Hybride part and method of manufacture

Abstract

A part (P) includes a first (FP), and a second portion (SP), which meet at an interface (IF). A channel (CH) extends from the first portion (FP) through the interface (IF) into the second portion (SP). Further there is a method to generate the part (P). To refurbish a part with tiny geometry channels, the second portion (SP) is produced by additive manufacturing technology on the interface (IF) with the first portion (FP), the channel (CH) has a first average diameter (DI) in the first portion (FP) and the interface (IF), and the channel (CH) has a second average diameter (D2) in the second portion (SP) at said interface (IF). The second diameter (D2) is larger than the first diameter (DI). The channel (CH) has a first tapered portion (TP) which narrows in the second portion (SP) at increasing distance from the interface (IF).

Claims

1. A hybride part comprising: a first portion; a second portion positioned at said first portion; an interface defining said first portion from said second portion; wherein said second portion is produced by additive manufacturing technology and is produced on said first portion and at said interface; a channel extending from said first portion through said interface and into said second portion; said channel has a first average diameter in said first portion and at said interface; said channel has a second average diameter in said second portion and at said interface; said second average diameter being larger than said first average diameter; wherein said channel tapers narrower along a first tapered section of said channel in said second portion wherein said first tapered section tapers narrower at increasing distance from said interface; wherein said channel extends along a first central axis in said first portion at least in proximity to said interface; wherein said channel also extends along a second central axis in said second portion at least in proximity to said interface; wherein said first axis is parallel to and offset from said second axis at and near said interface; and wherein an end of said channel in said first portion at said interface and a first end of said first tapered section of said channel in said second portion at said interface are at a same level, one side of said end of channel in said first portion is within a portion of said first end of said channel in said second portion, said portion being within a third average diameter of a second section of said channel in said second portion, said second section ending at a second end of said first tapered section, and another side of said end of said channel in said first portion is outside of said portion of said first end of said first tapered section of said channel in said second portion.

2. The hybride part according to claim 1, wherein said third average diameter of said second section of said channel in said second portion is nominally the same as said first average diameter.

3. The hybride part according to claim 1, wherein said second section has a round, oval, or elliptic cross section.

4. A method to produce the hybride part according to claim 1, the method comprising: providing said first portion for said hybride part; forming said second portion for said hybride part by adding material by additive manufacturing to said first portion and thereby also forming said interface between said first and said second portions in order to build up said second portion, and said interface defining said first portion from said second portion; providing said channel extending from said first portion, through said interface and into said second portion; providing said first portion, in which said channel extends through said first portion along said first central axis at least in proximity to said interface; wherein said channel has said first average diameter in said first portion at said interface; adding material to build up said second portion at said interface and causing said channel to extend along said second central axis at least in proximity to said interface; said channel has said second average diameter in said second portion at said interface; wherein said second average diameter is larger than said first average diameter; and wherein said channel in said second portion tapers along said first tapered section which becomes narrower in said second portion at increasing distance from said interface.

5. The method according to claim 4, wherein said second central axis of said second portion is offset from said first central axis over said interface, and said offset is smaller than the diameter of said channel in said second portion at said interface minus the diameter of said channel in said first portion at said interface.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) The FIGURE shows a schematic depicting a hybride part according to the invention made by a method according to the invention.

DESCRIPTION OF AN EMBODIMENT

(2) The FIGURE shows a schematic depiction of a hybride part P according to the invention comprising a first portion FP and a second portion SP which meet each other at an interface IF defining said first portion FP from the second portion SP. A channel CH1 extends from the first portion FP through the interface IF into the second portion SP. The channel CH1 in the first portion FP extends along a central first axis X1, and in the second portion SP, the channel CH2 extends along a second axis X2. The first axis X1 and the second axis X2 are nominally meant to be identical. But, in an actual hybride part, those axes are offset from each other by an offset OFF due to manufacturing or alignment inaccuracies. The second portion SP is built up on the interface IF with the first portion FP by additive manufacturing. In this example, the SP was built up by laser sintering.

(3) The channel CH1 in the first portion FP has a first diameter D1, especially in the area of the interface IF. The channel CH2 in the second portion SP in the area of the interface IF has a second diameter D2, which is larger than D1. At an increasing distance away from the interface IF, the channel CH2 in the second portion SP is tapered along a first tapered portion TP until that channel's diameter has a third diameter D3. The third diameter D3 here is identical with the first diameter D1. Diameter here means that the design has a nominal identical average diameter, which can deviate according to manufacturing accuracy. In this example, the tapering is conical with a conus-angle of α. However the tapering can have any geometry including a “tulip” shape aimed to reduce turbulence if the channel CH conducts a process fluid PF especially in the direction from the first portion FP to the second portion SP. Preferably, the channel is configured to conduct a process fluid PF in the direction from the first portion FP to the second portion SP with reduced pressure loss. Preferably, the channel CH2 extends all the way through the second part SP, such that the channel CH2 might join into a nozzle NZ.

(4) According to the method of the invention to manufacture the hybride part P, in a first step, the first portion FP is provided and the channel CH1 extends along a first central axis XI through the first portion FP.

(5) In a second step, material is added by additive manufacturing to the interface IF to build up the second portion SP. The channel CH2 in the second portion SP is provided with the above described geometry.

(6) Preferably, the offset OFF between the first axis X1 and the second axis X2 is less than (D2−D1), and preferably is (D2−D1)/2.