Method for manufacturing compressor components

A method for making a labyrinth seal for use in an internal-driven compressor, the labyrinth seal having a cylindrical body, an integral open cell structure, and a filler media within the open cell structure, the method comprising:

• providing a first layer of metallic powder;
• applying laser energy of a first power level to a first area of the first layer of metallic powder to form a first portion of the cylindrical body having a first weld strength;
• applying laser energy of a second power level to a second area of the first layer of metallic powder to form a first portion of the open cell structure having a second weld strength;
• applying laser energy of a third power level to a third area of the first layer of metallic powder to form a first portion of the filler material having a third weld strength;
• providing a second layer of metallic powder on top of the first portions of the cylindrical body, the open cell structure, and the filler media;
• applying laser energy of the first power level to a first area of the second layer of metallic powder to form a second portion of the cylindrical body;
• applying laser energy of the second power level to a second area of the second layer of metallic powder to form a second portion of the open cell structure;
• and
• applying laser energy of the third power level to a third area of the second layer of metallic powder to form a second portion of the filler material.

A labyrinth seal prepared by a process comprising the steps of:

• providing a first layer of metal-forming material;
• applying energy of a first power level to a first area of the first layer of metal-forming material to form a first portion of the labyrinth seal having a first density;
• applying energy of a second power level to a second area of the first layer of metal-forming material to form a second portion of the labyrinth seal having a second density;
• providing a second layer of the metal-forming material on top of the first portion and the second portion of the labyrinth seal;
• applying the energy of the first power level to a first area of the second layer of metal-forming material;
• and
• applying the energy of the second power level to a second area of the second layer of metal-forming material.