ADDITIVE MANUFACTURING METHOD FOR THE ADDITION OF FEATURES WITHIN COOLING HOLES
A method for forming a diffusion cooling hole in a substrate includes removing material from the substrate to form a metering section having an inlet on a first side of the substrate and removing material from the substrate to form a diffusing section that extends between the metering section and an outlet located on a second side of the substrate generally opposite the first side. The method also includes forming a feature on a substrate surface within one of the metering section and the diffusing section. Forming the feature includes depositing a material on the substrate surface and selectively heating the material to join the material with the substrate surface and form the feature.
1 . A gas turbine engine component comprising:
a wall having a first surface and an opposing second surface;
a diffusion cooling hole extending through the wall and fluidly connecting the first and second wall surfaces, the diffusion cooling hole comprising:
a metering section oriented along an axis and having an inner surface; and
a diffusing section adjacent to and downstream of the metering section;
the diffusing section having a top surface and a bottom surface; and
at least one raised feature formed in the diffusion cooling hole, a portion of the at least one raised feature being proximate a transition point between a downstream end of the metering section and an upstream end of the diffusing section.
2 . The component of claim 1 and further comprising: an inlet formed in the first wall surface upstream of the metering section.
3 . The component of claim 2 and further comprising: an outlet formed in the second wall section downstream of the diffusing section.
4 . The component of claim 3 , wherein the raised feature is formed on the top surface of the diffusing section.
5 . The component of claim 4 , wherein the at least one raised feature has a curved shape.
6 . The component of claim 4 , wherein the at least one raised feature obscures a line of sight between the inlet and the outlet.
7 . The component of claim 3 , wherein the diffusing section further comprises first and second opposing side surfaces extending between the top surface and bottom surface.
8 . The component of claim 7 , wherein the diffusing section bottom surface diverges longitudinally from the axis.
9 . The component of claim 8 , wherein the at least one raised feature comprises a first raised feature and a second raised feature.
10 . The component of claim 9 , wherein the first raised feature is formed in the metering section, and the second raised feature is formed on at least one of the top, bottom, or side surfaces of the diffusing section.
11 . The component of claim 9 , wherein the first and second raised features are formed from a technique selected from the group consisting of selective laser melting, direct metal laser sintering, selective laser sintering, electron beam melting, and combinations thereof.
12 . The component of claim 3 , wherein the diffusion cooling hole is formed by a technique selected from the group consisting of casting, drilling, laser drilling, machining, electrical discharge machining and combinations thereof.
13 . The component of claim 3 , wherein the wall is formed primarily from a metallic material.
14 . The component of claim 3 , wherein the gas turbine engine component is a vane, blade, combustor, or blade outer air seal.
15 . A gas turbine engine component comprising:
a wall having a first surface and an opposing second surface;
a diffusion cooling hole extending through the wall and fluidly connecting the first and second wall surfaces, the diffusion cooling hole comprising:
a metering section oriented along an axis and having an inner surface; and
a diffusing section adjacent to and downstream of the metering section;
the diffusing section having a top surface and a bottom surface; and
at least one raised feature formed on the top surface of the diffusion section.
16 . The component of claim 15 , wherein the at least one raised feature has a curved shape.
17 . The component of claim 15 , wherein the raised feature is formed from a technique selected from the group consisting of selective laser melting, direct metal laser sintering, selective laser sintering, electron beam melting, and combinations thereof.
18 . The component of claim 15 , wherein the diffusion cooling hole is formed by a technique selected from the group consisting of casting, drilling, laser drilling, machining, electrical discharge machining and combinations thereof.
19 . The component of claim 15 , wherein the diffusing section further comprises first and second opposing side surfaces extending between the top surface and bottom surface.
20 . The component of claim 19 , wherein the raised feature is further formed on the side and bottom surfaces.