Methods for manufacturing additively manufactured structures for internal combustion engines and said additively manufactured structures

An additively manufactured structure for an internal combustion engine, the additively manufactured structure comprising:

• a body member defining an external body surface and a body bore, the body bore defining an internal body surface;
• and
• at least two gas ports, each gas port defining an external port surface and a port bore, each port bore defining an internal port surface, and
• wherein surface areas of the internal body surface and each internal port surface are at least approximately 20 degrees offset from parallel to a build plate for the additively manufactured structure such that no portion of the surface areas is equivalent to an area of a circle having a radius of 5 mm or larger.

A method for manufacturing an additively manufactured structure for an internal combustion engine, the method comprising:

• identifying a start point on a build plate for construction of the additively manufactured structure, the additively manufactured structure comprising a body member and at least two gas ports, the body member defining an external body surface and a body bore, the body bore defining an internal body surface, each gas port defining an external port surface and a port bore, each port bore defining an internal port surface;
• identifying an orientation of the additively manufactured structure to the build plate such that surface areas of the internal body surface and each internal port surface are at least approximately 20 degrees offset from parallel to the build plate for the additively manufactured structure such that no portion of the surface areas is equivalent to an area of a circle having a radius of 5 mm or larger;
• preparing the build plate and a bed of metal powder for construction of the additively manufactured structure;
• welding a first layer of the additively manufactured structure and the first layer of support structures to the build plate using laser powder bed fusion, the support structures extending from the build plate to select external locations on the additively manufactured structure for support during construction;
• repeating the preparing of the build plate and the welding of the first layer to continue layer-by-layer construction of the additively manufactured structure and the support structures until a last layer is welded;
• removing the support structures from the additively manufactured structure;
• grinding, polishing, cleaning and/or honing the internal body surface on the body bore;
• applying a wear-resistant coating to at least a portion of the internal body surface of the body bore for subsequent contact by a piston or a piston ring;
• and
• direct age hardening the additively manufactured structure to increase tensile strength.