# US 10,500,633 B2 · Gas turbine engine airfoil impingement cooling > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,500,633 B2 - Document ID: US10500633B2 - Status: Granted - Kind: B2 - Application number: 14/883,060 - Filed: 2015-10-14 - Published: 2016-02-04 - Granted: 2019-12-10 - Earliest claimed: 2012-04-24 - Assignees: United Technologies Corporation - Applicants: United Technologies Corporation - Inventors: Tracy A. Propheter-Hinckley; Mark F. Zelesky; Dominic J. Mongillo, Jr.; Matthew A. Devore; Steven Bruce Gautschi; Benjamin T. Fisk - Web page: https://patentgrep.com/patent/US10500633B2 ## CPC - B22C 9/04: Use of lost patterns - B22C 9/10: Cores; Manufacture or installation of cores {(breaker cores B22C9/084)} - B22C 9/24: for hollow articles - B22F 3/1017: {Multiple heating or additional steps (B22F3/101 takes precedence)} - B22F 3/105: by using electric current {other than for infrared radiant energy}, laser radiation or plasma (B22F3/11 takes precedence){; by ultrasonic bonding (B22F3/115 takes precedence)} - B22F 5/04: of turbine blades - B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] - B23K 15/0086: {welding for purposes other than joining, e.g. build-up welding} - C21D 9/0068: {for particular articles not mentioned below} - F01D 5/187: {Convection cooling} - B22F 10/64: by thermal means (control of energy beam parameters for post heating B22F10/364) - B33Y 10/00: Processes of additive manufacturing - B33Y 80/00: Products made by additive manufacturing - F05D 2240/303: related to the leading edge of a rotor blade - F05D 2260/201: by impingement of a fluid - F05D 2260/202: by film cooling - F05D 2260/205: Cooling fluid recirculation, i.e. after cooling one or more components is the cooling fluid recovered and used elsewhere for other purposes - Y02P 10/25: Process efficiency - B22C: FOUNDRY MOULDING (moulding refractory materials in general B28B) - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM - C21D: MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING (surface treatment of metallic material involving at least one process provided for in class C23 and at least one process covered by this subclass C23F17/00; unidirectional solidification of eutectic materials or unidirectional demixing of eutectoid materials C30B) - F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D) - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract A method of manufacturing an airfoil includes the steps of depositing multiple layers of powdered metal onto one another. The layers are joined to one another with reference to CAD data relating to a particular cross-section of an airfoil. The airfoil is produced with leading and trailing edges joined by spaced apart pressure and suction sides to provide an exterior airfoil surface. An exterior wall provides the exterior airfoil surface at the leading edge. An impingement wall is integrally formed with the exterior wall to provide an impingement cavity between the exterior wall and the impingement wall. Multiple impingement holes are provided in the impingement wall. The impingement holes are spaced laterally across the impingement wall. ## Claims ### Claim 1 A method of manufacturing an airfoil comprising the steps of: depositing multiple layers of powdered metal onto one another; joining the layers to one another with reference to CAD data relating to a particular cross-section of an airfoil; and producing the airfoil with leading and trailing edges joined by spaced apart pressure and suction sides to provide an exterior airfoil surface, an exterior wall providing the exterior airfoil surface at the leading edge, an impingement wall integrally formed with the exterior wall to provide an impingement cavity between the exterior wall and the impingement wall, and multiple impingement holes provided in the impingement wall, the impingement holes spaced laterally across the impingement wall, wherein the impingement wall includes a surface from which a first leg extends outward, a second leg adjoins the first leg at an angle to provide a scoop arranged in a radially extending cooling passage with the second leg spaced from the surface, the impingement holes include an entrance facing the cooling passage, and an exit facing the impingement cavity, the scoop arranged at the entrance. ### Claim 2 (depends on 1) The method according to claim 1, comprising heating the airfoil to reconfigure the joined layers into a single, crystalline structure. ### Claim 3 (depends on 1) The method according to claim 1, wherein the impingement holes are spaced laterally across the impingement wall along rows extending in a radial direction. ### Claim 4 (depends on 1) The method according to claim 1, wherein the impingement wall includes a generally uniform thickness. ### Claim 5 (depends on 4) The method according to claim 4, wherein the exterior wall is a leading edge wall. ### Claim 6 (depends on 1) The method according to claim 1, wherein the impingement wall includes an arcuate shape in an airfoil thickness direction. ### Claim 7 (depends on 6) The method according to claim 6, wherein the arcuate shape extends toward the leading edge. ### Claim 8 (depends on 6) The method according to claim 6, wherein the arcuate shape extends away from the leading edge. ### Claim 9 (depends on 1) The method according to claim 1, wherein the impingement holes are spaced laterally across the impingement wall along rows extending in a radial direction. ### Claim 10 (depends on 1) The method according to claim 1, wherein the impingement holes include the entrance facing a radially extending cooling passage and extending to the exit facing the impingement cavity, the entrance and exit having different shapes. ### Claim 11 (depends on 10) The method according to claim 10, wherein the entrance is generally circular, and the exit is elongated and has a width that is substantially greater than a height. ### Claim 12 (depends on 11) The method according to claim 11, wherein the width is oriented in a radial direction or at an angle from the radial direction. ### Claim 13 (depends on 1) The method according to claim 1, comprising a film cooling hole in the airfoil exterior surface and fluidly connected to the impingement cavity. ### Claim 14 (depends on 13) The method according to claim 13, wherein the film cooling holes are arranged in gill rows on at least one of a pressure side and a suction side of the exterior wall. ### Claim 15 (depends on 1) The method according to claim 1, wherein the exterior wall is a pressure side wall. ### Claim 16 A method of manufacturing an airfoil comprising the steps of: depositing multiple layers of powdered metal onto one another; joining the layers to one another with reference to CAD data relating to a particular cross-section of an airfoil; and producing the airfoil with leading and trailing edges joined by spaced apart pressure and suction sides to provide an exterior airfoil surface, an exterior wall providing the exterior airfoil surface at the leading edge, an impingement wall integrally formed with the exterior wall to provide an impingement cavity between the exterior wall and the impingement wall, and multiple impingement holes provided in the impingement wall, the impingement holes spaced laterally across the impingement wall, wherein the impingement wall includes first and second legs adjoining one another at an angle to provide a scoop arranged in a radially extending cooling passage, the impingement holes include an entrance facing the cooling passage, and an exit facing the impingement cavity, the scoop arranged at the entrance.