Anti-deflection feature for additively manufactured thin metal parts and method of additively manufacturing thin metal parts

Abstract

A conduction riser is additively manufactured onto thin metal parts, the conduction riser extends in a build direction of the thin metal part and traverses a surface of the thin metal part as the conduction riser extends in the build direction. The conduction riser transfers heat from the upper layers of the additively manufactured part during manufacturing to prevent thermal deflection of the part during the manufacturing process.

1 . A method of manufacturing a gas turbine component, the method comprising:
 generating data defining a thin metal part;   determining a build direction of the thin metal part;   generating data defining at least one conduction riser, the at least one conduction riser located on a surface of the thin metal part; and   manufacturing the thin metal part and the at least one conduction riser using an additive manufacturing process.   
     
     
         2 . The method of  claim 1 , wherein the additive manufacturing process is selected from the group consisting of direct metal laser sintering, electron beam freeform fabrication, electron-beam melting, selective laser melting, and combinations thereof. 
     
     
         3 . The method of  claim 1 , wherein the thin metal part and the at least one conduction riser are made from one of nickel or a nickel alloy 
     
     
         4 . The method of  claim 1 , further comprising:
 machining the conduction riser off of the thin metal part.   
     
     
         5 . The method of  claim 1 , wherein the thin metal part comprises a baffle. 
     
     
         6 . The method of  claim 5 , wherein the at least one conduction riser comprises a continuous bulge projecting from the baffle. 
     
     
         7 . The method of  claim 6 , wherein the continuous bulge has a triangularly-shaped cross-section with fillets. 
     
     
         8 . The method of  claim 5 , wherein the at least one conduction riser extends in the build direction of the baffle. 
     
     
         9 . The method of  claim 8 , wherein the at least one conduction riser extends from a first end of the baffle towards a second end of the baffle. 
     
     
         10 . The method of  claim 9 , wherein the at least one conduction riser extends from the first end of the baffle towards the second end of the baffle and then back towards the first end of the baffle, such that the conduction riser forms an undulating conduction path. 
     
     
         11 . The method of  claim 1 , wherein the at least one conduction riser comprises a continuous bulge projecting from the thin metal part. 
     
     
         12 . The method of  claim 11 , wherein the continuous bulge has a triangularly-shaped cross-section with fillets. 
     
     
         13 . The method of  claim 1 , wherein the at least one conduction riser extends in the build direction of the thin metal part. 
     
     
         14 . The method of  claim 13 , wherein the at least one conduction riser extends from a first end of the thin metal part towards a second end of the thin metal part. 
     
     
         15 . The method of  claim 14 , wherein the at least one conduction riser extends from the first end of the thin metal part towards the second end of the thin metal part and then back towards the first end of the thin metal part, such that the conduction riser forms an undulating conduction path. 
     
     
         16 . The method of  claim 1 , wherein a ratio of a thickness of the at least one conduction riser to a thickness of the thin metal part is 1:1 to 1.3:1, inclusive. 
     
     
         17 . The method of  claim 1 , wherein the thin metal part comprises a length to thickness ratio greater than 3.5:1. 
     
     
         18 . The method of  claim 1 , wherein the at least one conduction riser comprises a mating projection configured to mate the thin metal part with another gas turbine component.