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US 11,976,569 B2Granted
Fused filament fabrication of abradable coatings
AssigneesROLLS-ROYCE plc, Rolls-Royce North American Technologies Inc.
InventorsQuinlan Yee Shuck, Scott Nelson, Raymond Ruiwen Xu, Brandon David Ribic, Matthew R. Gold
Life of this patent
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Abstract
In general, techniques are described for fused filament fabrication of abradable coatings. An additive manufacturing system comprising a substrate defining a major surface, a filament delivery device, and a computing device may be configured to perform various aspects of the techniques. The computing device may be configured to control the filament delivery device to deposit a filament on the substrate, the filament including a powder and a binder, wherein the binder is configured to be substantially removed from the filament and the powder includes a metal or alloy configured to be sintered to form an abradable layer.
Claims16
A method comprising:
- depositing, by a filament delivery device, a softened filament on a substrate defining a major surface to form an unsintered layer, the filament including a powder and a binder, the powder including a metal or an alloy, wherein the unsintered layer comprises a non-uniform unsintered layer in which a first portion is defined by a first plurality of filament blocks and a second portion is defined by a second plurality of filament blocks;
- removing substantially all of the binder;
- and
- sintering the unsintered layer to form an abradable layer for the substrate defining the major surface, wherein the first portion of the unsintered layer forms a first portion of the abradable layer and the second portion of the unsintered layer forms a second portion of the abradable layer, and wherein the first portion of the abradable layer defines a different porosity, density, composition, or microstructure than the second portion of the abradable layer.
1 more element
A method comprising:
- depositing, by a filament delivery device, a softened filament on a substrate defining a major surface to form an unsintered layer, the filament including a powder and a binder, the powder including a metal or an alloy, wherein the unsintered layer comprises a non-uniform unsintered layer in which a first portion is defined by a first plurality of filament blocks, a second portion of the non-uniform unsintered layer is defined by a second plurality of filament blocks, and a third portion of the non-uniform unsintered layer is defined by a third plurality of filament blocks;
- removing substantially all of the binder;
- and
- sintering the unsintered layer to form an abradable layer for the substrate defining the major surface, wherein the first portion of the unsintered layer forms a first portion of the abradable layer, the second portion of the unsintered layer forms a second portion of the abradable layer, the third portion of the unsintered layer forms a third portion of the abradable layer,
- wherein each filament block of the first plurality of filament blocks defines a first shape, each filament block of the second plurality of filament blocks defines a second shape, and each filament block of the third plurality of filament blocks defines a third shape, and wherein the third shape is rounded such that the third shape does not include relatively sharp edges, and wherein respective filament blocks of the third plurality of filament blocks are oriented to substantially align with a blade tip of a blade configured to contact a blade rub portion upon rotation of the blade in a circumferential direction.
2 more elements
An additive manufacturing system comprising:
- a substrate defining a major surface;
- a filament delivery device;
- and
- a computing device configured to:
- control the filament delivery device to deposit a softened filament on the substrate to form an unsintered layer, the filament including a powder and a binder, wherein the unsintered layer comprises a non-uniform unsintered layer in which a first portion is defined by a first plurality of filament blocks and a second portion of the non-uniform unsintered layer is defined by a second plurality of filament blocks;
- wherein the binder is configured to be substantially removed from the filament and the powder includes a metal or an alloy configured to be sintered to form an abradable layer, wherein the first portion of the unsintered layer forms a first portion of the abradable layer and the second portion of the unsintered layer forms a second portion of the abradable layer, and wherein the first portion of the abradable layer defines a different porosity, density, composition, or microstructure than the second portion of the abradable layer.
3 more elements
Dependencies are inferred from the claim text.