Patent ID: 12246380

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the present calibration components and method of fabricating calibration components, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation, rather than limitation of, the technology. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present technology without departing from the scope or spirit of the claimed technology. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims and their equivalents.

The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations. Additionally, unless specifically identified otherwise, all embodiments described herein should be considered exemplary.

The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the invention. As used herein, the terms “first”, “second”, and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components.

The term “fluid” may be a gas or a liquid. The term “fluid communication” means that a fluid is capable of making the connection between the areas specified.

As used herein, the terms “upstream” (or “forward”) and “downstream” (or “aft”) refer to the relative direction with respect to fluid flow in a fluid pathway. For example, “upstream” refers to the direction from which the fluid flows, and “downstream” refers to the direction to which the fluid flows. The term “radially” refers to the relative direction that is substantially perpendicular to an axial centerline of a particular component, the term “axially” refers to the relative direction that is substantially parallel and/or coaxially aligned to an axial centerline of a particular component and the term “circumferentially” refers to the relative direction that extends around the axial centerline of a particular component.

Terms of approximation, such as “about,” “approximately,” “generally,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and/or systems. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and/or systems. For example, the approximating language may refer to being within a 1, 2, 4, 5, 10, 15, or 20 percent margin in either individual values, range(s) of values and/or endpoints defining range(s) of values. When used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction. For example, “generally vertical” includes directions within ten degrees of vertical in any direction, e.g., clockwise or counter-clockwise.

The terms “coupled,” “fixed,” “attached to,” and the like refer to both direct coupling, fixing, or attaching, as well as indirect coupling, fixing, or attaching through one or more intermediate components or features, unless otherwise specified herein. As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

Here and throughout the specification and claims, range limitations are combined and interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.

As described in detail below, exemplary embodiments of the present subject matter involve the use of additive manufacturing machines or methods. As used herein, the terms “additively manufactured” or “additive manufacturing techniques or processes” refer generally to manufacturing processes wherein successive layers of material(s) are provided on each other to “build-up,” layer-by-layer, a three-dimensional component. The successive layers generally fuse together to form a monolithic component which may have a variety of integral sub-components.

The additive manufacturing processes described herein may be used for forming components using any suitable material. For example, the material may be plastic, metal, concrete, ceramic, polymer, epoxy, photopolymer resin, or any other suitable material that may be in solid, liquid, powder, sheet material, wire, or any other suitable form. More specifically, according to exemplary embodiments of the present subject matter, the additively manufactured components described herein may be formed in part, in whole, or in some combination of materials including but not limited to pure metals, nickel alloys, chrome alloys, titanium, titanium alloys, magnesium, magnesium alloys, aluminum, aluminum alloys, iron, iron alloys, stainless steel, and nickel or cobalt based superalloys (e.g., those available under the name Inconel® available from Special Metals Corporation). These materials are examples of materials suitable for use in the additive manufacturing processes described herein, and may be generally referred to as “additive materials.”

As used herein, references to “fusing” may refer to any suitable process for creating a bonded layer of any of the above materials. For example, if the material is ceramic, the bond may be formed by a sintering process. If the material is powdered metal, the bond may be formed by a melting or sintering process. One skilled in the art will appreciate that other methods of fusing materials to make a component by additive manufacturing are possible, and the presently disclosed subject matter may be practiced with those methods.

Each successive layer may be, for example, between about 10 μm and 200 μm, although the thickness may be selected based on any number of parameters and may be any suitable size according to alternative embodiments. Therefore, utilizing the additive formation methods described above, the components described herein may have cross sections as thin as one thickness of an associated powder layer, e.g., 10 μm, utilized during the additive formation process.

Notably, in exemplary embodiments, several features of the components described herein were previously not possible due to manufacturing restraints. However, the present inventors have advantageously utilized current advances in additive manufacturing techniques to develop exemplary embodiments of such components generally in accordance with the present disclosure. While the present disclosure is not limited to the use of additive manufacturing to form these components generally, additive manufacturing does provide a variety of manufacturing advantages, including ease of manufacturing, reduced cost, greater accuracy, etc.

Referring now to the drawings,FIG.1illustrates a schematic diagram of one embodiment of a turbomachine, which in the illustrated embodiment is a gas turbine10. Although an industrial or land-based gas turbine is shown and described herein, the present disclosure is not limited to a land-based and/or industrial gas turbine unless otherwise specified in the claims. For example, the invention as described herein may be used in any type of turbomachine including but not limited to a steam turbine, an aircraft gas turbine, or a marine gas turbine.

As shown inFIG.1, the gas turbine10generally includes a compressor section12. The compressor section12includes a compressor14. The compressor includes an inlet16that is disposed at an upstream end of the gas turbine10. The gas turbine10further includes a combustion section18having one or more combustors disposed downstream from the compressor section12. The gas turbine further includes a turbine section22that is downstream from the combustion section18. A shaft24extends generally axially through the gas turbine10.

The compressor section12may generally include a plurality of rotor disks21and a plurality of rotor blades23extending radially outwardly from and connected to each rotor disk21. Each rotor disk21in turn may be coupled to or form a portion of the shaft24that extends through the compressor section12. Additionally, the compressor section12may include a plurality of stator vanes19extending from ac compressor casing between the rotor blades23. The rotor blades23and the stator vanes19of the compressor section12may include turbomachine airfoils that define an airfoil shape (e.g., having a leading edge, a trailing edge, and side walls extending between the leading edge and the trailing edge).

The turbine section22may generally include a plurality of rotor disks27and a plurality of rotor blades28extending radially outwardly from and being interconnected to each rotor disk27. Each rotor disk27in turn may be coupled to or form a portion of the shaft24that extends through the turbine section22. The turbine section22further includes an outer casing32that circumferentially surrounds the portion of the shaft24and the rotor blades28. The turbine section22may include stator vanes or stationary nozzles26extending radially inward from the outer casing32. The rotor blades28and stator vanes26may be arranged in alternating stages along an axial centerline30of gas turbine10. Both the rotor blades28and the stator vanes26may include turbomachine airfoils that define an airfoil shape (e.g., having a leading edge, a trailing edge, and side walls extending between the leading edge and the trailing edge)

In operation, ambient air36or other working fluid is drawn into the inlet16of the compressor14and is progressively compressed to provide a compressed air38to the combustion section18. The compressed air38flows into the combustion section18and is mixed with fuel in one or more fuel nozzles45to form a combustible mixture. The one or more fuel nozzles45may be disposed at a forward end of the combustor20, e.g., coupled to an end cover48of the combustor20. The combustible mixture is burned within a combustion chamber40of the combustor20, thereby generating combustion gases42that flow from the combustion chamber40into the turbine section22. One or more Axial Fuel Stage (AFS) or fuel injectors46may be disposed downstream of the fuel nozzles45. The one or more secondary injectors may be in fluid communication with the combustion chamber40to inject a second combustible mixture of fuel and air into the combustion chamber40downstream of the fuel nozzles45. Energy (kinetic and/or thermal) is transferred from the combustion gases42to the rotor blades28, causing the shaft24to rotate and produce mechanical work. The combustion gases42exit the turbine section22and flow through the exhaust diffuser34across a plurality of struts or main airfoils44that are disposed within the exhaust diffuser34.

The gas turbine10may define a cylindrical coordinate system having an axial direction A extending along the axial centerline30, a radial direction R perpendicular to the axial centerline30, and a circumferential direction C extending around the axial centerline30.

To illustrate an example of an additive manufacturing system and process,FIG.2shows a schematic/block view of an additive manufacturing system100for generating an object122, which may be the calibration component200having a turbomachine component form factor. The additive manufacturing system100may be configured for direct metal laser sintering (DMLS) or direct metal laser melting (DMLM). For example, the additive manufacturing system100may fabricate objects, such as the calibration component200. For example, the object122may be fabricated in a layer-by-layer manner by sintering or melting a powder material in a powder bed112using an energy beam136generated by a source such as a laser120. The powder to be melted by the energy beam is supplied by reservoir126and spread evenly over a build plate102using a recoater arm116, which moves in a rocoater direction134, to maintain the powder at a level118and remove excess powder material extending above the powder level118to waste container128. The energy beam136sinters or melts a cross sectional layer of the object being built under control of the galvo scanner132. The build plate102is lowered and another layer of powder is spread over the build plate and the object being built, followed by successive melting/sintering of the powder by the laser120. The process is repeated until the object122is completely built up from the melted/sintered powder material. The laser120may be controlled by a computer system including a processor and a memory. The computer system may determine a scan pattern for each layer and control laser120to irradiate the powder material according to the scan pattern. After fabrication of the object122is complete, various post-processing procedures may be applied to the object122. Post processing procedures include removal of excess powder by, for example, blowing or vacuuming. Other post processing procedures include a stress release process. Additionally, thermal and chemical post processing procedures can be used to finish the object122.

As shown inFIG.2, in exemplary embodiments, the object122may include one or more representative quality indicators (RQIs)124disposed within the object122. As discussed below, the one or more representative quality indicators124may be voids or cavities filled with unfused powder material and disposed within the object122(e.g., below the exterior surface of the object122, such that the RQIs124are not in contact with ambient air). The RQIs124may be fabricated in a layer-by-layer manner by sintering or melting the powder material around the RQI124(i.e., the RQI124may be formed by not sintering or melting the powder material in the area designated for the RQI124. As such, as the object122is being formed, the RQI124may simultaneously be formed and slowly filled with unfused powder material. For example, because the RQI124may be a void or cavity disposed within the object122, as the object122and RQIs are being formed, the RQI is disposed below the level118of powder, such that the void or cavity slowly collect unfused powder material each time the recoater arm116passes. In this way, once the RQI124is fully formed in the object122, it may be a void or cavity defined by fused powder material that is filled with unfused powder material.

FIG.3illustrates a calibration component200, which may be formed by the additive manufacturing system100shown inFIG.2, andFIG.4illustrates a cross sectional view of the calibration component200shown inFIG.3, in accordance with embodiments of the present disclosure. The calibration component200may be used for calibrating (or tuning) a Computed Tomography (CT) system. The CT system may use irradiation (such as X-rays) to produce three-dimensional internal and external representations of a scanned object (such as the calibration component200). The sensitivity to material anomalies and measurement accuracy of CT systems are inversely related to the energy level of the X-ray source used in the CT systems. The amount and density of the material of the object impacts the ability of X-rays to penetrate the part and reach the X-ray detector. When insufficient X-rays reach the detector, the object has been considered uninspectable with X-rays of that energy level. However, it is desirable to maximize the sensitivity and accuracy of the CT system while minimizing the amount of X-rays used for inspection.

As shown, the calibration component200may include a main body202and one or more Representative Quality Indicators (RQIs)204disposed within the main body202of the calibration component200. If a CT system is able to detect the RQIs204within the main body202of the calibration component200, then the CT system will be able to detect flaws in production components having a similar size to the RQIs, in a similar location as the RQIs, and with a similar material density as the density as the RQI204.

In exemplary embodiments, the calibration component200may include a plurality of RQIs204disposed within the main body202of the calibration component200. Each of the RQI's may include a cavity206, which may be a void, space, or other space defined within the main body202. For example, the cavity206may be defined within the main body202beneath an exterior surface208of the main body202, such that the cavity206may be entirely defined by the main body202, and such that the cavity206is fluidly isolated from the ambient environment (i.e., the atmosphere or ambient air).

In many embodiments, the RQI204may further include material210disposed within the cavity206. In some embodiments, the material210may be a solid material. In other embodiments, the material210may be a fluid material (such as a liquid or a gas). In exemplary embodiments, the material210disposed in the cavity206may be a powder material in a powder form (such as a powdered metal material). Additionally, the main body202may be formed from the powder material (e.g., the main body202may be formed from the same powder material that is disposed in the cavity206, except the powder material from which the main body202is formed may be fused together). Stated otherwise, the main body202may be formed from a powdered metal material that is fused together, and the material210in the cavity206may be the same powdered metal material that is unfused. The cavity206may be filled with material210such that the boundaries defining the cavity206may be in contact with the material210. The material210may have a cross sectional shape of a circle. Each particle of the powder material disposed in the cavity206may define a diameter, and the diameter of each particle of the powder material may vary.

In some embodiment, the material210disposed within the cavity206may be a first material, and the main body202of the calibration component200may be formed from a second material that is different than the first material. For example, the first material may be selected from the following list: pure metals, nickel alloys, chrome alloys, titanium, titanium alloys, magnesium, magnesium alloys, aluminum, aluminum alloys, iron, iron alloys, stainless steel, and nickel or cobalt based superalloys (e.g., those available under the name Inconel® available from Special Metals Corporation). In such embodiments, the second material may be a different material selected from the following list: pure metals, nickel alloys, chrome alloys, titanium, titanium alloys, magnesium, magnesium alloys, aluminum, aluminum alloys, iron, iron alloys, stainless steel, and nickel or cobalt based superalloys (e.g., those available under the name Inconel® available from Special Metals Corporation).

As shown inFIG.3, the cavity206may be spherical (e.g., spherically shaped). The spherical shape of the cavity206may advantageously allow for the calibration component200to be additively manufactured (e.g., via the additive manufacturing system100) at any angle or orientation with respect to the build plate102, thereby maximizing the number of calibration components200that can be disposed on a singular build plate102. For example, the spherical shape of the cavity206may be “layered” or “sliced” in a similar manner no matter how the calibration component200is angled or oriented with respect to the build plate102, which would not be true for other shapes (such as e.g., a cube, cylinder, or others). As such, the spherical shape of the cavity206allows the RQIs204to be easily employed with a variety of different turbomachine components without regard to the components build orientation or angle. Additionally, the spherical shape of the cavity206does not require any removable (or temporary) supports during the additive manufacturing process.

As shown inFIGS.3and4, the plurality of representative quality indicators204may include differently sized representative quality indicators204. For example, each RQI204may define a diameter212, and the plurality of RQIs204may include different (or varying) diameters212. The varying diameters212may advantageously facilitate calibration or tuning of a CT system. For example, if a CT system is able to visualize or detect an RQI having a larger diameter but not an RQI having a smaller diameter, then the CT system may need to be calibrated or tuned (e.g., the X-ray intensity may be adjusted) such that the CT system can detect or visualize all the sizes of RQIs, thereby ensuring that the CT system will detect actual flaws in production components having similar sizes. In many embodiments, the calibration component200may include a first row214of RQIs204having a first size, a second row216of RQIs204having a second size, and a third row218of RQIs204having a third size. The first size may be smaller than the second size, and the second size may be smaller than the third size. Each row214,216,218may include two or more RQIs204disposed along a common axis (e.g., the RQIs204in the first row214may each be disposed along a first common axis, the RQIs204in the second row216may each be disposed along a second common axis, and the RQIs204in the third row218may each be disposed along a third common axis). The common axis for each row214,216,218may be generally parallel to one another.

In various embodiments, the diameter212of the RQIs204may be between about 0.01 inches and about 0.1 inches, or between about 0.015 inches and about 0.9, or between about 0.2 inches and about 0.8 inches, or between about 0.3 inches and about 0.7 inches, or between about 0.4 inches and about 0.6 inches.

When inspecting a component, the CT system attempts to detect flaws (such as porosity, lack of inclusion, non-fused area, non-overlapping printing areas). The CT system is able to detect such flaws by using contrast discrimination in the CT scan, which is related to the material density of the component being scanned. For example, lower density areas, or flawed areas (such as voids, lack of fusion, non-fused areas) will have a lower density than the body of the component, such that the flawed areas will appear darker in the scanned image. Accordingly, as should be appreciated, filling the cavity206with a material210(such as an unfused powder material) may be advantageous because it allows the CT system to be tuned or calibrated to a higher degree of specificity due to the minimal density difference. Additionally, the difference in density between the main body202and the RQI204(filled with powder material) is less than it would be if the RQI was empty (or filled with air), which allows the contrast discrimination of the CT system to be tuned more precisely, such that the CT system can have an increased likelihood of detecting flaws in production components.

In many embodiments, a first density of the material210within the cavity206may be less than a second density of the main body202. For example, in exemplary embodiments, the material210(e.g., unfused powder material) within the cavity206of the RQI204may have a first density that is between about 10% and about 90% less than a second density of the main body202. In other embodiments, the material210(e.g., unfused powder material) within the cavity206of the RQI204may have a first density that is between about 20% and about 80% less than a second density of the main body202. In some embodiments, the material210(e.g., unfused powder material) within the cavity206of the RQI204may have a first density that is between about 30% and about 70% less than a second density of the main body202. In various embodiments, the material210(e.g., unfused powder material) within the cavity206of the RQI204may have a first density that is between about 40% and about 60% less than a second density of the main body202.

FIGS.5and6each illustrate a cross-sectional view of a calibration component200having a main body202with one or more representative quality indicators204disposed in the main body202, in accordance with embodiments of the present disclosure. As shown, the calibration component200may include a first portion222and a second portion224. As shown, in many embodiments, the calibration component200may define an area of high manufacturing stress220, and the one or more representative quality indicators204may be disposed in the area of high manufacturing stress220. In various embodiments, the area of high manufacturing stress220may be a junction (such as a junction between the first portion222and the second portion224), angle or change in angle, or change in thickness of the calibration component200as the calibration component200extends in a vertical direction V (e.g., the build direction of the additive manufacturing system100). For example, an area of high manufacturing stress220may be defined between portions222,224of the calibration component200having an angle of greater than about 40°, or greater than about 80°, or greater than about 120°. Additionally, an area of high manufacturing stress220may be defined where a change in thickness of the calibration component200as the calibration component200extends in the vertical direction V (e.g., the build direction) is greater than about 20%, or greater than about 40%, or greater than about 60%, or greater than about 80%.

As shown inFIG.5, in some embodiments, the plurality of representative quality indicators204may be arranged in a pattern226. For example, the plurality of representative quality indicators204may be arranged in a square pattern, diamond pattern, triangle pattern, or any other pattern. For example, a pattern may be a repeated arrangement of RQIs204in a specified direction. In various embodiments, the RQIs204may be arranged in a pattern within the area of high manufacturing stress220. In other embodiments, as shown inFIG.6, the plurality of representative quality indicators204may not arranged in a pattern. In such embodiments, the RQIs204may be arranged randomly (i.e., with no repeated arrangement of RQIs204in a specified direction).

In exemplary embodiments the calibration component200may have a form factor of a turbomachine component. The form factor may define the size, shape, and physical structure of the calibration component200. For example, the form factor of the calibration component200may be one of a compressor section12component, a combustion section18component, or a turbine section22component. For example, the calibration component200may have a form factor of a compressor section12component, such as a rotor blade23, a stator vane19, or other compressor section12component. In other embodiments, the calibration component200may have a form factor of a combustion section18component, such as a fuel nozzle45(or a portion of a fuel nozzle45), a fuel injector46(or a portion of a fuel injector46), or other combustion section18components. In yet another embodiment, the calibration component200may have a form factor of a turbine section22component, such at a rotor blade28, a stator vane26, or other turbine section22component.

As one non-limiting example,FIG.7illustrates a calibration component200having a form factor of a fuel injector300(such as the fuel injector46shown inFIG.1), andFIG.8illustrates a cross-sectional view of the calibration component200along the line8-8shown inFIG.7, in accordance with embodiments of the present disclosure. As shown inFIGS.7and8, the fuel injector300includes end walls302spaced apart from one another and side walls304extending between the end walls302. In many embodiments, when installed in a combustion section18, the side walls304of the fuel injector300may extend parallel to the axial direction A. The end walls302of the fuel injector300include a forward end wall306and an aft end wall308disposed oppositely from one another. The side walls304may be spaced apart from one another and may extend between the forward end wall306and the aft end wall308. In many embodiments, both the forward end wall306and the aft end wall308may be arcuate and have a generally rounded cross-sectional shape, and the side walls304may extend generally straight between the end walls302, such that the end walls302and the side walls304collectively define an opening310having a cross section shaped as a geometric stadium. In various embodiments, the side walls304may be longer than the end walls302such that the opening310is the longest in the axial direction. The fuel injector300may further include at least one fuel injection member312, which may be disposed within the opening310and extend axially between the end walls302. The fuel injection members312may be substantially hollow bodies that function to provide fuel to the opening310via a plurality of fuel ports314defined through the fuel injection members312. Each of the fuel injection members may extend from a first end located at the forward end wall306to a second end positioned at the aft end wall308. In many embodiments, the fuel injection members312may be spaced apart from one another within the opening310may extend straight, i.e., without a sudden change in direction, from the forward end wall306to the aft end wall308in the axial direction A. In many embodiments, as shown, the side walls304may include a first side wall fuel injection member322and a second side wall fuel injection member324. For example, the side wall fuel injection members322,324may be integrally formed within the side walls304, such that they function to both partially define the opening310and inject fuel through the plurality of fuel ports314for mixing within the fuel injector300. Each fuel injection member312and the side wall fuel injection members322,324may define a fuel plenum325(which may be teardrop shaped).

As shown inFIG.8, the fuel injector300may include one or more Representative Quality Indicators (RQIs)204. For example, the RQIs204may be disposed below the exterior surface of the fuel injector300(e.g., internal to the fuel injector300). One or more RQIs may be disposed in the end walls302, side walls304, the fuel injection members312, the side wall fuel injection members322,324, or other locations on the fuel injector300. For example, a plurality of RQIs204may be spaced apart and generally circumscribe (or surround) the fuel plenum325of each fuel injection member312and the side wall fuel injection members322,324.

Referring now toFIG.9, a flow diagram of one embodiment of a method900of fabricating a calibration component200having a turbomachine component form factor using an additive manufacturing system100is illustrated in accordance with aspects of the present subject matter. In general, the method900will be described herein with reference to the gas turbine10, the calibration component200, and the additive manufacturing system100described above with reference toFIGS.1through8. However, it will be appreciated by those of ordinary skill in the art that the disclosed method900may generally be utilized with any suitable gas turbine and/or may be utilized in connection with any additive manufacturing system having any other suitable system configuration. In addition, althoughFIG.9depicts steps performed in a particular order for purposes of illustration and discussion, the methods discussed herein are not limited to any particular order or arrangement unless otherwise specified in the claims. One skilled in the art, using the disclosures provided herein, will appreciate that various steps of the methods disclosed herein can be omitted, rearranged, combined, and/or adapted in various ways without deviating from the scope of the present disclosure.

In many implementations, the method900may include at (902) irradiating a layer of powder in a powder bed112to form a fused region. In many embodiments, as shown inFIG.2, the powder bed112may be disposed on the build plate102, such that the fused region is fixedly attached to the build plate102. The method900may further include at (904) of providing a subsequent layer of powder over the powder bed112(e.g., from a first side of the powder bed112) by passing a recoater arm116over the powder bed112. The recoater arm116may distribute each layer of powder over the powder bed112by passing over the powder bed112from a first side to a second side while laying (e.g., dispensing) powder over the powder bed112. The method900further includes at (906) repeating steps902and904until the calibration component200is formed in the powder bed112.

In optional embodiments, passing the recoater arm116over the powder bed112at904may further include at (908) maintaining a level of the powder in the powder bed. For example, when the recoater arm passes from one side to the other while dispensing a new layer of powder, the recoater arm may brush or scrape along a plane to maintain a level118of powder. In many implementations, during fabrication of the calibration component200using the additive manufacturing system100, the cavity206may be disposed below (e.g., closer to the build plate102with respect to the build direction) the level118of powder. In optional embodiments, the method providing at904may further include at (910) filling the cavity206with powder during the fabrication of the calibration component200each instance that the recoater arm passes. For example, each time the recoater arm116passes and dispenses a new layer of powder, such powder may gradually collect within the cavity206until the cavity206is fully formed thereby encapsulating the unfused powder within the cavity206. Finally, in optional embodiments, the method900may further include at (912) removing the calibration component200from the build plate102(e.g., once the calibration component200is fully formed).

In some embodiments, the method900may further include scanning the calibration component with a CT scanning system to detect the RQIs204within the calibration component200by generating an image of the internal structure of the calibration component (e.g., the RQIs204should appear dark in the generated image). As a result of the scanning step, the CT system may be tuned or calibrated (e.g., by adjusting an intensity of the X-rays emitted by the CT system. For example, if an RQI204is not detected as a result of the scanning step, then the intensity of the X-rays of the CT system may be increased (or decreased in some CT systems).

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Further aspects of the invention are provided by the subject matter of the following clauses:

A calibration component having a form factor of a turbomachine component, the calibration component comprising: a main body; and one or more representative quality indicators disposed within the main body of the calibration component, the representative quality indicators comprising a cavity having a material disposed within the cavity.

The calibration component as in any of the preceding clauses, wherein the cavity is spherical.

The calibration component as in any of the preceding clauses, wherein the material disposed in the cavity is a powder material in powder form.

The calibration component as in any of the preceding clauses, wherein the main body is formed from the powder material.

The calibration component as in any of the preceding clauses, wherein the material is a first material, and wherein the main body of the calibration component is formed from a second material that is different than the first material.

The calibration component as in any of the preceding clauses, further comprising a plurality of representative quality indicators.

The calibration component as in any of the preceding clauses, wherein the plurality of representative quality indicators comprise differently sized representative quality indicators.

The calibration component as in any of the preceding clauses, wherein the plurality of representative quality indicators are arranged in a pattern.

The calibration component as in any of the preceding clauses, wherein the plurality of representative quality indicators are not arranged in a pattern.

The calibration component as in any of the preceding clauses, wherein the one or more representative quality indicators each define a diameter of between about inches and about 0.1 inches.

The calibration component as in any of the preceding clauses, wherein a first density of the material within the cavity may be less than a second density of the main body.

The calibration component as in any of the preceding clauses, wherein the first density is between about 10% and about 90% less than the second density of the main body.

The calibration component as in any of the preceding clauses, wherein calibration component comprises an area of high manufacturing stress, and wherein the one or more representative quality indicators are disposed in the area of high manufacturing stress.

The calibration component as in any of the preceding clauses, wherein the turbomachine component form factor is one of a compressor section component, a combustion section component, or a turbine section component.

A method of fabricating a calibration component having a turbomachine component form factor using an additive manufacturing system, the method comprising: irradiating a layer of powder in a powder bed to form a fused region, wherein the powder is disposed on a build plate; providing a subsequent layer of powder over the powder bed by passing a recoater arm over the powder bed; and repeating the irradiating and providing steps until the calibration component is formed on the build plate, the calibration component comprising: a main body; and one or more representative quality indicators disposed within the main body of the calibration component, the representative quality indicators comprising a cavity having the powder disposed within the cavity.

The method as in any of the preceding clauses, wherein passing the recoater arm over the powder bed further comprises maintaining a level of powder in the powder bed.

The method as in any of the preceding clauses, wherein the cavity is disposed below the level of powder during the fabrication of the calibration component.

The method as in any of the preceding clauses, further comprising filling the cavity with powder during the fabrication of the calibration component each instance that the recoater arm passes.

The method as in any of the preceding clauses, wherein the cavity is spherical.

The method as in any of the preceding clauses, further comprising removing the calibration component from the build plate.