Multiple additive manufacturing technique material deposition
A method of making a metallic component includes mounting a polymeric scaffold onto a mandrel, wherein the mandrel includes one or more chucks configured to secure the polymeric scaffold onto the mandrel and wherein the mandrel is configured to rotate the polymeric scaffold; depositing, with a second additive manufacturing (AM) technique using a material applicator, a component material onto the polymeric scaffold to form the metallic component on the polymeric scaffold, wherein the component has a shape that is the same as the polymeric scaffold; removing the polymeric scaffold; and the metallic component deposited on the polymeric scaffold from the mandrel; and removing the polymeric scaffold from the metallic component.
1 . A method of making a metallic component, comprising the steps of:
mounting a polymeric scaffold onto a mandrel, wherein the mandrel includes one or more chucks configured to secure the polymeric scaffold onto the mandrel and wherein the mandrel is configured to rotate the polymeric scaffold;
depositing, with a second additive manufacturing (AM) technique using a material applicator, a component material onto the polymeric scaffold to form the metallic component on the polymeric scaffold, wherein the component has a shape that is the same as the polymeric scaffold;
removing the polymeric scaffold and the metallic component deposited on the polymeric scaffold from the mandrel; and
removing the polymeric scaffold from the metallic component.
2 . The method of claim 1 , further comprising the step of:
building, using a first AM technique, the polymeric scaffold.
3 . The method of claim 2 , wherein the first AM technique is material extrusion (MEX).
4 . The method of claim 1 , wherein the polymeric scaffold is formed in the shape of a gas turbine engine combustor liner.
5 . The method of claim 4 , wherein the polymeric scaffold includes one or more apertures.
6 . The method of claim 4 , wherein the second AM technique is cold spray and the component material is copper or a copper alloy.
7 . The method of claim 6 , wherein the polymeric scaffold includes an inner bore configured to define a combustion chamber of the combustor liner when the component material is deposited onto the polymeric scaffold.
8 . The method of claim 7 , wherein the material applicator includes a moveable spray head that is configured to bend at least 90° to permit the component material to be deposited onto the inner bore of the polymer scaffold.
9 . The method of claim 1 , wherein the mandrel is removed from the polymeric scaffold after the metallic component is formed on the polymeric scaffold.
10 . The method of claim 9 , wherein the polymeric scaffold is removed from the metallic component after the mandrel is removed from the polymeric scaffold.
11 . The method of claim 10 , wherein the polymeric scaffold is removed from the metallic component using a chemical reagent.
12 . The method of claim 10 , wherein the polymeric scaffold is removed from the metallic component using a thermal removal process.