Apparatus and method for testing additively manufactured engine components
AssigneeRtx Corporation
InventorsLawrence Binek, David W. Morganson
Life of this patent
Estimating the term…
Abstract
A method for inspecting a component made using an additive manufacturing process, the component having an internal conduit, is disclosed. In various embodiments, the method includes the steps of: attaching a fluid-blocking header to the component, the fluid-blocking header having an internal conformal surface configured to mate with an external conformal surface of the component; introducing a plugging media into the internal conduit; activating the fluid-blocking header to freeze the plugging media in a vicinity of the fluid-blocking header; pressurizing the internal conduit of the component; and analyzing a fluid flow characteristic at an outlet of the component to assess an occurrence of a blockage within the internal conduit.
Claims16
A method for inspecting a component made using an additive manufacturing process, the component having an internal conduit, comprising:
- attaching a fluid-blocking header to the component, the fluid-blocking header having an internal conformal surface configured to physically contact an external conformal surface of the component, a coolant inlet on a first side of the fluid-blocking header orthogonal to the internal conformal surface, and a coolant outlet on a second side of the fluid-blocking header, the second side being opposite the first side;
- introducing a plugging fluid into a supply inlet of the internal conduit, the plugging fluid filling the internal conduit;
- activating the fluid-blocking header to freeze the plugging fluid in a vicinity of a first outlet of a plurality of outlets of the internal conduit, including routing a coolant from the coolant inlet, through the fluid-blocking header, and out the coolant outlet;
- pressurizing the plugging fluid in the internal conduit of the component to establish a fluid flow through the internal conduit and out a second outlet of the plurality of outlets;
- and
- analyzing a fluid flow characteristic at the second outlet of the component to assess whether a blockage has occurred within the internal conduit during the additive manufacturing process.
A fluid-blocking header configured for testing a component made using an additive manufacturing process, the component having an internal conduit, comprising:
- a body having an internal conformal surface configured to physically contact an external conformal surface of the component to facilitate heat transfer between the fluid-blocking header and the internal conduit within the component, a first side orthogonal to the internal conformal surface, and a second side opposite the first side;
- a cooling inlet on the first side of the body;
- a cooling outlet on the second side of the body;
- and
- a fluid cooling system coupled to the cooling inlet and the cooling outlet and configured route a coolant from the cooling inlet, through the body, and out the cooling outlet to freeze a plugging fluid within the internal conduit and adjacent the external conformal surface of the component.
A method for inspecting an engine casing made using an additive manufacturing process, the engine casing including a fuel rail configured to provide a fuel to a plurality of fuel injectors spaced circumferentially about the engine casing, comprising:
- attaching a first fluid-blocking header to the engine casing, the first fluid-blocking header having an internal conformal surface configured to physically contact an external conformal surface of the engine casing, a coolant inlet on a first side of the first fluid-blocking header orthogonal to the internal conformal surface, and a coolant outlet on a second side of the first fluid-blocking header, the second side being opposite the first side;
- introducing a plugging fluid into a fuel supply inlet of the engine casing and into the fuel rail, the plugging fluid filling the fuel rail;
- activating the first fluid-blocking header to freeze the plugging fluid in a vicinity of the first fluid-blocking header, including routing a coolant from the coolant inlet, through the first fluid-blocking header, and out the coolant outlet;
- pressurizing the fuel rail at the fuel supply inlet of the engine casing;
- and
- analyzing a fluid flow characteristic at a first fuel injector of the plurality of fuel injectors whether a blockage has occurred within the fuel rail during the additive manufacturing process.
Dependencies are inferred from the claim text.