# US 11,305,352 B2 · Powder fused components with unique internal structures for damping

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- Number: US 11,305,352 B2
- Document ID: US11305352B2
- Status: Granted
- Kind: B2
- Application number: 16/352,197
- Filed: 2019-03-13
- Published: 2020-09-17
- Granted: 2022-04-19
- Earliest claimed: 2019-03-13
- Assignees: The United States of America as represented by the Secretary of the Air Force
- Applicants: Government of the United States, as represented by the Secretary of the Air Force
- Inventors: Onome Scott-Emuakpor; Tommy George; Brian Runyon
- Web page: https://patentgrep.com/patent/US11305352B2

## CPC

- B22F 9/082: {atomising using a fluid (using centrifugal force B22F9/10)}
- B22F 5/10: of articles with cavities or holes, not otherwise provided for in the preceding subgroups
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 12/41: characterised by the type, e.g. laser or electron beam
- B33Y 10/00: Processes of additive manufacturing
- B33Y 50/00: Data acquisition or data processing for additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- F16F 15/02: Suppression of vibrations of non-rotating, e.g. reciprocating systems; Suppression of vibrations of rotating systems by use of members not moving with the rotating systems ({F16F15/005 takes precedence } ; layered products B32B; suppression of vibration in ships B63; {relieving load on bearings, using magnetic means F16C39/06})
- B22F 10/36: of energy beam parameters
- B22F 10/366: Scanning parameters, e.g. hatch distance or scanning strategy
- B22F 2301/15: Nickel or cobalt
- Y02P 10/25: Process efficiency
- 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
- 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
- F16F: SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

Methods, architectures, mechanisms and/or apparatus configured to manufacture a component (and components manufactured thereby) by optimizing a location of an internal feature of the component to be manufactured using powder fusion additive manufacturing (PFAM) based on an energy release rate being proportional to the third derivative of a component shape function and the shape function itself; the internal feature comprising one or more cavities having unfused powder disposed therein to provide vibration dampening.

## Claims

### Claim 1

A method of manufacturing a component an internal feature therein, the method comprising:
developing a component design of the component;
using the component design,
optimizing a location of the internal feature of the component to be manufactured using powder fusion additive manufacturing (PFAM) based on an energy release rate being proportional to the third derivative of a component shape function and the shape function itself; and
manufacturing the component using the optimized component design and a powder fusion additive manufacturing (PFAM) process based on an energy release rate being proportional to the third derivative of a component shape function and the shape function itself,
wherein the internal feature comprises one or more cavities having unfused powder disposed therein to provide vibration dampening.

### Claim 2 (depends on 1)

The method of claim 1, wherein using PFAM further comprises:
operating an energy source comprising a laser or an electron beam.

### Claim 3 (depends on 1)

The method of claim 1, wherein PFAM further comprises:
laser powder bed fusion additive manufacturing (LPBFAM).

### Claim 4 (depends on 1)

The method of claim 1, wherein the internal feature of the component includes a tip cavity and a middle cavity.

### Claim 5 (depends on 1)

The method of claim 1, wherein the component is formed from Inconel.

### Claim 6 (depends on 1)

The method of claim 1, wherein the unfused powder is a gas atomized powder, a reused gas atomized powder, a plasma atomized powder, or a plasma rotating electrode process powder.

### Claim 7 (depends on 1)

The method of claim 1, wherein the component is formed from a nickel alloy, a titanium alloy, a cobalt-chrome alloy, or a ferric-based alloy.

### Claim 8 (depends on 1)

The method of claim 1, wherein using PFAM further comprises:
operating an energy source selected from the group consisting of a directed energy deposition machine, an electron beam machine, a direct metal laser sintering machine, a direct metal laser melting machine, and a selective laser melting machine.