Rear-cone exhaust duct for additive manufacturing

A process of additively manufacturing a turbine exhaust case, comprising:

• additively manufacturing the turbine exhaust case on a substrate;
• and
• additively manufacturing a support structure for a portion of the turbine exhaust case on the substrate,
• wherein the turbine exhaust case includes:
• an outer shroud having a cylindrical shape with a first end and a second end, the outer shroud extending in a first direction parallel to a center axis and extending circumferentially around the center axis;
• a coupling ring disposed circumferentially around the outer shroud;
• a connector ring disposed at an angle to the outer shroud and coupling the coupling ring to the outer shroud;
• an inner shroud having frustoconical shape with a first end and a second end, the inner shroud disposed within the outer shroud, the inner shroud extending circumferentially around the center axis;
• a plurality of struts coupled to the outer shroud and the inner shroud, wherein each strut of the plurality of struts and is integrally formed with the inner shroud and the outer shroud at a fixed distance between the first end and the second end of the outer shroud, extends perpendicular from the outer shroud toward the inner shroud, and terminates at the inner shroud at intervals around the center axis;
• an inner cone having a frustoconical shape with a first end and a second end, the inner cone coupled to and extending into the inner shroud, the inner cone extending circumferentially around the center axis, the inner cone tapering at a first angle with respect to the center axis, the first end of the inner cone being coupled to the second end of the inner shroud via a circumferential edge defined by a radius;
• a first flat surface coupled to the second end of the inner cone;
• and
• a second flat surface formed by at least a portion of the coupling ring, the first flat surface and the second flat surface configured to be supported by the support structure during the additive manufacturing process, wherein the coupling ring, the outer shroud, the connector ring, the inner shroud, the plurality of struts, and the inner cone are monolithically formed during the additively manufacturing of the turbine exhaust case.

A turbine exhaust case, comprising:

• an inner cone having a frustoconical shape extending in a first direction from a first end to a second end, the first end being a flat, closed surface, the inner cone expanding in diameter from the first end to the second end;
• an inner shroud having a frustoconical shape extending in a second direction from a first end to a second end, the second direction being opposite the first direction, the first end of the inner shroud being coupled to the second end of the inner cone via a circumferential edge defined by a radius, the inner shroud expanding in diameter from the first end to the second end;
• a plurality of struts coupled to an outer surface of inner shroud;
• an outer shroud having a cylindrical shape extending in the first direction from a first end to a second end, the outer shroud being parallel to a central axis from the first end to the second end, wherein an inner surface of the outer shroud is coupled to the plurality of struts;
• a coupling ring defining a plurality of fastening holes;
• and
• a connector ring coupling the coupling ring to the outer shroud, the connector ring angled with respect to the outer shroud,
• wherein each of the inner cone, the inner shroud, the plurality of struts, the outer shroud, the coupling ring, and the connector ring are monolithically formed such that each strut of the plurality of struts is monolithically formed with the inner shroud and the outer shroud at a fixed distance between the first end and the second end of the outer shroud, extends perpendicular from the outer shroud toward the inner shroud, and terminates at the inner shroud at intervals around the center axis.