Additive manufacturing baffles, covers, and dies

Abstract

A method includes (a) depositing a layer ( 224 ) of a powder material ( 216 ) on a work stage ( 226 ), the layer ( 224 ) having a thickness, (b) solidifying a portion of the layer ( 224 ) based upon data that defines an insert ( 228 ) with a body that is shaped to fit into a cavity in a gas turbine engine component, and (c) lowering the work stage ( 226 ) by the thickness. Steps (a)-(c) can then be repeated until the insert ( 228 ) is complete. The insert ( 228 ) can then be removed from the work stage ( 226 ). An insert ( 228 ) formed by the above process is also disclosed.

1 . An insert comprising:
 a body formed by an additive manufacturing process and shaped to fit in a cavity in a gas turbine engine component, the body comprising:
 a base portion that is substantially flat; 
 walls extending upwards from the base portion; and 
 flanges, for attachment to the gas turbine engine component, extending outwards from the walls; 
   a hole in the body of the insert; and   a localized build-up adjacent the hole to promote cooling of the component.   
     
     
         2 . The insert of  claim 1 , wherein the insert is a baffle. 
     
     
         3 . The insert of  claim 2 , and further comprising:
 a plurality of holes in the walls.   
     
     
         4 . The insert of  claim 3 , and further comprising:
 a thickened wall portion surrounding the plurality of holes.   
     
     
         5 . The insert of  claim 1 , wherein the insert is a cover. 
     
     
         6 . The insert of  claim 5 , and further comprising:
 a plurality of holes in the base portion.   
     
     
         7 . The insert of  claim 6 , and further comprising:
 a thickened wall portion surrounding the plurality of holes.   
     
     
         8 . The insert of  claim 1 , and further comprising:
 localized protrusions in the body of the insert.   
     
     
         9 . The insert of  claim 1 , and further comprising:
 localized divots in the body of the insert.   
     
     
         10 . A gas turbine engine component with an insert, the component comprising:
 a body with an airfoil running between an outer platform and an inner platform;   a cavity with an opening on at least one of the outer platform or the inner platform; and   an insert, formed by an additive manufacturing process, placed in the cavity with localized build-up in a pre-selected area to promote cooling of the component.   
     
     
         11 . The component of  claim 10 , wherein the cavity runs through the airfoil and the insert is a baffle that is placed in the cavity. 
     
     
         12 . The component of  claim 10 , wherein the cavity extends a defined distance into at least one of the outer platform or the inner platform and the insert is a cover that is placed in the cavity.