ADDITIVELY MANUFACTURED TURBOMACHINERY COMPONENTS WITH DESIGNED ATMOSPHERE OF AN INNER VOIDED CORE FOR HEAT TRANSFER CONTROL

An additively manufactured component includes an outer shell, the outer shell enclosing a space therein. An inner lattice structure is in the space of the outer shell. Interspaces are formed in the inner lattice structure. A method of forming an additively manufactured component includes evacuating a chamber in which the additively manufactured component will be formed, and forming in the chamber layer by layer an outer shell enclosing a core. The core includes a lattice structure with interspaces formed in the lattice structure.

BACKGROUND

The present disclosure relates to additively manufactured components, and in particular, to additively manufactured turbomachinery components.

Turbomachinery components of environmental control systems often utilize two or more rotors within the same casing. Each of the rotors can have different flow streams which have different temperatures. Heat transfer between these rotors degrades unit performance. Therefore, cost effective techniques are desired to minimize parasitic heat fluxes between the rotors. Alternatively, the heat exchanger of the environment control system is desired to have high heat fluxes while decreasing weight and vibrational transfer. Therefore, cost effective techniques are desired to maximize thermal heat fluxes while minimizing vibrational transfer characteristics.

SUMMARY

In one embodiment, an additively manufactured component includes an outer shell, the outer shell enclosing a space therein. An inner lattice structure is in the space of the outer shell. Interspaces are formed in the inner lattice structure.

In another embodiment, a method of forming an additively manufactured component includes evacuating a chamber in which the additively manufactured component will be formed. and forming in the chamber layer by layer an outer shell enclosing a core. The core includes a lattice structure with interspaces formed in the lattice structure.

In another embodiment, an air cycle machine includes a first component which includes an outer shell and a core enclosed by the outer shell. The core includes a lattice structure with interspaces.

While the above-identified drawing figures set forth one or more embodiments, other embodiments are also contemplated. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the claims. The figures may not be drawn to scale, and applications and embodiments may include features and components not specifically shown in the drawings.

DETAILED DESCRIPTION

This disclosure relates to an additively manufactured (AM) component where within the manufactured component there is a lattice structure which has interspaces formed therein. The interspaces can be filled with a selected gas at a selected pressure. By filling the interspaces with the selected gas at the selected pressure the heat and vibrational transfer characteristics can be altered. The AM component will be discussed below with reference to FIGS.

FIG.1is a perspective view of an exemplary embodiment of additively manufactured component10. Additively manufactured component10includes outer shell12, inner lattice14, and interspaces16. A portion of outer shell12is removed inFIG.1to show inner lattice14.

As shown inFIG.1, inner lattice14is a foam metal core enclosed by outer shell12. Outer shell12is also metal and can be formed from the same metal as inner lattice14or a different metal. Outer shell12ofFIG.1can be connected to a larger assembly outside of additively manufactured component10through welding, brazing, or any other suitable attachment mechanism known to those of skill in the art. In the embodiment ofFIG.1, additively manufactured component10is an elongated rectangular rod, however additively manufactured component10can be cylindrically shaped, frustoconically shaped, shaped as a rod with a square cross section, shaped as turbomachinery components, or any other suitable shape which has outer shell12with inner lattice14therein. While additively manufactured component10inFIG.1is made of metal, additively manufactured component10can be formed by direct metal laser sintering, electron beam freeform fabrication, electron-beam melting, selective laser melting, or selective laser sintering in an additive fashion. The powder used to make outer shell12and inner lattice14can be made of a material selected from the group comprising stainless steel, corrosion-resistant steel, nickel-chromium alloy, titanium, aluminum, synthetic fiber, fiberglass, composites, and combinations thereof. Other suitable materials known to those of skill in the art to be able to be formed in an additive fashion can be used. Inside of outer shell12of additively manufactured component10is inner lattice14. Inner lattice14has plurality of interspaces16therein. Inner lattice14is formed by direct metal laser sintering, electron beam freeform fabrication, electron-beam melting, selective laser melting, or selective laser sintering the powder in an additive fashion.

Additively manufactured component10can be utilized in any application in which a lighter part is desired and/or in any application in which changes to the heat and vibration transfer characteristics is desired. Such application includes, but is not limited to, seal plates of air cycle machines, rotors of air cycle machines, and rotors of cabin air compressors. Other potential applications include components on aircraft, boats, automobiles, or spacecraft.

FIGS.2A-2Bdisclose examples of inner lattice14and will be discussed together.FIG.2Ais a cross sectional view of rhombus shaped inner lattice14where each interspace16of inner lattice14is fluidically isolated and separated from each other.FIG.2Bis a cross sectional view of rhombus shaped inner lattice14where some of plurality of interspaces16are interconnected. Inner lattice14is composed of plurality of interspaces16. Each interspace16can be filled with heat transfer medium18, as shown inFIG.2A, and can optionally be coated with thermal radiation reflective coating20. As shown inFIG.2B, each of plurality of interspaces16can be connected to each other through plurality of lattice interconnections22. Lattice interconnections22are passages that fluidically connect interspaces16with each other. Plurality of interspaces16can be connected to an ambient atmosphere through plurality of pressure equilibrium holes24. Pressure equilibrium holes24inFIG.2Bextend through outer shell12to connect plurality of interspaces16and plurality of lattice interconnections22to ambient atmosphere.

Inner lattice14can be rhombus shaped as shown in the embodiments ofFIGS.2A and2B. Alternatively inner lattice14can be triangular, quadrangular, hexagonal, spherical, non-symmetrical, or any other shape known to those of skill in the art to be able to form plurality of interspaces16in inner lattice14. Inner lattice14can be formed at the same time as forming outer shell12and can be integral with outer shell12. As such, inner lattice14can be formed of the same materials as outer shell12as discussed above with respect toFIG.1.

Each of interspaces16can be filled with heat transfer medium18. Heat transfer medium18can be a selected fluid at a selected pressure. The selected fluid can be a gas which can comprises at least one of krypton, argon, xenon, nitrogen, oxygen, and combinations thereof. The selected gas can further comprise any gas known to those of skill in the art as being insertable into interspaces16. The selected fluid can also be a liquid. The selected liquid can comprise at least one of water, oil, heat-transfer fluid, coolant, and combinations thereof. The selected liquid can further comprise any liquid known to those of skill in the art as being insertable into interspaces16. The selected pressure can be less than 0.3 atmosphere (ATM), which is approximately the pressure experienced by aerospace components at a cruising altitude of a plane. Alternatively, the selected pressure can be less than 0.03 ATM, which is considered a low vacuum. Alternatively, the selected pressure could be less than 0.003 ATM which is considered a medium vacuum. When heat transfer medium18is inserted at pressures which are considered low vacuum, medium vacuum, or at even lower pressures, additively manufactured component10can conduct heat through the component at significantly slower rates and vibrational transfer through additively manufactured component10can be significantly reduced.

Heat transfer medium18can be inserted into inner lattice14either during or after formation of interspaces16. Insertion of heat transfer medium18during formation of interspaces16comprises at least evacuating a chamber of the additive manufacturing machine used to form additively manufactured component10. The chamber is then filled with the selected fluid at the selected pressure. While the chamber is filled with the selected fluid at the selected pressure, the additive manufacturing machine forms additively manufactured component10in the chamber, thus trapping the selected fluid at the selected pressure within interspaces16of additively manufactured component10. Alternatively, heat transfer medium18can be inserted into interspaces16after formation of additively manufactured component10. If additively manufactured component10has plurality of lattice interconnections22and pressure equilibrium holes24, the selected fluid can be inserted into interspaces16at the selected pressure through pressure equilibrium holes24and into deeper interspaces16of additively manufactured component10through lattice interconnections22. After insertion of heat transfer medium18, pressure equilibrium holes24can be sealed, sealing in heat transfer medium18.

Thermal radiation reflective coating20can be coated on the insides of each of interspaces16. Thermal radiation reflective coating20is shown coated on the inside of a top rhombus interspace16and a right rhombus interspace16inFIGS.2A and2B. Thermal radiation reflective coating20can be coated on any number of interspaces16ranging from zero to n, where n is the number of interspaces16. When coated on zero interspaces, none of interspaces16are coated with thermal radiation reflective coating20and when coated on n interspaces, all of interspaces16are coated with thermal radiation reflective coating20. Thermal radiation reflective coating20reflects the thermal radiation that radiates from the object due to its increased temperature. Thermal radiation reflective coating20reduces the internal heat transfer of additively manufacture component10. Thermal radiation reflective coating20can be applied to interspaces16via a chemical or physical layer deposition. Thermal radiation reflective coating20can be formed directly into the side walls of interspaces16when additively manufacturing additively manufactured component10.

Interspaces16can be sectioned-off to form multiple sections of interspaces16within additively manufactured component10where each section of interspaces16is fluidically isolated from the other sections of interspaces16. In the example shown inFIG.2B, inner lattice14includes two sections of interspaces16. A single lattice interconnection22connects the top rhombi interspace16and the left rhombi interspace16to form a first section of connected interspaces16that share the same heat transfer medium18. The left rhombi interspace16and the bottom rhombi interspace16are connected by a single lattice interconnection22to form a second section of connected interspaces16that share the same heat transfer medium18and that is fluidically isolated from the first section of connected interspaces12if pressure equilibrium holes24are sealed.

Pressure equilibrium holes24extend through outer shell12into at least one or more of interspaces16. Pressure equilibrium holes24fluidically connect the at least one or more interspaces16to an outside ambient atmosphere with an ambient pressure. Pressure equilibrium holes24allow for an internal pressure within interspaces16of additively manufactured component10to be substantially the same as the ambient pressure. Interspaces16connected by lattice interconnections22to interspaces16with equilibrium holes24can also equilibrate to the ambient pressure. Maintaining interspaces16at the ambient pressure can reduce deflection, expansion or contraction of the part compared to maintaining interspaces16at a specific pressure if the pressure outside the part changes substantially.

FIGS.3A-3Cwill be discussed together since they show air cycle machine110and two applications of AM turbomachinery component10in air cycle machine110.FIG.3Ais a cross-sectional view of air cycle machine110.FIG.3Bis a cross-sectional view of insulating seal plate124positioned in air cycle machine110.FIG.3Cis a side view of dual-rotor component178with insulating lattice structure180therebetween with a portion of an outer shell removed to show insulating lattice structure180.

FIG.3Ais a cross-sectional view of air cycle machine110, which includes fan section112, compressor section114, first turbine section116, second turbine section118, tie rod120, fan and compressor housing122, seal plate124, first turbine housing126, and second turbine housing128. Fan section112includes fan inlet130, fan duct132, fan outlet134, and fan rotor136. Compressor section114includes compressor inlet140, compressor duct142, compressor outlet144, compressor rotor146, diffuser148, and compressor rotor shroud149. First turbine section116includes first turbine inlet150, first turbine duct152, first turbine outlet154, first turbine rotor156, and first turbine rotor shroud158. Second turbine section118includes second turbine inlet160, second turbine duct162, second turbine outlet164, and second turbine rotor166. Air cycle machine110further includes first journal bearing170, first rotating shaft172, second journal bearing174, and second rotating shaft176. Also shown inFIG.1is axis Z.

Fan section112, compressor section114, first turbine section116, and second turbine section118are all mounted on tie rod120. Tie rod120rotates about axis Z. Fan and compressor housing122is connected to seal plate124and first turbine housing126with fasteners. Seal plate124separates flow paths in fan and compressor housing122from flow paths in first turbine housing126. First turbine housing126is connected to second turbine housing128with fasteners. Fan and compressor housing122, first turbine housing126, and second turbine housing128together form an overall housing for air cycle machine110. Fan and compressor housing122houses fan section112and compressor section114, first turbine housing126houses first turbine section116, and second turbine housing128houses second turbine section118.

Fan section112includes fan inlet130, fan duct132, fan outlet134, and fan rotor136. Fan section112typically draws in ram air from a ram air scoop or alternatively from an associated gas turbine or other aircraft component. Air is drawn into fan inlet130and is ducted through fan duct132to fan outlet134. Fan rotor136is positioned in fan duct132adjacent to fan outlet134and is mounted to and rotates with tie rod120. Fan rotor136draws air into fan section112to be routed through air cycle machine110.

Compressor section114includes compressor inlet140, compressor duct142, compressor outlet144, compressor rotor146, and diffuser148. Air is routed into compressor inlet140and is ducted through compressor duct142to compressor outlet144. Compressor rotor146and diffuser148are positioned in compressor duct142. Compressor rotor146is mounted to and rotates with tie rod120to compress the air flowing through compressor duct142. Diffuser148is a static structure through which the compressor air can flow after the air has been compressed with compressor rotor146. Air exiting diffuser148can then exit compressor duct142through compressor outlet144. Compressor rotor shroud149is positioned radially outward from and surrounds compressor rotor146.

First turbine section116includes first turbine inlet150, first turbine duct152, first turbine outlet154, first turbine rotor156, and first turbine rotor shroud158. Air is routed into first turbine inlet150and is ducted through first turbine duct152to first turbine outlet154. First turbine rotor156is positioned in first turbine duct152and is mounted to and rotates with tie rod120. First turbine rotor156will extract energy from the air passing through first turbine section116to drive rotation of tie rod120. First turbine rotor shroud158is positioned radially outward from and surrounds first turbine rotor56.

Second turbine section118includes second turbine inlet160, second turbine duct162, second turbine outlet164, and second turbine rotor166. Air is routed into second turbine inlet160and is ducted through second turbine duct162to second turbine outlet164. Second turbine rotor166is positioned in second turbine duct162and is mounted to and rotates with tie rod120. Second turbine rotor166will extract energy from the air passing through second turbine section118to drive rotation of tie rod120.

FIG.3Bis a cross-sectional view of seal plate124positioned in air cycle machine110.FIG.3Bshows fan and compressor housing122, seal plate124, first turbine housing126, compressor duct142, compressor rotor146, diffuser148, compressor rotor shroud149, first turbine duct152, first turbine rotor156, first turbine rotor shroud158. Seal plate124includes body200and bore202. Body200includes first side210, second side212, radially inner end214, radially outer end216, hub218, first disk portion220, second disk portion222, third disk portion224, fourth disk portion226, first plurality of holes228, second plurality of holes230, third plurality of holes232, and groove234. As shown inFIG.4, body200further includes outer shell12and inner lattice structure14.

Air cycle machine110has a similar structure to the structure and design of additively manufactured component10as described above in reference toFIG.3A. Seal plate124includes body200with bore202extending through a center of body200. Body200has a plate shape and includes first side210and second side212opposite of first side210. Body200also has radially inner end214and radially outer end216opposite of radially inner end214. Radially inner end214of body200defines bore202extending through body200of seal plate124.

Body200includes hub218extending from radially inner end214and positioned adjacent to bore202. Hub218is a center portion of body200. First disk portion220of body200extends radially outward from hub218. Second disk portion222of body200extends radially outward from first disk portion220. Third disk portion224of body200extends radially outward from second disk portion222. Fourth disk portion226of body200extends radially outward from third disk portion224to radially outer end216. First plurality of holes228are positioned around and extend through second disk portion222of body200. Second plurality of holes230are positioned around and extend through third disk portion224of body200. Third plurality of holes232are positioned around and extend through fourth disk portion226of body200. Groove234is positioned on fourth disk portion226of body200and extends into body200from second side212of body200. Groove234is configured to receive an o-ring to seal against other components of air cycle machine110.

Outer shell12completely surrounds inner lattice structure14in an interior of body200and forms an exterior of seal plate124. Outer shell12is a solid, continuous surface. Inner lattice structure14is a lattice structure. Inner lattice structure14can take any shape as discussed above with respect toFIGS.1-2B. Inner lattice structure14includes members arranged in a3D crisscrossing pattern with interspaces16between the members. Inner lattice structure14can vary in density as shown inFIG.3B.

Seal plate124can be additively manufactured. Any suitable additive manufacturing process (also known as a3D printing process) can be used to manufacture seal plate124, including, any process discussed above with respect toFIGS.1-2B. Seal plate124can be made from any material that can be used in an additive manufacturing process as discussed above with respect toFIGS.1-2B.

Traditional seal plates for rotary machines have solid cross-sections and can be manufactured by subtractive manufacturing processes, such as hogout, or compression molding. Additively manufacturing seal plate124allows inner lattice structure14to be used in seal plate124. Using inner lattice structure14in seal plate124allows seal plate124to have a reduced weight compared to traditional seal plates, as there are hollow interspaces16within inner lattice structure14. Seal plate124has an equivalent strength as traditional seal plates due to the increased strength provided by inner lattice structure14.

Inner lattice structure14in seal plate124can also improve the thermal resistance of seal plate124. Seal plate124is used as a heat transfer barrier between compressor section114and first turbine section116. Manufacturing seal plate124with inner lattice structure14improves the thermal resistance of seal plate124, as there are interspaces16in inner lattice structure14that reduce the thermal conductivity of seal plate124while improving the insulating abilities of seal plate124. As discussed above with respect toFIGS.1-2B, interspaces16can be filled with heat transfer medium18to further impede heat transfer from first side210to second side212. As discussed above with respect toFIGS.1-2B, the pressure of the heat transfer medium18can be substantially near a vacuum, thus significantly reducing the heat transfer through seal plate124. As discussed above with respect toFIGS.1-2B, interspaces16can be coated with thermal radiation reflective coating20which further impedes heat transfer from first side210to second side212. These improvements further improve the ability of seal plate124to reduce parasitic heat fluxes which would otherwise reduce the efficiency of air cycle machine110. These parasitic heat fluxes originate from the fact that second side212is at an increased temperature compared to first side210. Heat transfer across seal plate124is energy lost to entropy, thus the energy lost to heat transfer cannot do useful work.

Inner lattice structure14in seal plate124can also improve the vibrational transfer characteristics of seal plate124. As discussed above with respect toFIGS.1-2B, interspaces16can be filled with heat transfer medium18at a selected pressure. The lower the pressure in interspaces16, the less noise that propagates through seal plate124. As such, seal plate124will transfer significantly less noise from one section of air cycle machine110to the other sections.

Hub218of seal plate124abuts a seal that interfaces with rotating components, including compressor rotor146and first turbine rotor156of air cycle machine110. A first side of first disk portion220of seal plate124is positioned adjacent first turbine rotor156, and a second side of first disk portion220of seal plate124is positioned adjacent compressor rotor146. A first side of second disk portion222of seal plate124abuts first turbine rotor shroud158. Bolts extend through first plurality of holes228in second disk portion222to bolt seal plate124to first turbine rotor shroud158. A second side of second disk portion222of seal plate124is positioned adjacent to a radially outer end of compressor rotor146. A first side of third disk portion224of seal plate124abuts a flange of first turbine housing126, and a second side of third disk portion224of seal plate124abuts diffuser148. Bolts extend through second plurality of holes230to bolt seal plate124between diffuser148and first turbine housing126. Fourth disk portion226of seal plate124is positioned between and fan and compressor housing122and first turbine housing126. Bolts extends through third plurality of holes232to bolt seal plate124between fan and compressor housing122and first turbine housing126.

There are gaps between compressor rotor146and surrounding components, such as compressor rotor shroud149, and between first turbine rotor156and surrounding components, such as first turbine rotor shroud158, to prevent contact between compressor rotor146and first turbine rotor156and surrounding components. Contact between compressor rotor146and first turbine rotor156and surrounding components can damage the components. The gaps between compressor rotor146and first turbine rotor156and surrounding components have to account for deflections that compressor rotor146and first turbine rotor156and surrounding components, such as seal plate124, can be subjected to during operation of compressor rotor146and first turbine rotor156as well as deflections induced by pressure changes. Thus, the more deformation that compressor rotor146, first turbine rotor156, and seal plate124are subjected to during operation of compressor rotor146and first turbine rotor156, the larger the gaps need to be to ensure component safety. However, air can leak from air cycle machine110through the gaps, which leads to inefficiencies in air cycle machine110. Thus, minimizing the gaps between compressor rotor146and first turbine rotor156and surrounding components is desired. If seal plate124has pressure equilibrium holes24in outer shell12, seal plate124would not deflect as much due to pressure induced changes, thus reducing the minimum sizes required for the gaps.

Seal plate124is one example of a seal plate in which inner lattice structure14can be used. In alternate embodiments, inner lattice structure14can be used in any suitable seal plate having any geometry. Further, air cycle machine110is one example of a turbomachinery or rotary machine in which seal plate124or any other seal plate with inner lattice structure14can be used. In alternate embodiments, seal plate124or any other seal plate with inner lattice structure14can be used in any other rotary machine having a seal plate.

FIG.3Cis a side view of dual-rotor component178with dual rotor interconnection plate180therebetween. Dual rotor component178includes compressor rotor146and first turbine rotor156. Between and connecting compressor rotor146and first turbine rotor156is dual rotor interconnection plate180which includes outer shell12and inner lattice structure14.

Dual rotor component178is an alternative embodiment to those discussed above in reference toFIGS.3A and3B. Dual rotor component combines compressor rotor146and first turbine rotor156ofFIGS.3A and3Binto a single component. As such, first disk portion220of seal plate124can be removed. Further the gap between first turbine rotor156and first side210of seal plate124as well as the gap between compressor rotor146and second side212of seal plate124can be removed. Removing these gaps increases the efficiency of air cycle machine110. However, parasitic heat fluxes from a hot side on compressor rotor146to a cold side on first turbine rotor156can affect efficiency. These parasitic heat fluxes can be reduced significantly by dual rotor interconnection plate180.

Dual rotor interconnection plate180includes outer shell12and inner lattice structure14. Inner lattice structure14can have interspaces16therein. As discussed above with respect toFIGS.1-2Binterspaces16of inner lattice structure14of dual rotor interconnection180can be filled with heat transfer medium18. Heat transfer medium18can alter the heat flux dynamics of dual rotor178, reducing the parasitic heat fluxes thus negating the primary reason not to combine compressor rotor146and first turbine rotor156into a single component. Further, as discussed above with respect toFIGS.1-2B, interspaces16of inner lattice structure14can be coated with thermal radiation reflective coating20, further reducing the parasitic heat fluxes through the component.

Alternatively, interspaces16of inner lattice structure14of dual rotor interconnection180can be connected to an ambient atmosphere through pressure equilibrium holes24(not shown inFIG.3C). By connecting interspaces16to the ambient atmosphere, if the pressure changes drastically, the part will not expand or contract as a result of the pressure change. As such, the gaps between compressor rotor146and compressor rotor shroud149as well as the gaps between first compressor rotor156and first rotor shroud158can be further reduced, increasing the efficiency of air cycle machine110. Increasing the efficiency of air cycle machine110is important as increased efficiency enables a reduction in the size and weight of air cycle machine to achieve the same results and thus decreases fuel burn rate on an aircraft.

FIGS.4A and4Bwill be discussed together since they show cabin air compressor310and an application of AM turbomachinery component10in cabin air compressor310.FIG.4Ais cross-sectional view of cabin air compressor310.FIG.4Bis a cross-sectional view of rotor326with pressure equilibrium holes24positioned in cabin air compressor310.

Cabin air compressor310includes compressor section312and motor section314mounted on tie rod316. Tie rod316is configured to rotate about axis A. Compressor section312includes compressor inlet housing318and compressor outlet housing320that are connected to one another. Motor section314includes motor housing322, which is connected to compressor outlet housing320. Variable diffuser324is positioned between compressor inlet housing318and compressor outlet housing320. Rotor326is positioned between compressor inlet housing318and compressor outlet housing320. Rotor326is mounted on tie rod316, which rotatably connects rotor326and motor section314. Rotor shroud328is positioned radially outward from and partially surrounds compressor rotor326.

Variable diffuser316includes backing plate340, inboard plate342, diffuser vanes344, drive ring346, drive ring bearing348, pinion350, backup ring352, and variable diffuser actuator354. Backing plate340abuts compressor outlet housing320on a first side and inboard plate342on a second side. Inboard plate342abuts backing plate340on a first side and diffuser vanes344on a second side. Diffuser vanes344abut inboard plate342on a first side and rotor shroud328on a second side. Diffuser vanes344are configured to direct the compressed air from rotor326into outlet duct334. Drive ring346is positioned radially outward from rotor shroud328, and drive ring bearing348is positioned between driver ring346and rotor shroud328. Drive ring346abuts rotor shroud328on a first side and backup ring350on a second side. Backup ring350is positioned radially outward of rotor shroud328. Pinion352is connected to variable diffuser actuator354and is coupled to drive ring346. Pinion352permits control of variable diffuser316. Drive ring346is coupled to diffuser vanes344with pins, and as drive ring346is rotated drive ring346will drag diffuser vanes344and cause them to rotate.

Motor section314includes motor housing322, motor rotor360, and motor stator362. Motor housing322surrounds motor rotor360and motor stator362. Motor rotor360is disposed within motor stator362and is configured to rotate about axis A. Motor rotor360is mounted to tie rod316to drive rotation of tie rod316.

Motor rotor360of motor section314drives rotation of shafts in cabin air compressor310, which rotates rotor326. The rotation of rotor326draws air into inlet330of compressor inlet housing318. The air flows through inlet duct332to rotor326and will be compressed by rotor326. The compressed air is then routed through variable diffuser316and into outlet duct334of compressor outlet housing320. The air then exits cabin air compressor310through outlet336of compressor outlet housing320and can be routed to another component of an environmental control system, such as an air cycle machine.

Cabin air compressor310further includes first journal bearing370, first rotating shaft372, second journal bearing374, and second rotating shaft376. First journal bearing370is positioned in compressor section312and is supported by compressor outlet housing320. First rotating shaft372extends between and rotates with rotor326and motor rotor360. Motor rotor360drives rotation of rotor326with first rotating shaft372. A radially outer surface of first rotating shaft372abuts a radially inner surface of first journal bearing370. Second journal bearing374is positioned in motor section314and is supported by motor housing322. Second rotating shaft376extends from and rotates with motor rotor360. A radially outer surface of second rotating shaft376abuts a radially inner surface of second journal bearing374.

Rotor shroud328is positioned radially outward from rotor326and partially surrounds rotor326. Rotor326includes hub400and blades402attached to and extending outward from hub400. Bore404extends through a center of hub400and a tie rod of a rotary machine can extend through bore404. Hub400has first side410and second side412opposite of first side410. Hub400also has radially inner end414and radially outer end416opposite of radially inner end414. Radially inner end414defines bore404extending through hub400of rotor326.

Hub400has shaft portion418that extends axially from first side410to second side412of hub400along axis A. When in operation, rotor326increases the pressure in a flow path which is on second side412, while the pressure on a backside of rotor326outside of the flow path, which is on first side410would stay at an ambient pressure. Disk portion420extends radially outwards from shaft portion418toward radially outer end416of hub400near first end410of hub400. Hub400further includes first flange422, second flange424, and third flange426. First flange422is positioned on disk portion420near radially outer end416of hub400and extends axially outward from first side410of hub400. First flange422of hub400of rotor326forms a labyrinth seal that seals against compressor outlet housing320. As rotor326rotates with tie rod316, the labyrinth seal on first flange422will rotate against compressor outlet housing320, which is a stationary component of cabin air compressor310. Second flange424is positioned on shaft portion418at first side410of hub410and extends axially outward from first side410of hub400. Second flange424of hub400of rotor326abuts and rotates with first rotating shaft372. Third flange426is positioned on shaft portion418near second side412of hub400and extends radially inward from shaft portion418of hub400. Blades402are positioned on hub400and extend radially and axially outward from hub400. Third flange426of hub400of rotor326abuts and rotates with tie rod316. Third flange426of hub400mounts rotor326to tie rod316.

Hub400and blades402further include outer shell12that surrounds inner lattice structure14in an interior of hub400and blades402. Outer shell12is a solid, continuous surface. Inner lattice structure14has interspaces16therein. Inter spaces16can hold heat transfer medium18therein. Interspaces16can be interconnected through lattice interconnections22(not shown inFIG.4B) and can further be connected to an ambient atmosphere through pressure equilibrium holes24which extend through outer shell12and connect interspaces16to the ambient atmosphere. As shown inFIG.4B, pressure equilibrium holes24are substantially larger than interspaces16. Alternatively, pressure equilibrium holes can be substantially smaller than interspaces16. In the embodiment shown inFIG.4B, there are only 2 pressure equilibrium holes24. In alternative embodiments, there can be a single pressure equilibrium hole. In another alternative embodiment, there can be a plurality of pressure equilibrium holes24.

There is a gap between blades402of rotor326and rotor shroud328to prevent contact between blades402of rotor326and rotor shroud328. Contact between blades402and rotor shroud328can damage both components. The gap between blades402and rotor shroud328has to account for deflection that hub400and blades402of rotor326can be subjected to during operation of rotor326. Thus, the more deformation that hub400and blades402are subjected to during operation of rotor326, the larger the gap needs to be to ensure component safety. However, air can leak from cabin air compressor310through the gap, which leads to inefficiencies in cabin air compressor310. Thus, minimizing the gap between blades402of rotor326and rotor shroud328is desired. Pressure equilibrium holes24can reduce the gap required as rotor326would deflect less due to changes in pressure. The expansion can be further reduced if interspaces16are interconnected with lattice interconnections22. Thus interspaces16connected together through lattice interconnections22to pressure equilibrium holes24would be at a pressure experienced at first side410. Thus, more of the interspaces would be connected to an ambient pressure. Pressure equilibrium holes24are placed on first side410to avoid the increased pressure created by blades402of rotor326when in operation. In alternative embodiments, pressure equilibrium holes24can be placed on second side412, thus interspaces16connected together through lattice interconnections22to pressure equilibrium holes24would be at a pressure experienced at the second side.

As discussed above with respect toFIGS.1-2B, any suitable additive manufacturing process (also known as a3D printing process) can be used to manufacture rotor326, including, for example, direct metal laser sintering, electron beam freeform fabrication, electron-beam melting, selective laser melting, or selective laser sintering. As discussed above with respect toFIGS.1-2B, additively manufacture component10, such as rotor326, can be made out of any material that can be used in an additive manufacturing process, including any of stainless steel, corrosion-resistant steel, nickel-chromium alloy, titanium, aluminum, synthetic fiber, fiberglass, composites, and combinations thereof.

Traditional compressor rotors for rotary machines have solid cross-sections and are manufactured by forging and/or subtractive manufacturing processes, such as hogout. Additively manufacturing rotor326allows inner lattice structure14to be used in rotor326. Using inner lattice structure14in rotor326allows rotor326to have a reduced weight compared to traditional rotors, as there are interspaces16between lattice structure14. Rotor326also has an equivalent strength as traditional rotors due to the increased strength of inner lattice structure14.

Reducing the weight while maintaining the strength of rotor326allows for the gap between blades402of rotor326and rotor shroud328to be reduced. Reducing the gap between blades402of rotor326and rotor shroud28increases the compression efficiency of cabin air compressor310as more air is forced through rotor326and into variable diffuser324.

Rotor326is one example of a rotor in which inner lattice structure14can be used. In alternate embodiments, inner lattice structure14can be used in any suitable rotor, for example a turbine rotor, having any geometry. Further, cabin air compressor310is one example of a turbomachinery or rotary machine in which rotor326or any other rotor with inner lattice structure14can be used. In alternate embodiments, rotor326or any other rotor with inner lattice structure14can be used in an air cycle machine or any other rotary machine

Discussion of Possible Embodiments

An additively manufactured component comprising an outer shell, the outer shell enclosing a space therein, an inner lattice structure in the space of the outer shell, and interspaces formed in the inner lattice structure.

A further embodiment of the additively manufactured component, wherein the interspaces of the inner lattice structure are interconnected.

A further embodiment of the additively manufactured component, wherein the outer shell is sealed to an outside environment.

A further embodiment of the additively manufactured component, wherein a heat transfer medium is in the interspaces of the inner lattice structure.

A further embodiment of the additively manufactured component, wherein the heat transfer medium is a gas.

A further embodiment of the additively manufactured component, wherein the heat transfer medium is a liquid.

A further embodiment of the additively manufactured component, wherein the outer shell comprises a pressure equilibration hole extending through the outer shell to an outside environment.

A further embodiment of the additively manufactured component, wherein an inner surface of the interspaces is coated with a thermal radiation reflective coating.

A method of forming an additively manufactured component comprising evacuating a chamber in which the additively manufactured component will be formed and forming in the chamber layer by layer an outer shell enclosing a core, wherein the core comprises a lattice structure with interspaces formed in the lattice structure.

The method forming an additively manufactured component of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:

A further embodiment of the method of forming an additively manufactured component, further comprising flooding the chamber with a selected gas at a selected pressure before forming the outer shell and the core.

A further embodiment of the method of forming an additively manufactured component, wherein the selected gas comprises at least one of krypton, argon, xenon, nitrogen, oxygen, and combinations thereof.

A further embodiment of the method of forming an additively manufactured component, wherein the selected pressure is less than 0.3 ATM.

A further embodiment of the method of forming an additively manufactured component, wherein the selected pressure is less than 0.03 ATM.

A further embodiment of the method of forming an additively manufactured component, further comprising forming a pressure equilibration hole in the outer shell and applying a thermal radiation reflective coating to the lattice structure.

A further embodiment of the method of forming an additively manufactured component,

An environmental control system comprising a first component comprising an outer shell and a core enclosed by the outer shell, wherein the core comprises a lattice structure with interspaces.

A further embodiment of the environmental control system, wherein the interspaces are interconnected.

A further embodiment of the environmental control system, wherein the interspaces are connected to an ambient atmosphere by a pressure equilibration hole extending through the outer shell.

A further embodiment of the environmental control system, the environmental control system further comprising an air cycle machine comprising a hot section with a first impeller and a cold section with a second impeller wherein the first component is a plate axially between the first impeller and the second impeller.

A further embodiment of the environmental control system, wherein the first component is an impeller, and the outer shell of the impeller comprises a flow path surface with at least one blade and a back surface located outside of a flow path of the impeller and a pressure equilibration hole extending through the back surface of the outer shell.