Flow devices and methods of making the same

Abstract

A method for producing a device having at least one internal feature includes manufacturing an internal volume of the internal features out of a first material, disposing the internal volume in a parent material that has a higher melting point than the first material, causing the internal volume to melt within the parent material, and allowing at least a portion of the first material to diffuse into the parent material, thereby leaving behind the at least one internal feature within the parent material.

Claims

1. A flow device, comprising: a parent material defining a flow channel; and a channel material diffused into the parent material through a wall that defines the flow channel, wherein the channel material is only partially diffused into the parent material from the flow channel such that there is a portion of the parent material that includes the channel material and a portion of the parent material that does not include the channel material.

2. The flow device of claim 1, wherein a diffusion gradient exists such that an amount of channel material becomes greater closer to the wall that defines the flow channel.

3. The flow device of claim 1, wherein the flow device is a fuel nozzle and the flow channel is one or more fuel circuits.

4. The flow device of claim 1, wherein the parent material includes at least one of a metal, metal alloy, a composite material, or a ceramic.

5. The flow device of claim 1, wherein the channel material includes at least one of BNi-2, BNi-6, NB 30, NB 150, Bni-3, MBF-60, MBF-80, DF-3, NiCrBSi, Haynes 230 doped with B, Al, Al+SiO.sub.2, B.sub.2O.sub.3, or Oxynitride glass.

6. The flow device of claim 5, wherein the wall that defines the flow channel includes a mirror finish.

7. A flow device, comprising: a parent material defining a flow channel; and a channel material diffused into the parent material through a wall that defines the flow channel, wherein a diffusion gradient exists such that an amount of channel material becomes greater closer to the wall that defines the flow channel.

8. The flow device of claim 7, wherein the flow device is a fuel nozzle and the flow channel is one or more fuel circuits.

9. The flow device of claim 7, wherein the parent material includes at least one of a metal, metal alloy, a composite material, or a ceramic.

10. The flow device of claim 7, wherein the channel material includes at least one of BNi-2, BNi-6, NB 30, NB 150, Bni-3, MBF-60, MBF-80, DF-3, NiCrBSi, Haynes 230 doped with B, Al, Al+SiO.sub.2, B.sub.2O.sub.3, or Oxynitride glass.

11. A flow device, comprising: a parent material defining a flow channel; and a channel material diffused into the parent material through a wall that defines the flow channel, wherein the flow device is a fuel nozzle and the flow channel is one or more fuel circuits.

12. The flow device of claim 11, wherein the parent material includes at least one of a metal, metal alloy, a composite material, or a ceramic.

13. The flow device of claim 11, wherein the channel material includes at least one of BNi-2, BNi-6, NB 30, NB 150, Bni-3, MBF-60, MBF-80, DF-3, NiCrBSi, Haynes 230 doped with B, Al, Al+SiO.sub.2, B.sub.2O.sub.3, or Oxynitride glass.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, embodiments thereof will be described in detail herein below with reference to certain figures, wherein:

(2) FIG. 1 is a block diagram of an embodiment of a method in accordance with this disclosure;

(3) FIG. 2 is a perspective view of an embodiment of a flow volume in accordance with this disclosure;

(4) FIG. 3 is a cross-sectional view of an embodiment of a forming assembly, showing a flow volume made of a channel material disposed in a parent material within a container; and

(5) FIG. 4 is a perspective view of an embodiment of a fuel nozzle shaped from the parent material of FIG. 3.

DETAILED DESCRIPTION

(6) Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a block diagram of an embodiment of a method in accordance with the disclosure is shown in FIG. 1 and is designated generally by reference character 100. Other embodiments and/or aspects of this disclosure are shown in FIGS. 2-4. The systems and methods described herein can be used to additively manufacture flow devices with complex interior flow channels that are smooth.

(7) A method for producing a device having at least one internal feature includes manufacturing an internal volume of the internal features out of a first material, disposing the internal volume in a parent material that has a higher melting point than the first material, causing the internal volume to melt within the parent material, and allowing at least a portion of the first material to diffuse into the parent material, thereby leaving behind the at least one internal feature within the parent material.

(8) While the embodiments herein are described such that the internal feature is a flow channel, the internal volume is a flow volume, and the first material is a channel material, any other suitable internal features, internal volumes, and/or first materials are contemplated herein.

(9) Referring to FIG. 1, a method 100 for producing a device having a flow channel defined therein includes, e.g., in block 101, manufacturing a flow volume (e.g., flow volume 200 as shown in FIG. 2) of the flow channel out of a channel material. The method 100 can also include, e.g., in block 103, selecting a parent material (e.g., parent material 303 shown disposed in a container 301 as shown in FIG. 3) that has a higher melting point than the channel material.

(10) The parent material can be selected to have at least one desired diffusion characteristic to facilitate a desired diffusion of the channel material within the parent material. For example, the parent material can be selected to have a desired porosity, grain size, molecular structure, and/or any other suitable characteristic that affects diffusion of the channel material to the parent material.

(11) In certain embodiments, the parent material can be selected to include a powder. The powder can include at least one of a metal powder, an alloy powder, a composite powder, or a ceramic powder. It is contemplated that the parent material can include a non-powder or any other suitable material.

(12) Referring additionally to FIG. 2, manufacturing the flow volume 200 can include additively manufacturing the flow volume 200 (e.g., via laser sintering, material deposition, or any other suitable means). In certain embodiments, the method 100 can further include smoothing an exterior surface 201 of flow volume 200 (e.g., to remove roughness from additive manufacturing).

(13) The channel material that makes up the flow volume 201 can include at least one of BNi-2, BNi-6, NB 30, NB 150, Bni-3, MBF-60, MBF-80, DF-3, NiCrBSi, Haynes 230 doped with B, Al, Al+SiO.sub.2, B.sub.2O.sub.3, or Oxynitride glass. However, it is contemplated that the flow volume 201 can be made of any suitable material (e.g., metal, plastic) that is configured to permeate into the parent material. In certain embodiments, the channel material can be selected as a function of the selected parent material, and vice versa.

(14) The flow volume 200 can have any suitable shape and is the negative of at least part of a desired flow channel inside the flow device. In certain embodiments, manufacturing the flow volume 200 can include forming the flow volume 200 such the flow channel defines at least part of a fuel flow circuit.

(15) Referring additionally to FIG. 3, the method 100 further includes, e.g., in block 105, disposing the flow volume (e.g., flow volume 200 as shown) in the parent material 303 (e.g., by placing the flow volume 201 in the container 301 and filling parent material 301 around the flow volume 201). The container 301 can include any suitable shape (e.g., a mold shape for a desired flow device). The parent material 303 can be consolidated to a suitable porosity after disposing the parent material 303 around the flow volume 201.

(16) The method 100 can also include, e.g., in block 107, causing the flow volume (e.g., flow volume 200) to melt within the parent material 303 and allowing at least a portion of the channel material to diffuse into the parent material 303, thereby leaving behind the flow channel within the parent material 303.

(17) Causing the flow volume (e.g., flow volume 200) to melt can include subjecting the channel material of the flow volume and the parent material 303 to at least one of cold isostatic pressing or hot isostatic pressing. For example, the parent material 303 having the flow volume 200 disposed therein can be subjected to increased temperature and/or pressure suitable to melt the channel material. Any other suitable method to melt the flow volume (e.g., flow volume 200) is contemplated herein.

(18) The method 100 can further include fusing the parent material 303 together after or during melting the channel material within the parent material 303. This causes the parent material 303 to take a rigid shape defining the flow channels therein.

(19) In certain embodiments, the channel material is only partially diffused into the parent material from the flow channel such that there is a portion of the parent material that includes the channel material and a portion of the parent material that does not include the channel material. In certain embodiments, a diffusion gradient can exist such that an amount of channel material becomes greater closer to the wall that defines the flow channel. In certain embodiments, the wall of the parent material that ultimately defines the flow channel can include a mirror finish or any other suitable smoothness.

(20) The method 100 can further include shaping the parent material. For example, referring additionally to FIG. 4, the parent material 303 can be shaped (e.g., via at least one of milling, casting, subtractive manufacturing, and/or additive manufacturing) into a fuel nozzle 400 for a turbomachine after fusing the parent material 303 together.

(21) Utilizing the methods above, a flow device can include improved surface finish of complex internal flow channels which can increase life of flow devices (e.g., fuel nozzles) and improve performance. The methods and systems of the present disclosure, as described above and shown in the drawings, provide for improved flow devices with superior properties including smooth complex interior flow channels. While the apparatus and methods of the subject disclosure have been shown and described with reference to embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the spirit and scope of the subject disclosure.