US 10,471,542 B1Granted

Cladding and freeform deposition for coolant channel closeout

AssigneeUnited States of America as represented by the Administrator of NASA

InventorsPaul R. Gradl, William Brandsmeier

Life of this patent

Estimating the term…

Loading patent…

Abstract

A base structure is clad and coolant channels are formed through the cladding and into the base structure. A line of tangency relative to the outer clad surface is defined for each point thereon. Linear rows of a metal feedstock are directed towards and deposited on the outer clad surface as a beam of weld energy is directed to the metal feedstock so-deposited. The metal feedstock is the same material as the cladding or one that is weld compatible therewith. A first angle between the metal feedstock so-directed and the line of tangency is maintained in a range of 20-90°. The beam is directed towards a portion of the linear rows such that less than 30% of the cross-sectional area of the beam impinges on a currently-deposited one of the linear rows. A second angle between the beam and the line of tangency is maintained in a range of 5-65°.

Claims18

Dependent claims

A method of fabricating a coolant channel closeout jacket, comprising the steps of:

providing a base structure having an outer surface;
cladding said outer surface with a first material wherein a clad structure is fabricated, said clad structure having an outer clad surface;
machining coolant channels in said clad structure wherein each of said coolant channels extends through said first material and into said base structure, wherein a line of tangency relative to said outer clad surface is defined for each point on said outer clad surface;
providing a feedstock supply for depositing linear rows of a metal feedstock onto said outer clad surface of said clad structure having said coolant channels, said metal feedstock being selected from the group consisting of said first material and a second material wherein said second material is weldable to said first material;
providing an energy source for generating a beam of weld energy having a cross-sectional area;
positioning said feedstock supply to deposit said linear rows of said metal feedstock onto a portion of said outer clad surface having said coolant channels, wherein a first angle between said metal feedstock discharged from said feedstock supply and said line of tangency is maintained in a range of 20-90°;
and
positioning said energy source to direct said beam of weld energy towards a portion of said linear rows deposited on said portion of said outer clad surface, wherein less than 30% of said cross-sectional area of said beam of weld energy impinges on a currently-deposited one of said linear rows, and wherein a second angle between said beam of weld energy and said line of tangency is maintained in a range of 5-65°.

5 more elements

A method of fabricating a coolant channel closeout jacket, comprising the steps of:

providing a base structure having an outer surface;
cladding said outer surface with a first material wherein a clad structure is fabricated, said clad structure having an outer clad surface;
machining coolant channels in said clad structure wherein each of said coolant channels extends through said first material and into said base structure, wherein a line of tangency relative to said outer clad surface is defined for each point on said outer clad surface;
directing a metal feedstock towards a portion of said outer clad surface of said clad structure where said coolant channels are formed therein, said metal feedstock being selected from the group consisting of said first material and a second material wherein said second material is weldable to said first material, said metal feedstock being directed along a first angle between said metal feedstock and said line of tangency, said first angle being maintained in a range of 20-90°, wherein said metal feedstock is deposited in a linear row on said portion of said outer clad surface;
generating a beam of weld energy having a cross-sectional area;
and
directing said beam of weld energy towards said linear row wherein less than 30% of said cross-sectional area of said beam of weld energy impinges on said linear row, and wherein a second angle between said beam of weld energy and said line of tangency is maintained in a range of 5-65°.

4 more elements

A method of fabricating a coolant channel closeout jacket, comprising the steps of:

providing a base structure having an outer surface;
cladding said outer surface with a first material wherein a clad structure is fabricated, said clad structure having an outer clad surface;
machining coolant channels in said clad structure wherein each of said coolant channels extends through said first material and into said base structure, wherein a line of tangency relative to said outer clad surface is defined for each point on said outer clad surface;
directing a metal feedstock towards a portion of said outer clad surface of said clad structure where said coolant channels are formed therein, said metal feedstock being selected from the group consisting of said first material and a second material wherein said second material is weldable to said first material, said metal feedstock being directed along a first angle between said metal feedstock and said line of tangency, said first angle being maintained in a range of 20-90°, wherein said metal feedstock is deposited in a linear row on said portion of said outer clad surface;
generating a beam of weld energy having a cross-sectional area;
directing said beam of weld energy towards said linear row wherein less than 30% of said cross-sectional area of said beam of weld energy impinges on said linear row, and wherein a second angle between said beam of weld energy and said line of tangency is maintained in a range of 5-65°;
and
repeating said steps of directing until said coolant channels are covered by a plurality of said linear row.

5 more elements

Dependencies are inferred from the claim text.