Chemical processing of additive manufactured workpieces

Abstract

A method for chemical processing an internal cavity of an additive manufactured (AM) metal workpiece is disclosed in which a connector is provided in fluid connection with the internal cavity and a chemical polishing solution is flowed through the connector and the internal cavity to process the internal cavity to a desired finish.

Claims

1. A method for chemical processing an internal cavity of an additive manufactured (AM) metal workpiece, the method comprising: (a) providing an AM metal workpiece having an internal cavity, with an internal surface exhibiting metal debris, excess surface roughness, or temporary support structures; (b) providing at least a first connector in fluid-tight connection with the internal cavity; and (c) circulating a chemical polishing solution from an external reservoir through the first connector and the internal cavity and back to the external reservoir, to process the internal cavity to a desired finish and remove the metal debris, excess surface roughness, or temporary support structures, wherein the chemical polishing solution is capable of chemically reacting with the metal of the AM metal workpiece, wherein the workpiece is immersed in a bath during flowing of the chemical polishing solution through the internal cavity, the bath having liquid and being configured to maintain the workpiece at a constant temperature during flowing of the chemical polishing solution.

2. The method according to claim 1, wherein providing the first connector in fluid-tight connection with the internal cavity comprises aligning a bore of the first connector with an opening to the internal cavity and temporarily adhering the first connector to the workpiece.

3. The method according to claim 2, wherein aligning the bore with the opening to the internal cavity comprises providing an alignment extension made from a soluble polymer that fits into the opening to ensure correct alignment into the cavity.

4. The method according to claim 1, wherein providing the first connector in fluid-tight connection with the internal cavity comprises providing the first connector on a connection jacket having a shape to fit around the workpiece and sealing the first connector to an opening to the internal cavity.

5. The method according to claim 4, wherein the connection jacket is manufactured by additive manufacturing.

6. The method according to claim 1, further comprising providing a second connector in fluid-tight connection with the internal cavity and flowing the chemical polishing solution through the first connector into the internal cavity and out through the second connector.

7. The method according to claim 6, wherein the internal cavity is a blind hole and the first and second connectors are integrated to provide flow to and from the blind hole.

8. The method according to claim 1, wherein the bath is provided with an indicator or equipped with detectors to detect leakage of chemical polishing solution from the internal cavity.

9. The method according to claim 1, wherein the chemical polishing solution is flowed through the internal cavity at a rate that is sufficient to avoid localized bubble formation.

10. The method according to claim 1, wherein after the desired finish is achieved, the first connector is removed.

11. The method according to claim 1, further comprising sealing the internal cavity to prevent entry of chemical polishing solution and performing chemical processing of an external surface of the workpiece.

12. The method of claim 1, wherein the AM metal workpiece is selected from the group consisting of: jet engine fuel nozzles, nozzles, atomizers, impellers, propellers, rotor assemblies, turbine blades, exhaust manifolds, exhaust pipes, gas diffusers, flow manifolds, flow valve manifolds, stationary serpentine passages, heat exchangers, pipe elbows, coil pipes, and mandrels having internal passages with cross-sectional areas of less than 1 mm.sup.2.

13. A method for chemical processing an internal cavity of an additive manufactured (AM) metal workpiece, the method comprising: (a) providing an AM metal workpiece having an internal cavity, with an internal surface exhibiting metal debris, excess surface roughness, or temporary support structures; (b) providing at least a first connector in fluid-tight connection with the internal cavity; and (c) flowing a chemical polishing solution through the first connector and the internal cavity to process the internal cavity to a desired finish and remove the metal debris, excess surface roughness, or temporary support structures, wherein the chemical polishing solution is capable of chemically reacting with the metal of the AM metal workpiece, wherein the workpiece is immersed in a bath during flowing of the chemical polishing solution through the internal cavity, the bath having liquid and being configured to maintain the workpiece at a constant temperature during flowing of the chemical polishing solution, and wherein the desired finish is determined by non-destructive direct inspection using: a borescope; 3D X-ray CT inspection; or ultrasonic imaging.

14. The method according to claim 13, wherein the defined finish is determined by monitoring a parameter of the flowed solution selected from the group consisting of: measuring the differential pressure between the inlet and outlet; measuring the flow rate through the cavity; measuring the concentration of the chemical polishing solution components at the outlet; and measuring the concentration of the dissolved alloy components at the outlet.

15. A method for chemical processing an internal cavity of an additive manufactured (AM) metal workpiece, the method comprising: (a) providing an AM metal workpiece having an internal cavity, with an internal surface exhibiting metal debris, excess surface roughness, or temporary support structures; (b) providing at least a first connector in fluid-tight connection with the internal cavity; and (c) flowing a chemical polishing solution through the first connector and the internal cavity to process the internal cavity to a desired finish and remove the metal debris, excess surface roughness, or temporary support structures, wherein the chemical polishing solution is capable of chemically reacting with the metal of the AM metal workpiece, wherein the workpiece is immersed in a bath during flowing of the chemical polishing solution through the internal cavity, the bath having liquid and being configured to maintain the workpiece at a constant temperature during flowing of the chemical polishing solution, and wherein an amount of chemical polishing solution required to achieve a desired finish is calculated and the amount is flowed through the internal cavity until the chemical polishing solution is exhausted.

Description

SHORT DESCRIPTION OF DRAWINGS

(1) The present invention will be discussed in more detail below, with reference to the attached drawings, in which:

(2) FIG. 1A and FIG. 1B illustrate schematically the attachment of a connector to a cavity in a workpiece according to an aspect of the present invention;

(3) FIGS. 2A and 2B illustrate in plan and side views a first embodiment of a connection to a cavity having an irregular form;

(4) FIGS. 2C and 2D illustrate in plan and side views a second embodiment of a connection to a cavity having an irregular form;

(5) FIG. 3 illustrates schematically a connection to a blind hole cavity according to a further embodiment of the invention;

(6) FIG. 4 illustrates schematically a heated buffer bath in which the invention may be performed; and

(7) FIG. 5 illustrates schematically an apparatus for carrying out the invention.

DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

(8) 1. This invention pertains to the chemical polishing of all metals including but not limited to Titanium, Ti-6V-4Al, Nickel based alloys such as Inconel, Stainless Steels, Cobalt Chrome, Scalmalloy® alloys. 2. Chemical polishing solutions for the various alloys listed above can be found in literature, including: Voort. G F Vander 1999 Appendix G, Chemical Polishing Solutions Metallography Principles and Practice (ASM International) pp 552-61; and William T. Harris, 1976 Chemical Milling: Technology of Cutting Materials by Etching (Oxford Series on Advanced Manufacturing). The invention is of course not limited to published formulations. Examples of other possible chemical polishing solution per alloy that can be used, but not limited, are: Aluminum: 60 mL H.sub.2SO.sub.4 (96%)/30 mL H.sub.3PO.sub.4 (85%)/10 mL HNO.sub.3 (65%)/@ 85° C. Stainless steel: [% by weight]: [30%] HCl (35%)/[40%] H.sub.2SO.sub.4 (96%)/[5.5%] titanium tetrachloride/0.5% HNO.sub.3 (65%) [Optional]/BAL water/@ 70-80° C. Nickel: {% by vol}: {30%} HNO.sub.3 (65%)/{10%} H.sub.2SO.sub.4 (96%)/{10%} H.sub.3PO.sub.4 (85%)/{50%}acetic acid (glacial)/@ 85-95° C. Inconel: Solution A=>30 g CuCl.sub.2 500 mL HCl (35%)/1000 mL H.sub.2O Solution B=>60 mL acetic acid/40 mL HNO.sub.3 (65%)/0.5 mL HCl Pump solution A first followed by solution B. Titanium: [% by vol] {50%} HNO.sub.3 (65%)/{50%}HF (50%) 3. In most cases, it is vital that the connections to the ports of the internal cavities conform to their shape and size. Otherwise, either erosion or inadequate finishing will result. This may not apply when the ports are non-critical. In certain cases, temporary ports may be manufactured as part of the AM process and may be removed once processing of the internal cavity is completed. If this is not possible or desirable, ports may be joined to the workpiece by the following methods. a) If the cavity ports are cylindrical, the connection to the workpiece can be made as follows: i. FIG. 1A shows a workpiece 1 with a cavity opening 2, a wire or alignment object 3, a short tubing 4 (aligned to the cavity by wire 3), a generic tube fitting 5 (also aligned to the cavity by wire 3), and a sealant substance 6 (fixing all the tubing and fittings system to workpiece 1). ii. A wire or other cylindrical alignment object 3 with an outer diameter approximating the cavity's internal diameter is inserted into the cavity opening 2. iii. Tubing 4 with an internal diameter closely approximating that of the cavity is used to enclose alignment object 3. iv. A generic fitting body 5 is inserted surrounding tubbing 4 and wire 3. v. Silicone rubber or another sealant 6 is molded against the fitting body 5 and the workpiece 1 to fix the tubing to the cavity opening 2 and the workpiece 1. vi. After drying, the inserted wire or other object 3 is removed (FIG. 1B). vii. A proper nut fitting 7 with the proper tubing 8 is connected to the generic fitting body union 5. viii. Tubing 8 and 4 are long enough to make direct contact and press tightly in position one from the other. ix. The chemical polishing solution is pumped F through tubing 8 into opening cavity 2. b) If the cavity openings have an irregular shape, the connection to the workpiece can be made as follows: i. FIG. 2A is a plan view of workpiece 1 with the connection fitting 9 made to fit into the opening cavity 10 with an irregular shape. FIG. 2B is a side view of a cross-section through the workpiece 1. ii. The connection fitting 9 can be custom made by 3D printing, or any other machining or molding process, such that it conforms exactly to the shape of the irregular opening 10 in the workpiece 1. The dimensions may be based on the CAD model used for the workpiece. iii. Connection fitting 9 has an alignment extension 11 at its base that fits into the cavity opening. iv. The alignment extension 11 is made from a soluble polymer such that there is an extension beyond the base of the fitting that fits into the opening to ensure correct alignment into the cavity 10. v. The alignment extension 11 is inserted into the opening and connection fitting 9 is glued with a sealing compound 12 to the workpiece 1. vi. After the connection fitting 9 is firmly affixed to the workpiece 1, the interior soluble polymer of the alignment extension 11 is dissolved with a suitable solvent. vii. Connection fitting 9 is fabricated with a suitable fitting at its upper end so that it can be easily connected to a nut fitting with a tube that will deliver the chemical polishing solution, such as the fitting 7 and tubing 8 presented in FIG. 1B. viii. In FIGS. 2C and 2D, a more complex connecting arrangement is shown in similar views to those of FIGS. 2A and 2B. The connecting arrangement can be built to form a strap or jacket 13 around the workpiece 1 to secure the connection fittings 9 to the tubing system 8. The jacket 13 can be secured with a clip 14, or any other kind of securing system. The connection fitttings 9 may be integrally formed with the jacket 13 or connected thereto by mechanical means or by welding, adhesive or the like. c) If the cavity opening is a blind hole (cavity), the connection to the workpiece can be made as follows: i. FIG. 3 is a drawing showing a blind hole cavity 15 in workpiece 1, with the connection fitting 16 made to fit onto the opening of the blind hole cavity 15. ii. The connection fitting 16 can be custom made by 3D printing, or any other machining or molding process, such that it conforms exactly to the shape and dimensions of the blind hole cavity 15 based on the CAD model. iii. Connection fitting 16 is connecting a tube-in-tube configuration in which inner tube 17 (used as the inlet by which the chemical polishing solution will be pumped in) is a tube small enough to fit inside of the blind hole cavity 15, reaching the bottom of the cavity and leaving enough room with respect to the outer tube 18 (used as the outlet by which the chemical polishing solution will be pumped out) for free flowing F of the chemical polishing solution. iv. The connection fitting 16 is adhered with a sealing compound 19 to the workpiece 1. v. Connection fitting 16 is fabricated with a suitable fitting at its upper end so that it can be easily connected to a nut fitting 20 with outer tube 18, which will be connected to inner tube 17 that will deliver the chemical polishing solution. vi. A more complex connecting fitting can be built to form a strap or a jacket 21 around the workpiece 1 to secure the connections 16 to the blind hole cavity 15. The jacket or strap 21 can also be secured with a clip, or any other kind of securing system, such as clip 14 presented in FIG. 2D.
Note: This tube-in-tube configuration for blind cavities also applies to the connection configurations described in Example a (FIG. 1) and Example b (FIG. 2) of this section, or any minor modifications thereof. 4. The workpiece 1 with its fittings 5 and attached tubings 8, is immersed in a heated buffer bath 30 as shown in FIG. 4. The buffer bath 30 is maintained at approximately the same temperature as that of the polishing chemistry solution by heating and stirring plate 32. Preferentially, the solution of the buffer bath 30 has a pH close to 7, but this will depend on the workpiece material. The buffer salts and indicators will be chosen accordingly. This bath has two important features: first, it will keep the temperature of the system constant and will buffer any change in temperatures during the process; and secondly, any failure in the pumping system where the corrosive and dangerous polishing solution leaks out will be immediately noticed and neutralized. 5. An acid/base indicator may be added to the bath. It is used to detect leakage at the connections and to ensure the bath is neutralizing the polishing chemistry. In a more complicated set-up, the bath may be be equipped with several chemical detectors to detect leakage too, such as pH sensors, ion selective electrodes, etc. 6. Once the temperature of the workpiece 1 is equilibrated with the temperature of the buffer bath 30, the polishing chemistry solution may be pumped F from a chemical polishing solution bath 34 through the inlet tubing using a pump 36 and apparatus as shown in FIG. 5. 7. The pump 36 may be a constant volumetric flow pump such as that provided by a piston pump. 8. The outlet tubing may be immersed into a secondary bath 38 to capture the effluent, making it harmless by dilution and/or neutralization. As an alternative method the effluent can be recirculated to the solution bath 34 using a valve 42 to control recirculation. 9. The rate of pumping is preferably set at a high enough volumetric flow such that no gas collects in the cavity and the interior walls of the cavity are uniformly covered with chemistry that is essentially at the same concentration and temperature throughout the cavity. 10. The chemical polishing solution in the solution bath 34 is maintained at a constant temperature for that specific working polishing solution (it will vary depending on the alloy). This may require heating of the solution or alternatively cooling to below ambient using heating and stirring plate 40. 11. If a constant volumetric flow pump 36 is used, the degree of finishing can be detected by measuring certain flow parameters. Since partially melted powder from the AM process and the support cavities will be removed faster than a smooth surface, the rate of change of the parameters will change at a faster rate initially, but then dramatically decrease as the loosely held and/or partially melted powder and/or the support structures are removed. There are several methods of monitoring this, but not limited to: a) Measuring the differential pressure between the inlet and outlet using pressure sensors 44, 46. b) Measuring the flow rate through the cavity. c) Measuring the concentration of the chemical polishing solution components, or the dissolved alloy components, at the outlet. 12. The degree of finishing can also be determined with non-destructive direct inspection using, but limited to: a) Borescope b) 3D X-ray CT inspection c) Ultrasonic imaging
Process Determination Methods:
Method I 1. Assume that the surface texture of the interior surfaces is no greater than twice that of the exterior surface, for example the S.sub.dr (Developed Interfacial Area Ratio) of the interior vs the exterior. It may be greater than the exterior, depending on the size of the cavity and supports structures. For cavities greater than approximately 3 mm, its “ceiling” may have more partially melted powder and the cavity may also have support structures. 2. The nominal interior and exterior surface areas are known from the 3D model. 3. Experimentally determine the amount of stock removed per volume of polishing solution. This can be done by: a. Obtain a test specimen made by the same AM process. e.g., 20 mm×20 mm×5 mm rectangle b. Make a chemical polishing solution with a concentration close to a not-working formulation (this will be vary per chemical polishing solution) c. Place 50 mL of that chemical polishing solution in a Teflon beaker and set it up to the specific working temperature for that chemical polishing solution. d. Dip the test specimen in the polishing solution beaker until the chemistry is exhausted. e. Measure the amount of stock removed. f. If more stock removal is required to attain the required surface finish, repeat the process with the specimen until another 50 mL of fresh chemistry is exhausted. g. Repeat as necessary until maximum finishing has been reached. h. From this easy experimental set-up one can calculate the stock removal/unit area/volume of chemistry. i. Knowing the surface area of the cavity, the volume of polishing chemistry required to finish the cavity can be easily calculated. 4. Make tight seals at the openings to the cavity with tubing. 5. Immerse the part in a liquid bath with tubing connections to the openings and let the workpiece temperature equilibrate with the bath. 6. Recirculate the calculated volume of the polishing chemistry, at its working temperature, through the cavity at a high enough rate so that bubble formation is not an issue. 7. Recirculate the chemistry until it is exhausted.
Method II 1. Obtain a test specimen made by the same AM process. e.g., 20 mm×20 mm×5 mm rectangle. 2. Dip the test specimen in a volume of polishing chemistry large enough such that its concentration and temperature essentially stays constant. 3. Measure the time necessary to reach the required surface finish. 4. Now pump the solution through the cavity using the same procedure as in Method I for one to two times (tacking into account the removal of the support structures in the interior of the cavity) the duration to finish the test specimen in Step 1. 5. If the cavity size is smaller than 3 mm, the cavity's interior should be finished in the same time as that measured in Step 3. 6. If the cavity is larger than 3 mm, then the cavity will have more partially melted powder on the ceiling and support structure. Therefore, it is advisable to process the part for twice the time measured in Step 3.
Method III 1. The partially melted/sintered powder and/or temporary support structures in a cavity increases the pressure drop across the cavity as chemistry is pumped through it. 2. As chemistry is pumped through, the flow rate will increase and the pressure drop will decrease during finishing as the partially melted powder and support structures are removed. 3. The rate of change in pressure drop or flow rate will slow down after the partially melted powder is removed. 4. The pressure or flow rate can be measured with a pressure transducer at the inlet and a flow meter, respectively. It is also possible to measure the differential pressure at the inlet and outlet with a differential pressure transducer. 5. A constant flow pump pumps chemistry through the cavity. 6. The process is stopped when the rate of change significantly drops.
Method IV 1. The metal debris will be dissolved in the internal cavity as the polishing chemistry is pumped through it. 2. As the polishing chemistry is pumped through, the concentration of the dissolved alloy and their byproducts will increase as the partially melted powder and support structures are removed. 3. The concentration of the alloys and/or polishing reaction byproducts can be measured with a chemical sensor. 4. A constant increase of metal alloy and/or polishing reaction byproducts concentration is indicative of the dissolution of the metal debris on the cavity and surface finishing process. 5. The process is stopped when the concentration of the metal alloy and/or polishing reaction byproducts drops and reaches a constant plateau.
Method V 1. Specialized instrumentation inspection systems, such as 3D X-ray CT and/or borescope and/or ultrasonic imaging, can also be used to monitor the surface integrity of the surface of AM interior cavities. 2. If the actual surface area can be measured accurately, then the time to pump fresh chemistry through the cavity can be calculated to remove the partially melted powder and/or support structure. 3. Alternatively, if the inspection system is available at the chemical polishing site, then the pumping can done incrementally with inspections done to determine the extent of surface finishing.

(9) In each case, processing of the external surface of the component may take place, if required, prior to or after the finishing of the internal cavities. To this end, the internal cavities may be stoppered to prevent ingress of polishing solution and the whole component may then be processed in a processing bath, with or without media (abrasive or non-abrasive) by otherwise conventional methods. This may use the same chemical polishing solution as used for the internal cavity or a different solution. Post-processing of the external surface of the component may also assist in removing any remains of the connector.

(10) The present invention has been described above with reference to a number of exemplary embodiments as shown in the drawings. Modifications and alternative implementations of some parts or elements are possible, and are included in the scope of protection as defined in the appended claims.