component segment 104 and may be formed as a recess. In other non-limiting examples (see, e.g., fig. 12), the passage 108 may extend completely through the monolithic body 102 and/or the component segment 104, and may include two openings exposed and/or formed on a surface of the component segment 104 of the component 100.

The passageway 108 as shown in fig. 1 and 2 may include an opening 110. That is, the passageway 108 may be at least partially defined by the opening 110, and/or the opening 110 may be in fluid communication with the passageway 108. The opening 110 may have a first predetermined size (D1). For example, where the opening 110 is substantially circular in shape, the opening 110 of the passageway 108 may include a first predetermined dimension (D1) corresponding to a circumference of the opening 110. As shown in the exploded view of fig. 1, and turning briefly to fig. 4, after removal of the supplemental segment 106, the passage 108 and/or the opening 110 may be exposed and/or formed adjacent to a "finished" surface 112 formed on the component segment 104, as discussed herein. Prior to removal of the supplemental segment 106, and as discussed herein, the "finished" surface 112 may be considered a reference surface, an artificial surface, and/or an intended surface of the component segment 104 of the component 100 that may be formed/disposed below the supplemental segment 106 and/or "covered" by the supplemental segment.

It should be understood that the shapes and/or geometries of the passages 108 and/or openings 110 shown herein are exemplary. Accordingly, the passage 108 and/or the opening 110 may include any geometric shape and/or size that may correspond to the intended function and/or operation of the component segment 104. Additionally, although illustrated as being shaped consistent with and/or substantially similar to the remainder of the passage 108 extending at least partially within the component segment 104, it should be understood that the opening 110 may be shaped and/or sized differently than the passage 108. Further, the number of passages 108/openings 110 formed in the component segments 104 of the monolithic body 102 shown herein may also be exemplary, and the monolithic body 102 of the component 100 may include more or fewer passages 108 and/or openings 110 than those shown and discussed herein.

As discussed herein, the monolithic body 102 of the component 100 may also include a supplemental segment 106. The supplemental segment 106 may be integrally formed with the component segment 104 of the monolithic body 102 of the component 100. That is, although shown exploded or separate from the component segment 104 in fig. 1, the supplemental segment 106 may be integrally formed with, a portion of, and/or integral with the component segment 104 of the monolithic body 102 (see fig. 2). The Dashed Line (DL) shown in fig. 2 may represent a location within the component 100 that separates or distinguishes the component segment 104 and the supplemental segment 106. In the non-limiting example shown in fig. 1 and 2, the supplemental segment 106 may be integrally formed with at least a portion of the "finished" surface 112 of the component segment 104. Additionally, and as discussed herein, removal of the supplemental segment 106 from the component segment 104 of the monolithic body 102 may substantially define and/or expose the "finished" surface 112, as well as the passages 108/openings 110 (e.g., features) formed in the component segment 104 of the monolithic body 102. Although shown as being formed on and/or integrally formed with "finished" surface 112 of component segment 104, it should be understood that supplemental segment 106 may be formed on other portions or surfaces of component segment 104 (see fig. 12) and/or between build surface 20 of build plate 18 and component segment 104 of monolithic body 102 (not shown), with component 100 being built directly on a build plate of an additive manufacturing system.

In the non-limiting example shown in fig. 1 and 2, supplemental segment 106 may include a geometry similar to component segment 104. That is, the supplemental segment 106 may include a geometry, shape, and/or size (e.g., width, depth) similar or substantially the same as a portion of the component segment 104 including the passage 108 and/or the opening 110. Thus, the supplemental segment 106 may overlie and/or may be disposed on the component segment 104 of the monolithic body 102. More specifically, the supplemental segment 106 may be disposed on and/or may define a "finished" surface 112, and may substantially cover, be positioned adjacent to, and/or may be disposed on a passage 108/opening 110 (e.g., a feature) formed in the component segment 104. In another non-limiting example (not shown), the supplemental segment 106 may include a geometry, shape, and/or size (e.g., width, depth) that is substantially different from the component segment 104 of the monolithic body 102. In this non-limiting example, the supplemental segment 106 may be sized and/or may include a geometry that may cover and/or be disposed over only a portion of the component segment 104 that includes the features (e.g., the passages 108/openings 110) formed therein. Accordingly, different portions of the component segment 104, and more particularly a portion of the "finished" surface 112 of the component segment 104, may not be covered by the supplemental segment 106, and may be fully exposed during post-build processing, as discussed herein.

As shown in fig. 1 and 2, the supplemental segment 106 may also include at least one channel 118. More specifically, the channel 118 may be formed in the supplemental segment 106 and/or may extend at least partially through the supplemental segment. The channel 118 of the supplemental segment 106 may be in fluid communication with the passage 108/opening 110 (e.g., feature) formed in the component segment 104 of the monolithic body 102. The channels 118 may allow a fluid (e.g., pressurized air) to flow through the passages 108 formed in the component segments 104 of the monolithic body 102 in order to remove any unsintered powder material and/or particles that may undesirably remain in the passages 108 of the component segments 104 after the component 100 is formed. Additionally or alternatively, the channel 118 may allow a test fluid to flow through the passage 108 formed in the component segment 104 to test operating parameters and/or characteristics of the passage 108. For example, where the passage 108 may be formed as a cooling passage in the component 100, the channel 118 of the supplemental segment 106 may allow test fluid to be provided to the passage 108 to ensure that the test/actual flow rate and/or flow pressure meets the desired operating flow rate and/or flow pressure.

In the non-limiting example shown in fig. 1 and 2, the channel 118 of the supplemental segment 106 may also include an opening 120. Specifically, the channel 118 extending at least partially through the supplemental segment 106 may include an opening 120 formed in, on, and/or through a surface 122 of the monolithic body 102. The channel 118 may be exposed in the component 100 due to the opening 120 forming the channel 118 on the surface 122 of the monolithic body 102. Additionally, and because the channel 118 is in fluid communication with the passage 108/opening 110 extending at least partially through the component segment 104, the opening 120 forming the channel 118 on the surface 122 of the monolithic body 102 may also expose the passage 108 in the "intermediately" formed component (i.e., the component 100).

In the non-limiting example shown in fig. 1 and 2, the monolithic body 102 of the component 100 may also include a transition duct 124. The transition duct 124 may be positioned within the component segment 104 and the supplemental segment 106. More specifically, the transition duct 124 may be positioned within, may be formed/built within, and/or may be disposed within at least a portion of both the component segment 104 and the supplemental component 106 of the monolithic body 102. In a non-limiting example, the transition duct 124 may extend between the transition between the component segment 104 and the supplemental segment 106, as defined by the Dashed Line (DL) shown in fig. 2, and as discussed herein. The transition duct 124 may be integrally formed within the monolithic body 102 using a (single) additive manufacturing process and/or an AMS, and/or may be formed during the same additive manufacturing process and/or using the same AMS that may form features (e.g., the passage 108, the channel 118) within the monolithic body 102, as discussed herein. As shown in fig. 1 and 2, and as discussed herein, the transition duct 124 may include a second dimension (D2) that is greater than the first dimension (D1) of the opening 110 of the passage 108 that extends at least partially through the component segment 104.

FIG. 3 illustrates a cross-sectional front view of a portion of the unitary body 102 taken along line CS-CS in FIG. 2. As shown in fig. 3, and with continued reference to fig. 1 and 2, a transition duct 124 of the monolithic body 102 may also extend between the passage 108 of the component segment 104 and the channel 118 of the supplemental segment 106. Thus, the transition conduit 124 may fluidly couple the passage 108 extending through the component segment 104 with the channel 118 extending through the supplemental segment 106 of the monolithic body 102. In the non-limiting example shown in fig. 1-3, the transition duct 124 may also be frustoconical in shape and/or geometry. More specifically, the transition duct 124 may include a first end 126 (see fig. 3) positioned directly adjacent to and in direct fluid communication with the opening 110 of the passage 108 formed in the component segment 104 and a second end 128 (see fig. 3) positioned opposite the first end 126. The second end 128 may be positioned directly adjacent to and in direct fluid communication with the channel 118 positioned in the supplemental segment 106. In a non-limiting example, the first end 126 of the transition duct 124 may be formed, constructed and/or defined with the component segment 104 of the monolithic body 102, while the second end 128 of the transition duct 124 may be formed, constructed and/or defined with the supplemental segment 106 of the monolithic body 102. The first end 126 of the transition duct 124 may include or may have a dimension (e.g., a third dimension) (D3) that may be (slightly) greater than the first dimension (D1) of the opening 110 of the passage 108. The second end 128 of the transition duct 124 may include a second dimension (D2) that is greater than the first dimension (D1) of the opening 110 of the passage 108 and greater than the third dimension (D3) of the first end 126. Additionally, as shown in fig. 3, the second dimension (D2) may be substantially similar to the dimension of the channel 118 of the supplemental segment 106 of the monolithic body 102. Accordingly, and based on the frustoconical shape of the transition duct 124, the entire transition duct 124 may include a larger size (e.g., D2, D3) than the opening 110 of the passage 108, and the difference in size may increase as the distance between the opening 110 and the second end 128 of the transition duct 124 increases.

The formation and/or positioning of the transition duct 126 within the monolithic body 102 may prevent, eliminate, and/or reduce undesirable results and/or effects imposed on the component 100 after performing post-build processes on the monolithic body 102, and is a variety of segments/features. That is, once the component 100 is additively manufactured to include the component segment 104, the supplemental segment 106, and various features (e.g., the passage 108, the channel 118, etc.) therein, the monolithic body 102 of the component 100 may undergo various post-build processes. The post-build process may include, for example, removing the supplemental segment 106 from the component segment 104 of the monolithic body 102. As discussed herein, the supplemental segment 106 may be removed from the component segment 104 such that the component segment 104 of the component 100 may represent a "final" configuration that may be used by the component, device, and/or system for an intended purpose. As shown in fig. 3 and 4, the supplemental segment 106 may be removed from the component segment 104 at an imaginary line (DL), also identified in the figures as a Separation Line (SL) (see fig. 3). As shown in fig. 3, the parting line (SL) may pass through a transition conduit 124 that extends between and fluidly couples the passage 108 of the component segment 104 and the channel 118 of the supplemental component 106. Additionally, and as described herein with respect to fig. 2, a reference dashed line/Separation Line (SL) may identify a location where the component segment 104 ends within the monolithic body 102 and/or a location where the supplemental segment 106 begins in the monolithic body 102. Accordingly, and as discussed herein, the supplemental segment 106 may be completely removed from the component segment 104 along the Separation Line (SL) during the post-build removal process.

The supplemental segment 106 may be removed from the component segment 104 using any suitable material removal technique and/or process. For example, the monolithic body 102 of the component 100 may be machined (e.g., cut, milled, etc.) along the Separation Line (SL) to completely remove the supplemental segment 106 from the component segment 104. In another non-limiting example, the monolithic body 102 of the component 100 may be subjected to an electrical discharge machining process to remove the supplemental segment 106 from the component segment 104 along the Separation Line (SL). As a result of removing the supplemental segment 106 from the component segment 104, the "finished" surface 112 of the component segment 104 may be exposed, formed, and/or defined. Additionally, the remaining portion 130 of the transition duct 124 (including the first end 126) as well as the passage 108 and the opening 110 of the component segment 104 may be exposed via the "finished" surface 112.

The supplemental segments 106 of the monolithic body 102 of the component 100 may be formed by AMS to include predetermined build characteristics that are substantially similar to or different from the predetermined build characteristics of the component segments 104 of the monolithic body 102. In non-limiting examples where the predetermined build characteristics between the supplemental segment 106 and the component segment 104 are different, the material density or material porosity of the supplemental segment 106 may be different than the material density or material porosity of the component segment 104. More specifically, the material density or material porosity of the supplemental segment 106 may be less than the material density or material porosity of the component segment 104. The reduced material density or material porosity of the supplemental segment 106 may enable easier removal of the supplemental segment 106 from the component segment 104. In the non-limiting example discussed herein with respect to fig. 1-4, the supplemental segment 106 may be removed from the component segment 104 at a Separation Line (SL) that may also coincide with a Dashed Line (DL) that distinguishes the supplemental segment 106 and the component segment 104. As discussed herein, the component segment 104 may be free of the supplemental segment 106, and thus may not include any portion of the supplemental segment 106 having a reduced density or porosity. The AMS may construct the supplemental segment 106 to include predetermined construction characteristics different from those of the component segment 104 by, for example, adjusting the intensity or power output of the energy emitting devices used to form the supplemental segment 106 and the component segment 104, and/or the speed of the energy emitting devices used to form the supplemental segment 106 and the component segment 104.

In other non-limiting examples (see fig. 9 and 10), the Separation Line (SL) where the supplemental segment 106 is removed from the component segment 104 may not coincide with the Dashed Line (DL) that distinguishes the supplemental segment 106 from the component segment 104. As such, a portion of the component segment 104 may be removed with the supplemental segment 106 and/or a portion of the supplemental segment 106 may remain with the component segment 104. In these examples, component segment 104 and supplemental segment 106 may include similar predetermined build characteristics.

In a non-limiting example, once the supplemental segment 106 is removed from the component segment 104, the component segment 104 of the component 100 may be implemented, installed, and/or used for its intended purpose. That is, the component segment 104, including the remaining portion 130 of the transition duct 124, the passageway 108, and the opening 110, may be considered a finished, and/or ready-to-use component that may be used for its intended purpose and/or within an intended device without additional post-construction processing.

Turning to fig. 5, this figure shows an enlarged portion of the component segment 104 of fig. 4 after a machining process is performed on the monolithic body 102 to remove the supplemental segment 106. In a non-limiting example, burrs 132 may be formed along "trim" surface 112 and/or may extend into transition duct 124. That is, performing a machining process to remove the supplemental segment 106 from the component segment 104 may result in excess material or flash 132 being formed, pushed inward, and/or extending from the "finished" surface 112 into the transition duct 124. As a non-limiting example, the burr 132 extending into the transition duct 124 may not close, block, and/or otherwise block the passage 108 (e.g., allow fluid to flow in and/or out). That is, even if burr 132 is included, passage 108 of component segment 104 may be exposed and/or able to receive and/or expel fluid through opening 110 and/or transition duct 124 that includes burr 132. Because transition duct 124, and more specifically the remaining portion 130 of transition duct 124 formed directly adjacent to "trim" surface 112, has a dimension greater than the first dimension (D1) of opening 110 and/or passage 108, passage 108 of component segment 104 may not be obstructed by burr 132. In this way, the passage 108 of the component segment 104 may be used for its intended purpose with no or negligible reduction in operating or operational parameters.

In another non-limiting example, the component segment 104 of the monolithic body 102 that is substantially free of the supplemental segment 106 may undergo additional post-build processes. For example, and with continued reference to fig. 5, it may be desirable to remove burr 132 from component segment 104. As such, the deburring process may be performed on the component segment 104 after the supplemental segment 106 is removed from the monolithic body 102 using a machining technique. Turning to fig. 6, burr 132 may be removed via a deburring process and/or using any suitable technique and/or system that may be configured to remove burr 132 (shown in phantom). Performing the deburring process on the component segment 104 may also restore and/or reshape the remaining portion 130 of the transition duct 124 to its original form, geometry, and/or shape prior to performing the removal process on the monolithic body 102 of the component 100 (see, e.g., fig. 3). Additionally, when performing a deburring process on the component segment 104, the working tool and/or system performing the deburring process (e.g., deburring tool) may contact, recover, and/or reshape the remaining portion 130 of the transition duct 124 only while removing the burr 132. Thus, the configuration, geometry, and/or shape of the opening 110 and/or the passage 108 of the component segment 104 may be unaltered, and/or may retain a desired/constructed geometry. Removing burr 132, which may extend into transition duct 124, may ensure that passage 108/opening 110 of component segment 104 may operate as intended when used for its purpose and/or may perform with desired operating parameters and characteristics.

Fig. 7-10 illustrate additional non-limiting examples of the monolithic body 102 of the component 100. More specifically, fig. 7-10 show front cross-sectional views of a portion of the monolithic body 102 including the integrally formed component segment 104 and the supplemental segment 106 (e.g., fig. 7 and 9), and cross-sectional views of the supplemental segment 106 removed from the component segment 104 (e.g., fig. 8 and 10). It should be appreciated that similarly numbered and/or named components may function in a substantially similar manner. Redundant explanations of these components have been omitted for the sake of clarity.

In the non-limiting example shown in fig. 7 and 8, the shape of the transition duct 124 may be substantially uniform and/or linear. That is, and with respect to the various transition ducts 124 discussed herein with respect to fig. 1-6, the shape of the transition duct 124 may not be frustoconical and/or include varying/converging dimensions. In contrast, the transition duct 124 shown in fig. 7 and 8 may be substantially linear and include a single uniform dimension (D2) between the first end 126 and the second end 128. A uniform second dimension of transition duct 124 extending between and fluidly coupling passage 108 and channel 118 may be greater than the first dimension (D1) of opening 110 and/or passage 108. When the supplemental segment 106 is removed from the component segment 104, as shown in fig. 8, the remaining portion 130 of the transition duct 124 may include or maintain a uniform second dimension (D2) that may be greater than the first dimension (D1) of the opening 110. As similarly discussed herein with respect to fig. 5 and 6, transition duct 124, and more specifically a remaining portion 130 of transition duct 124 including the larger second dimension (D2), may prevent burr 132 (see fig. 5) from blocking passage 108/opening 110. Additionally or alternatively, the remaining portion 130 of the transition duct 124 including the uniform second dimension (D2) may prevent the passage 108/opening 110 from being undesirably reshaped or reconfigured by a tool or system (e.g., a deburring tool) that may be used to remove the burr 132 extending into the transition duct 124 after removal of the supplemental segment 106.

Turning to fig. 9 and 10, the passage 108 may extend through the component segment 104 at an angle (a). More specifically, the passage 108 extends at least partially through the component segment 104 at a non-perpendicular angle relative to a "finished" surface 112 (see fig. 10) on the component segment 104 of the monolithic body 102. Similarly, as discussed herein, the "finished" surface 112 may expose an angled or non-perpendicular passage 108 of the component segment 104 upon removal of the supplemental segment 106 from the component segment 104.

Additionally, fig. 9 and 10 show non-limiting examples in which supplemental segment 106 is not removed from component segment 104 at Reference Line (RL) and/or at the transition between component segment 104 and supplemental segment 106. That is, the supplemental segment 106 may be removed from the component segment 104 at a Separation Line (SL) that is different from a Reference Line (RL) indicating a transition between the two segments 104, 106 of the monolithic body 102. In a non-limiting example, the Separation Line (SL) may be positioned adjacent to and/or above the Reference Line (RL). As similarly discussed herein, the Separation Line (SL) may still be positioned by the transition duct 124 formed, positioned, defined, and/or extending between the component segment 104 and the supplemental segment 106. However, unlike the non-limiting examples discussed herein with respect to fig. 1-8, the Separation Line (SL) shown in fig. 9 may be located only through a portion of the transition duct 124 that is located, defined, and/or extended within the supplemental segment 106 of the monolithic body 102.

Turning to fig. 10, with supplemental segment 106 removed at Separation Line (SL) located adjacent to and/or above Reference Line (RL), a portion of supplemental segment 106 may remain with component segment 104. That is, the final configuration formed by the monolithic body 102 of the additively manufactured component 100 may include an unremoved or remaining portion 134 of the supplemental segment 106. In this non-limiting example, the "finished" surface 112 may be formed by a remaining portion 134 of the supplemental segment 106 of the monolithic body 102 that is not removed and/or remains integrally formed with the component segment 104. Exposing/defining the "finished" surface 112 formed by the remaining portion 134 of the supplemental segment 106 may also expose the remaining portion 130 of the transition duct 124, the passage 108 of the component segment 104, and the opening 110, as similarly discussed herein.

Fig. 11-13 illustrate additional non-limiting examples of monolithic bodies 202 of components 200. More specifically, fig. 11-13 illustrate a front cross-sectional view of a portion of a monolithic body 202 including an integrally formed component segment 204 and a supplemental segment 206. In each of the non-limiting examples, and as discussed herein, the component segment 204 may include a plurality of passages 208A, 208B extending therein. It should be understood that the number of passages 208 formed in the component segments 204 of the monolithic body 202 illustrated herein may be exemplary, and the monolithic body 202 of the component 200 may include more or fewer passages 208 than those illustrated and discussed herein.

In the non-limiting example shown in fig. 11, the component segment 204 may include a first passage 208A and a different second passage 208B. The first passage 208A may extend at least partially through the component segment 204 and may include a first opening 210A having a first dimension (D1). The first passage 208A may be substantially similar to the passage 108 discussed herein with respect to fig. 1-6. The second passage 208B of the monolithic body 102 may extend at least partially through the component segment 204 adjacent to the first passage 208A. The second passage 208B may also include a second opening 210B having a third size (D3).

As shown in fig. 11, the supplemental segment 206 may include a plurality of channels 218A, 218B, each channel corresponding to one of the plurality of passages 208A, 208B formed in the component segment 204. That is, the supplemental segment 206 may be disposed on, formed on, and/or may cover the first opening 210A of the first passageway 208A and the second opening 210B of the second passageway 208B, and may include a plurality of corresponding channels 2018A, 2018B extending therein. For example, the supplemental segment 206 may include a first channel 218A in fluid communication with the first passage 208A. First channel 218A may include a first opening 220A formed through surface 222, and may be in fluid communication with first passage 208A via a first transition conduit 224A positioned between first channel 218A and first passage 208A. As similarly discussed herein, a first transition duct 224A may extend, form, define, and/or be positioned between the component segment 204 and the supplemental segment 206 to fluidly couple the first channel 218A and the first passage 208A. As similarly discussed herein, the first transition conduit 224A may include a frustoconical shape, and the entire transition conduit 224A may have a dimension (e.g., D2) greater than the first dimension (D1) of the first opening 210A of the first passageway 208A. Additionally, the size difference may increase as the first transition duct 224A transitions into the first channel 218A and/or away from the first opening 210A.

In the non-limiting example shown in fig. 11, the supplemental segment 206 may also include a different second channel 218B. The second passage 218B may extend at least partially through the supplemental segment 206 and may be in fluid communication with the second passage 208B. That is, the second channel 218B may extend at least partially through a portion of the supplemental segment 206 disposed on the second passage 208B and may include an opening 220B formed in the surface 222. Second channel 218B may also be in fluid communication with second passage 208 extending at least partially through member segment 204.

Additionally, and as shown in fig. 11, the monolithic body 202 may include a second transition conduit 224B positioned within and/or extending between the component segment 204 and the supplemental segment 206. A segment transition conduit 224 may extend between the second passage 208B of the component segment 204 and the second channel 218B of the supplemental segment 206 to fluidly couple the second passage 208B and the second channel 218B. In the non-limiting example shown in fig. 11, and as similarly discussed herein with respect to fig. 7 and 8, the second transition duct 224B may have a substantially uniform fourth dimension (D4). The fourth dimension (D4) of the second transition duct 224B may be greater than the third dimension (D3) of the second opening 210B of the second passage 208B. Although shown as having a substantially uniform fourth dimension (D4), it should be understood that the second transition duct 224B may alternatively be formed to include a frustoconical shape (see fig. 12), wherein the entire second transition duct 224B may have a dimension (e.g., D4) that is greater than the third dimension (D3) of the second opening 210B of the second passage 208B.

Turning to fig. 12, the monolithic body 202 of the component 200 may include similar features (e.g., the passageways 208A, 208B, the openings 210A, 210B, and/or the transition ducts 224A, 224B), such as those shown and discussed herein with respect to fig. 11. It should be appreciated that similarly numbered and/or named components may function in a substantially similar manner. Redundant explanations of these components have been omitted for the sake of clarity.

Unlike fig. 11, the non-limiting example of fig. 12 shows a supplemental segment 206 that includes a single channel 218 extending therein. More specifically, the supplemental segment 206 of the monolithic body 202 may include a single channel 218, which may include a single opening 220 formed in and/or through a surface 222. In a non-limiting example, a single channel 218 may be in fluid communication with each of first and second passages 208A, 208B that extend at least partially through component segment 204. The single channel 218 may also be in direct fluid communication with and/or fluidly coupled to each of the first and second transition ducts 224A, 224B. Thus, the first transition conduit 224A may fluidly couple the first passage 208A to the single channel 218, and the second transition conduit 224B may also fluidly couple the second passage 208B to the single channel 218.

In the non-limiting example shown in fig. 13, the supplemental segment 206 may include a manifold 236 formed therein. The manifold 236 of the supplemental segment 206 may be in fluid communication with each of the first and second channels 218A, 218B that extend at least partially through the supplemental segment 206. As shown in fig. 13, the manifold 236 may include a single opening 238 formed in the surface 222 of the supplemental segment 206. A single opening 238 may be in fluid communication with multiple branches 240, 242 of the manifold 236. Each branch 240, 242 may correspond to and/or may be fluidly coupled to a channel 218A, 2018B of the supplemental segment 206. For example, a first branch 240 of the manifold 236 may be fluidly coupled to the first channel 218A, and a second branch 242 may be fluidly coupled to the second channel 218B. As discussed herein, the manifold 236 of the supplemental segment 206 may also be a passage 208A, 208B for fluid to flow to and/or from the component segment 204 via the channels 218A, 218B.

Fig. 14 shows a front view of a component 300 comprising a unitary body 302. In a non-limiting example, the component segment 304 monolithic body 302 may include a first passage 308A and a second passage 308B extending therethrough and in fluid communication with and/or fluidly coupled to a cavity 344 formed therein. As shown, the second passage 308B may extend at least partially through the component segment 304 at an angle (e.g., perpendicular) relative to the first passage 308A. Thus, and unlike the non-limiting examples discussed herein with respect to fig. 11-13, when the component segment 304 is in a final form and/or configuration for use, the second passage 308B may be exposed on a different "finished" surface (e.g., "finished" surface 112) than the first passage 308A.

Thus, the monolithic body 302 of the component 300 may include a first supplemental segment 306A and a second, different supplemental segment 306B integrally formed with the component segment 304. That is, the first supplemental segment 306A may be integrally formed with the component segment 304 and may be disposed over and/or cover the first passage 308A/first opening 310A. The monolithic body 302 shown in fig. 14 may include a first passage 318A extending at least partially through the first supplemental segment 306A and in fluid communication with the first passage 308A. As similarly discussed herein, the monolithic body 302 may also include a first transition conduit 324A extending between and/or positioned within the component segment 304 and the first supplemental segment 306A. A first transition conduit 324A may extend between first passage 308A of component segment 304 and first channel 318A of first supplemental segment 306A to fluidly couple first passage 308A and first channel 318A.

The second supplemental segment 306B may be integrally formed with a different portion of the component segment 304 of the monolithic body 302. That is, the second supplemental segment 306B may be integrally formed with the component segment 304 and may be disposed over and/or cover the second passageway 308B/second opening 310B. As shown in fig. 14, second supplemental segment 306B of monolithic body 302 may include a second channel 318B extending at least partially through second supplemental segment 306B. The second channel 318B may be in fluid communication with the second passage 308B. In a non-limiting example, the monolithic body 302 may also include a second transition conduit 324B extending between and/or positioned within the component segment 304 and the second supplemental segment 306B. A second transition conduit 324B may extend between the second passage 308B of the component segment 304 and the second channel 318B of the second supplemental segment 306B to fluidly couple the second passage 308B and the second channel 318B. As similarly discussed herein, each of the first and second supplemental segments 306A, 306B may be removed along a respective separation line (SL1, SL2) to form a final configuration of the component 300 (e.g., component segment 304) that may be used for its intended purpose.

While shown as two distinct supplemental segments 306A, 306B, it should be understood that the non-limiting example shown in fig. 14 may include a single supplemental segment 306 that may be disposed on and/or cover both the first and second passageways 308A, 308B. For example, a void 346 (shown in phantom) may be formed between first supplemental segment 306A and second supplemental segment 306B during an additive manufacturing build process to separate monolithic body 302 and/or distinguish first supplemental segment 306A and second supplemental segment 306B. In another non-limiting example, void 346 shown in fig. 14 may comprise an additive manufactured material or build material that may bridge between, form, extend and/or define first and second supplemental segments 306A and 306B as a single integral supplemental segment of monolithic body 302.

Fig. 15 illustrates a non-limiting example process of forming a component using an additive manufacturing process and/or system. Specifically, fig. 15 is a flow diagram illustrating an exemplary process for forming a component including a component segment and a supplemental segment. In some cases, the process may be used to form the components 100, 200, 300, as discussed herein with respect to fig. 1-14.

In process P1, a monolithic body of a component may be additively manufactured or built. That is, an Additive Manufacturing System (AMS) may perform a build process (e.g., direct metal laser melting) to build a body entirety of a component. The unitary body of the component may be constructed to include the various segments and at least one feature formed therein. For example, an additive manufactured monolithic body may include a component segment that includes at least one passage extending at least partially through the component segment. The passageway may include an opening having a first size. In a non-limiting example, an additive-manufactured monolithic body may include additive-manufactured passages at non-perpendicular angles relative to a finished surface of the monolithic body. The additive-manufactured monolithic body may also include a supplemental segment integrally formed with the component segment. The supplemental segment may be disposed on the channel of the component segment and may include a channel extending at least partially through the supplemental segment. The channel of the supplemental segment may be in fluid communication with the passage of the component segment. Additionally, the additive-manufactured monolithic body may include a transition conduit positioned within and/or extending between the component segment and the supplemental segment. The transition duct may extend between the passage of the component segment and the channel of the supplemental segment to fluidly couple the passage and the channel.

The transition duct may also be additively manufactured to have a second size that is greater than the first size of the opening of the passage of the component segment. In a non-limiting example, the second dimension of the transition duct may be substantially uniform in shape and/or size. In another non-limiting example, the transition duct may be additively manufactured into and/or include a frustoconical shape in process P1. The frustoconical transition conduit may be additively manufactured to include a first end positioned directly adjacent to and in direct fluid communication with an opening of a passage extending in the component segment. The first end of the frustoconical transition conduit may have a third dimension that is greater than the first dimension of the opening of the passage of the component section. The frustoconical transition duct may also be additively manufactured to include a second end positioned opposite the first end. The second end may be positioned directly adjacent to and in direct fluid communication with a channel positioned in the supplemental segment. The second end may also have a second dimension that is greater than the first dimension of the opening of the passageway and the third dimension of the first end of the transition duct.

In additional non-limiting examples, the monolithic body may include a plurality of passageways. More specifically, the additive manufacturing performed in process P1 may also include additive manufacturing a first passage extending at least partially through the component segment. The first passageway may include a first opening having a first size. Additionally, process P1 may also include additively manufacturing a second via extending at least partially through the component segment adjacent to the first via. The second passageway may include a second opening having a third size.

As a result of forming two (or more) passages, the supplemental segment may include at least one channel and/or the monolithic body may include a plurality of transition ducts. Continuing with the above example, process P1 may include additively manufacturing a second channel extending at least partially through the supplemental segment and in fluid communication with the second passageway. The supplemental segment may be disposed on the first opening of the first passageway and the second opening of the second passageway. Additionally, process P1 may also include additively manufacturing a second transition duct positioned within the component segment and the supplemental segment. A second transition conduit may extend between the second passage of the component segment and the second channel of the supplemental segment to fluidly couple the second passage and the second channel. In this non-limiting example, the (first) channel of the supplemental section is in fluid communication with the first passageway via a (first) transition conduit, and the second channel of the supplemental section is in fluid communication with the second passageway via a second transition conduit.

In another non-limiting example, where the component segment includes a first passageway and a second passageway, process P1 may further include additively manufacturing a second supplemental segment that is integrally formed with the component segment and disposed on a second opening of the second passageway. The second supplemental segment may be different from the (first) supplemental segment and may include a second channel extending at least partially through the second supplemental segment and in fluid communication with the second passageway. Additionally, in a non-limiting example, the additive-manufacturing monolithic body in process P1 may include additive-manufacturing a second transition conduit positioned within the component segment and the second supplemental segment. A second transition conduit may extend between the second passage of the component segment and the second channel of the second supplemental segment to fluidly couple the second passage and the second channel.

In any non-limiting example in which the component segment includes a first passageway and a second passageway and the supplemental segment includes a first channel and a second channel, additively manufacturing the monolithic body in process P1 may further include additively manufacturing a manifold in the supplemental segment. The manifold that is additively manufactured in the monolithic body of the component may be in direct fluid communication with the channel and the second channel of the supplemental segment.

In process P2 (shown as optional in phantom), at least one post-build process may be performed on the component including the monolithic body. Specifically, and after integrally forming and/or additively manufacturing (e.g., process P1) the component segment and the supplemental segment, one or more post-build processes may be performed on the monolithic body of the component including the integrally formed component segment and supplemental segment. Post-construction processes performed on components including monolithic bodies can prepare monolithic bodies of components to be used by the components, devices, and/or systems for intended purposes. Performing at least one post-build process on the component including the monolithic body may also include, for example, shot peening the monolithic body and/or recrystallizing the component including the monolithic body.

In process P3, the supplemental segment may be removed from the monolithic body. That is, the supplemental segment is removable from the component segment of the unitary body of the component. Removing the supplemental segment from the component segment of the additive-manufactured monolithic body may substantially expose, define, and/or form a "finished" surface of the component segment of the monolithic body. In addition, removing the supplemental segment from the component segment of the monolithic body may also expose at least a remaining portion of the transition duct and a passage of the component segment. The supplemental segments may be removed by performing any now known or later developed cutting process (e.g., Electrical Discharge Machining (EDM), cutting wheel, etc.). For example, removing the supplemental segment may include machining the supplemental segment through the transition duct to define a finished surface of the monolithic body/component segment of the component. The finished surface may include portions of the exposed/remaining transition duct and the passage of the component segment. By removing/machining the supplemental section through the transition duct, at least a portion of the transition duct having a second dimension that is greater than the first dimension of the opening/passage of the component section may remain in and/or on the component section of the component.

In process P4 (shown as optional in dashed lines), additional post-build processes may be performed on the monolithic body. In particular, and after removal of the supplemental segment from the component segment of the monolithic body, additional post-build processes may be performed on the component segment of the component to prepare the component segment and/or provide the component segment for its intended use. In a non-limiting example in which the shot peening process is performed only in process P2, the component segment may be subjected to a recrystallization process without a supplemental segment. Additionally or alternatively, the burr removal process may be performed after removal of the supplemental segment. For example, where a machining process is used to remove a supplemental segment from a component segment, burrs may be formed on the "finished" surface. The burr may extend from a remaining portion of the transition duct and may extend at least partially into and/or adjacent to the opening/passage of the component segment. Accordingly, process P4 may include performing a flash removal process after removing the supplemental segment from the component segment of the monolithic body to remove at least one flash extending into and/or from a remaining portion of the transition duct.

The components 100, 200, 300 may be formed in a variety of ways. In one embodiment, the components 100, 200, 300 may be made by casting. However, as described herein, additive manufacturing is particularly suitable for manufacturing components 100, 200, 300 that include monolithic bodies. As used herein, Additive Manufacturing (AM) may include any process that produces an article by continuously layering materials rather than removing materials (which in the case of conventional processes is material removal). Additive manufacturing can form complex geometries without the use of any kind of tool, die or fixture, and with little or no waste of material. Rather than machining a part from a solid plastic or metal blank, many of which are cut away and discarded, the only material used in additive manufacturing is that required to shape the part. Additive manufacturing processes may include, but are not limited to: 3D printing, Rapid Prototyping (RP), Direct Digital Manufacturing (DDM), binder jetting, Selective Laser Melting (SLM), and Direct Metal Laser Melting (DMLM). In the current setup, a DMLM or SLM has been found to be advantageous.

To illustrate an example of an additive manufacturing process, fig. 16 shows a schematic/block diagram of an illustrative computerized additive manufacturing system 900 for generating an article 902. In this example, system 900 is arranged for a DMLM. It should be understood that the general teachings of the present disclosure are equally applicable to other forms of additive manufacturing. An article 902 is shown as a component 100, 200, 300 (see fig. 1-14). The AM system 900 generally includes a computerized Additive Manufacturing (AM) control system 904 and an AM printer 906. As will be described, the AM system 900 executes code 920 that includes a set of computer-executable instructions that define the components 100, 200, 300 to physically generate the item 902 using the AM printer 906. Each AM process may use a different raw material in the form of, for example, a fine-grained powder, a liquid (e.g., polymer), a sheet, etc., a stock solution of which may be held in the chamber 910 of the AM printer 906. As shown, the applicator 912 can form a thin layer of raw material 914 that is spread as a blank canvas on the build plate 915 of the AM printer 906 from which each successive slice of the final article will be formed. In other cases, the applicator 912 may apply or print the next layer directly onto the previous layer as defined by code 920, for example, where a metal bond spray process is used. In the example shown, the laser or electron beam 916 melts the particles for each slice as defined by code 920, but this may not be necessary if a fast-setting liquid plastic/polymer is employed. The various parts of the AM printer 906 can be moved to accommodate the addition of each new layer, for example, after each layer, the build platform 918 can be lowered and/or the chamber 910 and/or applicator 912 can be raised.

The AM control system 904 is shown as being implemented as computer program code on a computer 930. To this extent, computer 930 is shown including memory 932, processor 934, input/output (I/O) interface 936, and bus 938. Further, computer 930 is shown in communication with external I/O devices/resources 940 and storage system 942. Generally speaking, the processor 934 executes computer program code, such as the AM control system 904, stored in the memory 932 and/or storage system 942, under instructions from the code 920 representing the components 100, 200, 300 described herein. When executing computer program code, processor 934 can read and/or write data to/from memory 932, storage system 942, I/O devices 940, and/or AM printer 906. The bus 938 provides a communication link between each of the components in the computer 930, and the I/O devices 940 can include any device (e.g., keyboard, pointing device, display, etc.) that enables a user to interact with the computer 940. Computer 930 is merely 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, the memory 932 and/or the storage system 942 may reside at one or more physical locations. Memory 932 and/or storage system 942 can include any combination of various types of non-transitory computer-readable storage media, including magnetic media, optical media, Random Access Memory (RAM), Read Only Memory (ROM), and the like. Computer 930 may include any type of computing device, such as a web server, desktop computer, laptop computer, handheld device, mobile phone, pager, personal digital assistant, etc.

The additive manufacturing process begins with a non-transitory computer-readable storage medium (e.g., memory 932, storage system 942, etc.) that stores code 920 representing components 100, 200, 300. As noted, code 920 includes a set of computer-executable instructions defining an outer electrode that can be used to physically generate a tip when system 900 executes the code. For example, the code 920 may include precisely defined 3D models of the components 100, 200, 300, and may be generated by a variety of well-known computer-aided design (CAD) software systems, such as AutoTurbo Design cad 3D Max, etc.). In this regard, code 920 may be in any now known or later developed file format. For example, code 920 may be a standard surface subdivision language (STL) created by a stereolithography CAD program for 3D systems, or an Additive Manufacturing File (AMF), which is an American Society of Mechanical Engineers (ASME) standard, the latter being 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 manufactured on any AM printer. Code 920 may be based onIt is necessary to translate between different formats, convert to a set of data signals, and transmit, receive and convert to code, be stored, etc. as a set of data signals. The code 920 may be an input to the system 900 and may come from a part designer, an Intellectual Property (IP) provider, a design company, an operator or owner of the system 900, or from other sources. In any case, the AM control system 904 executes the code 920 to divide the component 100, 200, 300 into a series of sheets assembled using the AM printer 906 in successive layers of liquid, powder, sheet, or other material. In the DMLM example, each layer is fused into the exact geometry defined by code 920 and fused to the previous layer. Subsequently, the components 100, 200, 300 may be exposed to any of a variety of finishing processes, such as those described herein for reshaping or other minor machining, sealing, polishing, and the like.

Technical effects of the present disclosure include, for example, providing a component formed from a monolithic body including a component segment, a supplemental segment, and a transition conduit extending between and fluidly coupling a passage of the component segment and a channel of the supplemental segment. When performing a post-formation process (e.g., burr removal) on the component segment, a transition conduit positioned between the component segment and the supplemental segment of the monolithic body allows the supplemental segment to be removed from the component segment without blocking the passage of the component segment and/or eliminating the risk of the passage being undesirably modified.

The flowchart and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present disclosure. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.

As discussed herein, various systems and components are described as "acquiring" data. It should be appreciated that any solution may be used to obtain the corresponding data. For example, a corresponding system/component can generate and/or be used to generate data, retrieve data from one or more data stores (e.g., databases), receive data from another system/component, and/or the like. When data is not generated by a particular system/component, it is understood that another system/component can be implemented in addition to the illustrated system/component that generates and provides data to the system/component and/or stores data for access by the system/component.

The foregoing figures illustrate some of the associated processing according to several embodiments of the present disclosure. In this regard, each figure or block within the flow chart of the figures represents a process associated with an embodiment of the method. It should also be noted that in some alternative implementations, the acts noted in the figures or blocks may occur out of the order noted in the figures or, for example, may in fact be performed substantially concurrently or in the reverse order, depending upon the acts involved. Also, one of ordinary skill in the art will recognize that additional boxes describing the process may be added.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. "optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.

Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms (such as "about", "about" and "substantially") is not to be limited to the precise value specified. In at least some cases, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. "about" as applied to a particular value of a range applies to both values and may indicate +/-10% of one or more of the stated values unless otherwise dependent on the accuracy of the instrument measuring the value.

The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the disclosure in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. The embodiments were chosen and described in order to best explain the principles of the disclosure and the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.