GB2440546A

GB2440546A - Fluid carrying arrangement and its manufacture using a solid freeform fabrication process

Info

Publication number: GB2440546A
Application number: GB0615517A
Authority: GB
Inventors: Richard Nicholson
Original assignee: Rolls Royce PLC
Current assignee: Rolls Royce PLC
Priority date: 2006-08-04
Filing date: 2006-08-04
Publication date: 2008-02-06
Also published as: GB0615517D0

Abstract

A fluid carrying arrangement 10 comprises an inner conduit 12 for carrying a first fluid 12A, and an outer conduit 14 for carrying a second fluid 14A. The inner and outer conduits 12, 14 are formed integrally and contemporaneously with each other. Preferably, at least one connecting member 20 for spacing the inner conduit 12 from the outer conduit 14 is also formed alongside the conduits. The connecting member(s) may extend axially along the length of the fluid carrying arrangement (as shown), or may comprise at least one strut member, which may be present in an array. The Fluid carrying arrangement is preferably manufactured from a sintered and/or melted metallic powder using a solid freeform fabrication process, e.g. selective laser or electron beam sintering and/or melting.

Description

* 2440546

FLUID CARRYING ARRANGEMENT

This invention relates to fluid carrying arrangement.

More particularly, but not exclusively, the invention relates to fluid carrying conduits, such as fluid pipes.

This invention may also relate to methods of forming fluid carrying arrangements.

In gas turbine engines, it is often necessary to provide coaxial pipes where one pipe extends within another. However, known coaxial pipes are restricted in that they are required to be of simple shapes that allow the pipes to be fitted together. Moreover, limitations exist on length and curvature as well as on the complexity of the end features. Moreover, it is difficult to ensure that the pipes remain separated under all operations.

According to one aspect of this invention, there is provided a fluid carrying arrangement comprising an inner conduit for carrying a first fluid, and an outer conduit for carrying a second fluid, wherein the inner and outer conduits are formed integrally with each other.

The inner conduit may comprise a pipe. The outer conduit may comprise a pipe.

A connecting member may be provided to connect the inner and outer conduit to each other. In some embodiments, a plurality of connecting members are provided.

The connecting members may be spaced from each other around the inner and outer conduits. The connecting members may be spaced from each other peripherally around the first and second condition. In one embodiment, where the inner and outer pipes are of a substantially cylindrical configuration, the connecting members may be spaced circumferentially around the first and second conduits.

In the first embodiment, the connecting members may be spaced from each other axially along the fluid carrying arrangement. In the first embodiment, the connecting members are arranged in a plurality of coplanar arrays, wherein each array is spaced from an adjacent array axially along the fluid carrying arrangement.

In a second embodiment, each connecting member may extend axially along the fluid carrying arrangement.

The connecting members may extend radially between the inner and outer conduits. Alternatively, the connecting members may extend tangentially from the inner conduit.

The fluid carrying arrangement may be formed of a sintered and/or melted metallic material. The fluid carrying arrangement may be formed by a solid freeform fabrication process, which may comprise selective melting and/or sintering. In one embodiment, the solid freeform fabrication process may comprise selective or electron beam melting and/or sintering.

The inner conduit may be formed of a metallic material, such as titanium. The outer conduit may be formed of a metallic material such as titanium.

According to another aspect of this invention, there is provided a method of forming a fluid carrying arrangement comprising providing a powder of a metallic material, processing the powder into an inner conduit for carrying a first fluid, and into an outer conduit for carrying a second fluid, wherein the inner and outer conduits are formed integrally with each other.

The inner and outer conduits may be formed contemporaneously with each other.

The step of processing the powder may comprise forming connecting members to connect the inner and outer conduits to each other. The method may involve forming the connecting members contemporaneously with the formation of the inner and outer conduits. The step of forming the connecting members may comprise forming the connecting members spaced from each other peripherally around the first and second conduits. The step of forming the connecting members may comprise forming the connecting members spaced from each other axially along the fluid carrying arrangement. In one embodiment, the step of forming the connecting members may comprise forming an array of axially spaced connecting members wherein each array comprises a plurality of substantially coplanar connecting members.

In a second embodiment the step of forming the connecting members may comprise forming the connecting members such that they extend axially along the fluid carrying arrangement.

The step of forming the connecting members may comprise forming connecting members that extend radially between the inner and outer conduits. Alternatively, the step of forming the connecting members may comprise forming connecting members tangentially from the inner conduit.

The step of processing the powder may comprise solid freeform fabrication. The step of processing the powder may comprise sintering and/or melting the powder to provide the fluid carrying arrangement. The step of processing the powder may comprise selective laser or electron beam sintering and/or melting.

The first conduit may be formed of a metallic material, and the second conduit may be formed of a metallic material. The metallic material may be titanium.

According to another aspect of this invention, there is provided a fluid carrying arrangement comprising a first part and a second part, wherein at least one of the first and second parts can carry a fluid, and at least one of the first and second parts is formed by a solid freeform fabrication process.

According to another aspect of this invention, there is provided a method of forming a fluid carrying arrangement comprising a first part and a second part in the first part, wherein at least one of the first and second parts can carry a fluid, and the method comprising forming at least one of the first and second parts by a solid freeform fabrication process.

The solid freeform fabrication process may comprise a selective melting or sintering process, such as selective laser or electron beam melting or sintering.

The first and second parts may extend axially with respect to one another. At least one of the first and second parts may comprise a conduit, such as a pipe.

Embodiments of the invention will now be described by way of example, with reference to the accompanying drawings, in which: Fig 1 is a front sectional view of a first embodiment of a fluid carrying arrangement; Fig 2 is a front sectional view of a second embodiment of a fluid carrying arrangement; Fig 3 is a perspective view of a third embodiment of a fluid carrying arrangement; Fig 4 is a front sectional view of a fourth embodiment of a fluid carrying arrangement; Fig 5 is a front sectional view of a fifth embodiment of a fluid carrying arrangement; Fig 6 is a side view of a portion of a carrying fluid arrangement; Fig 7 is a sectional view of an end region of a fluid carrying arrangement; Fig 8 is a diagrammatic view showing a first method of forming a fluid carrying arrangement; and Fig 9 is a diagrammatic view of a second method for forming a fluid carrying arrangement.

Referring to Fig 1, there is shown a fluid carrying arrangement 10 comprising an inner pipe 12 for carrying a first fluid 12A and a pipe 14 for carrying a second fluid 14A.

Connecting members 16 extend between the inner and outer pipes 12, 14. The inner and outer pipes 12, 14 are formed of a metallic material, such as titanium. The pipes may be formed by a suitable solid freeform fabrication process, such as selective laser or electron beam melting or sintering.

In the embodiment shown in Fig 1, the inner and outer pipes 12, 14 are cylindrical pipes and are arranged coaxially with respect to one another. The connecting members 16 extend radially between the inner and outer pipes 12, 14.

Referring to Fig 2, there is shown a further embodiment of the fluid carrying arrangement 10 and the same features have been designated with the same reference numerals as in Fig 1. In the embodiment shown in Fig 2, the inner and outer pipes 12, 14 are connected to each other by connecting members 18. In the embodiments shown in Fig 2, the connecting members 18 extend tangentially from the inner pipe 12 to the outer pipe 14.

The connecting members 16 shown in Fig 1 and the connecting members 18 shown in Fig 2 are in the form of struts and are arranged in an array as shown. A plurality of the arrays of the connecting members are spaced from one another along the axial length of the fluid carrying arrangement 10. Each of the connecting members 18 is in the form of a strut.

Fig 3 shows a further embodiment, and again the features in Fig 3 which are the same as those in Figs 1 and 2 have been designated with the same reference numerals. In the embodiments shown in Fig 3, the inner and outer pipes 12, 14 are connected to one another by axially extending connecting members 20.

As can be seen, the axially extending connecting members extend not only longitudinally along the fluid carrying arrangement 10, but also extend in a circumferential direction around the fluid carrying arrangement 10. It will be appreciated, however, that the connecting member 20 could simply extend longitudinally along the fluid carrying arrangement shown in Fig 3.

Referring to Figs 4 and 5, there is shown two further embodiments of a fluid carrying arrangement 10 in which the inner and outer pipes 12, 14 are of non circular profile.

In the embodiment shown in Fig 4, radially extending connecting members 16 are provided but it would be appreciated that any other suitable configuration of connecting members could be used.

The inner and outer pipes 12, 14 in Fig 4 are of an oval configuration, and are coaxial with respect to one another. The inner and outer pipes 12, 14 shown in Fig 4 are also concentric with respect to one another.

In Fig 5, the inner and outer pipes 12, 14 are each of a generally rectangular configuration. Moreover, the inner pipe 12 is arranged off-centre with respect to the outer pipe 14. Angled connecting members 22 are provided. It will be appreciated that the angled connecting members 22 could be in the form of struts wherein pairs of the struts are axially spaced from one another, or the connecting members 22 could be in the form of elongate connecting members extending axially along the fluid carrying arrangement 10.

The method for manufacturing the fluid carrying arrangements 10 shown in Figs 1 to 4 has the advantage of allowing complicated structures to be formed within the fluid carrying arrangement 10. For example, in Fig 6, a bend 24 is provided in the fluid carrying arrangement 10.

Also, in the bend 24, the inner pipe 12 is of a narrowed configuration at the bend 24 as at the region designated 26.

It will be appreciated that other complex structures of the fluid carrying arrangement 10 could be formed.

Referring to Fig 7 there is shown an example of an end region of fluid carrying arrangement 10, in which the outer pipe 14 terminates at an end region 28 and has a branch pipe 30 extending therefrom, for example to allow the fluid 14A to flow to a first region. The inner pipe 12 extends through the end region 28 of the outer pipe 14, for example to deliver the first fluid 12 to a second region which could be placed from the first region.

Referring to Fig 8, there is shown a first embodiment of a method of forming any of the fluid carrying arrangements 10 shown in Figs 1 to 7.

The method comprises providing a manufacturing compartment 130 within which a laser or electron beam device 132 is provided. A mirror 134 acts to control a beam 136 of laser light or electrons. A work piece 138 is provided beneath the manufacturing compartment 130 such that the upper portion 140 thereof extends in to the manufacturing compartment 130. A film 142 of a titanium powder 143 is provided within the manufacturing compartment and covers the work piece 138. A supply 144 of the powder 143 is provided in which a piston 146 can deliver the powder 143 into the manufacturing compartment 130. The film 142 of the powder 143 is levelled by a levelling device 146. In operation, the vertical position of the work piece 138 is controlled by a height control device 148 which can move up and down as shown by the arrows A. The laser or electron beam device 132 transmits a beam of electrons or laser light at the film 142 of the metallic powder covering the work piece 138 to sinter the metallic powder 142 in a layer on the work piece 138. After a layer has been formed, the height control device 148 moves the work piece downwardly and further powder 142 is then provided over the work piece 138, and the electron beam device is actuated to produce a further layer of the material on the work piece 138. This process is repeated until the desired fluid carrying arrangement 10 has been fully formed from the work piece 138.

The laser/electron beam device 132 is controlled by a suitable computer controlled system as would be understood by those skilled in the art. Appropriate computer software can be provided to allow complex regions and end regions, such as those shown in Figs 6 and 7, to be formed.

In the embodiment shown in Fig 9, many of the features shown in 8 are present, and these have been designated with the same reference numerals as in Fig 8. The embodiment shown in Fig 9 comprises a support platform 150 on which the work piece 138 is provided. A further laser or electron beam device 232 is provided and supported by a positioning and scanning device 234. A powder dispenser 236 is also supported by the positioning and scanning device 234. The powder dispenser 236 dispenses a layer of the powder 143 onto the work piece 138 for formation into a layer of the work piece 138.

The positioning and scanning device 234 positions the laser or electron beam device 232 to transmit a beam of laser light or electrons at the work piece after the powder dispenser has dispensed a layer of powder on to the work piece 138.

After each time that the laser or electron beam device has transmitted the beam of laser light or electron to sinter the metallic powder 143 to form a further layer of the work piece 138, a further layer of powder 143 is dispensed by the powder dispenser 236 onto the work piece 138. This is repeated until the work piece 138 is fully formed into the desired fluid carrying arrangement 10.

Various modifications can be made without departing from the scope of the invention. For example other shapes of fluid carrying arrangements 10 can be formed having the features of claim 1.

Although in the described embodiments titanium powder is referred to, it will be appreciated that a powder form of any suitable material may be used instead.

Claims

CLAI MS

1. A fluid carrying arrangement (10) comprising an inner conduit (12) for carrying a first fluid, and an outer conduit (14) for carrying a second fluid, wherein the inner and outer conduits are formed integrally and contemporaneously with each other.

2. A fluid carrying arrangement (10) according to claim 1 wherein the inner and outer conduits (12, 14) each comprise respective inner and outer pipes.

3. A fluid carrying arrangement (10) according to claim 1 or 2 wherein a plurality of connecting members (16) are provided to connect the inner and outer conduits (12, 14) to each other.

4. A fluid carrying arrangement (10) according to claim 3 wherein the connecting members (16) are spaced from each other around the inner and outer conduits (12, 14) 5. A fluid carrying arrangement (10) according to claim 4 wherein where the inner and outer conduits (12, 14) are of a substantially cylindrical configuration, the connecting members (16) are spaced circumferentially around the inner and outer conduits.

6. A fluid carrying arrangement (10) according to claim 3, 4 or 5 wherein the connecting members (16) are spaced from each other axially along the fluid carrying arrangement.

7. A fluid carrying arrangement (10) according to claim 6 wherein the connecting members (16) are arranged in a plurality of coplanar arrays, wherein each array is spaced from an adjacent array axially along the fluid carrying arrangement.

8. A fluid carrying arrangement (10) according to claim 6 wherein each connecting member (16) extends axially along the fluid carrying arrangement.

9. A fluid carrying arrangement (10) according to any of claims 3 to 8 wherein the connecting members (16) extend radially between the inner and outer conduits (12, 14) 10. A fluid carrying arrangement (10) according to any of claims 3 to 9 wherein the connecting members (16) extend tangentially from the inner conduit (12) 11. A fluid carrying arrangement (10) according to any preceding claim wherein the fluid carrying arrangement is formed of a sintered and/or melted metallic material by a solid freeform fabrication process.

12. A fluid carrying arrangement (10) according to claim 11 wherein the solid freeform fabrication process comprises selective or electron beam melting and/or sintering.

13. A fluid carrying arrangement (10) according to any preceding claim wherein the inner and outer conduits (12, 14) are formed of a metallic material.

14. A fluid carrying arrangement (10) according to any preceding claim wherein the inner and outer conduits (12, 14) are formed of titanium.

15. A method of forming a fluid carrying arrangement (10) comprising providing a powder of a metallic material, processing the powder into an inner conduit (12) for carrying a first fluid, and into an outer conduit (14) for carrying a second fluid, wherein the inner and outer conduits are formed integrally and contemporaneously with each other.

16. A method according to claim 15 wherein the step of processing the powder comprises forming connecting members (16) to connect the inner and outer conduits (12, 14) to each other, said connecting members being formed contemporaneously with the formation of the inner and outer conduits.

17. A method according to claim 16 wherein the step of forming the connecting members (16) comprises forming the connecting members spaced from each other around the first and second conduits (12, 14) 18. A method according to claim 16 or 17 wherein the step of forming the connecting members (16) comprises forming the connecting members spaced from each other axially along the fluid carrying arrangement (10).

19. A method according to claim 17, 18, or 19 wherein the step of forming the connecting members (16) comprises forming an array of axially spaced connecting members wherein each array comprises a plurality of substantially coplanar connecting members.

20. A method according to any of claims 17 to 20 wherein the step of forming the connecting members (16) comprises forming the connecting members such that they extend axially along the fluid carrying arrangement (10) 21. A method according to any of claims 16 to 20 wherein the step of forming the connecting members (16) comprises forming connecting members that extend radially between the inner and outer conduits (12, 14) 22. A method according to any of claims 16 to 20 wherein the step of forming the connecting members (16) comprises forming connecting members tangentially from the inner conduit (12) 23. A method according to any of claims 15 to 22 wherein the step of processing the powder comprises solid freeform fabrication.

24. A method according to any of claims 15 to 23 wherein the step of processing the powder comprises sintering and/or melting the powder to provide the fluid carrying arrangement.

25. A method according to any of claims 15 to 24 wherein the step of processing the powder comprises selective laser or electron beam sintering and/or melting.

26. A method according to any of claims 15 to 25 wherein the inner and outer conduits (13, 14) are formed of a metallic material.

27. A method according to any of claims 15 to 26 wherein the inner and outer conduits (12, 14) are formed of titanium.

28. A fluid carrying arrangement (10) comprising a first part and a second part (12, 14), wherein at least one of the first and second parts can carry a fluid, and at least one of the first and second parts is formed by a solid freeform fabrication process.

29. A fluid carrying arrangement (10) according to claim 28 wherein the solid freeform fabrication process comprises selective laser or electron beam melting or sintering.

30. A fluid carrying arrangement (10) according to claim 28 or 29 wherein the first and second parts (12, 14) extend axially with respect to one another.

31. A fluid carrying arrangement (10) according to any of claims 28 to 30 wherein at least one of the first and second parts (12, 14) comprises a conduit.

32. A method of forming a fluid carrying arrangement (10) comprising a first part (12) and a second part (14) in the first part (12) , wherein at least one of the first and second parts can carry a fluid, and the method comprising forming at least one of the first and second parts by a solid freeform fabrication process.

33. A method according to claim 32 wherein the solid freeform fabrication process comprises a selective melting or sintering process.

34. A method according to claim 32 or 33 wherein the solid freeform fabrication process comprises selective laser or electron beam melting or sintering.

35. A method according to claim 32, 33 or 34 wherein the first and second parts (12, 14) extend axially with respect to one another.

36. A method according to any of claims 33 to 35 wherein at least one of the first and second parts (12, 14) comprises a conduit.

37. A fluid carrying arrangement substantially as herein described with reference to the accompanying drawings.

38. A method of forming a fluid carrying arrangement substantially as herein described with reference to the accompanying drawings.

39. Any novel subject matter or combination including novel subject matter disclosed herein, whether or not within the scope of or relating to the same invention as any of the preceding claims.