RU2723431C2 - Destructible support structure for additive production - Google Patents

Abstract

FIELD: production of composite materials.SUBSTANCE: invention relates to production of articles by means of additive technologies, in particular, to production of fuel injector. Fuel injector comprises destructible supporting structure for nozzle first and second surfaces opposite in vertical direction. Destructible supporting structure has first base connected to first surface and extending towards second surface, a second base connected to the second surface and extending towards the first surface, and a bridge connecting the first base to the second base. Bridge can be selectively broken under the effect of thermal stress and includes the main part and the weakened zone formed in the said main part.EFFECT: ensuring absence of product shape distortion and separation of article parts located in close proximity to each other.20 cl, 8 dwg

Description

BACKGROUND OF THE INVENTION

[0001] The present invention generally relates to additive manufacturing methods, according to which supporting structures are used in the construction process, as well as to new supporting structures used in the framework of said AM processes.

[0002] In contrast to subtractive production methods, additive technologies (AM) typically include the buildup of one or more materials to form an object having a final or near final shape (NNS). Although the term “additive manufacturing” refers to industry standards, AM includes various manufacturing and prototyping technologies known under various names, including the creation of arbitrary shape objects, 3D printing, rapid prototyping / processing, etc. AM technology can provide the manufacture of complex objects made of a variety of materials. As a rule, an independent object can be manufactured according to a computer-aided design (CAD) model. In a certain type of AM technology, an energy beam is used, for example, an electron beam or electromagnetic radiation, such as a laser beam, to sinter or melt a powdered metal material to form a solid bulk object in which particles of the powder material are bonded to each other. Different groups of materials are used, for example, structural plastics, thermoplastic elastomers, metals and ceramics. Laser sintering or melting refers to the well-known AM technology used to quickly produce functional objects, prototypes and tools.

[0003] The expressions "selective laser sintering", "direct laser sintering", "selective laser melting" and "direct laser melting" are generally accepted industry terms related to the production of three-dimensional (3D) objects using a laser beam for the sintering or melting of finely divided metal powder. These processes may be referred to herein as additive manufacturing using metal powder. More precisely, sintering involves the fusion (agglomeration) of powder particles at a temperature below the melting point of the powder material, while melting involves the complete melting of the powder particles to form a solid homogeneous mass. Physical processes associated with laser sintering or laser melting include the transfer of heat to the powder material and then either sintering or melting of the powdered metal material.

[0004] Using additive technologies using metal powder, layers of molten metal are created or metal agglomerates over already formed layers of solidified metal. In those places where the hardened metal is under a new layer, it serves as a support for the new layer. One problem of additive manufacturing is the construction of surfaces that are not vertical, such as non-supported horizontal surfaces or surfaces tilted from a vertical, that is, tilted relative to the horizontal and not supported underneath. In particular, in those places where part of the new layer is located not on top of the previously formed, already hardened metal, located nearby, the thermally untreated metal powder does not provide sufficient support, and gravity adversely affects the final shape of the object. It is known that to resolve this situation, in the process of additive production of a metal object using metal powder and in order to support non-ground surfaces, support structures are formed that are part of the metal object. For example, support structures may be formed in fuel nozzles used in gas turbines in order to maintain separation between parts, for example, spaced concentric tubular components located in close proximity to one another. In many applications, the supporting structures are removed from the finished metal object, for example, if the operation of the object does not provide for the presence of supporting structures or the destruction of the specified structure can cause additional damage. In these cases, the supporting structures are removed during processing processes following the AM production, such as machining or chemical processes. In some cases, supporting structures embedded in a metal object can be left in it. In this case, the destruction of the supporting structures can provide stresses (for example, thermal stress) arising during the operation of a metal object. For example, under stresses arising inside the object, destruction in order to improve operation can be achieved by providing greater freedom of movement. In some applications, it is difficult to create such a configuration of supporting structures that during operation would ensure their destruction in a way that does not affect the object at all. Although these difficulties have been described in relation to additive production using metal powder, they are also inherent in other types of additive production.

SUMMARY OF THE INVENTION

[0005] According to a first aspect of the invention, there is provided an additive manufacturing method having a first surface, a second surface that is vertically opposite the first surface, and a collapsible support structure that has a first base connected to the first surface and extending toward the second surface, a second base connected to the second surface and extending toward the first surface, and a jumper that connects the first base to the second base may selectively fail under the influence of thermal stress and has a main part and a weakened zone formed in the main part.

[0006] According to a second aspect of the invention, there is provided a method for manufacturing an object, comprising molding an object together with a collapsible supporting structure using additive technology, wherein the collapsible supporting structure includes a first base connected to a first surface of the object and extending toward the second surface of the object, which the vertical direction is located opposite the first surface, the second base connected to the second surface and passing towards the first surface, and a jumper that connects the first base to the second base and has a main part and a weakened zone formed therein; moreover, the method also includes ensuring the destruction of the jumper under the influence of thermal stress after molding an object using additive technology.

[0007] According to a third aspect of the invention, there is provided a collapsible support structure for vertically opposed first and second surfaces of an object, which comprises a first base connected to the first surface and extending toward the second surface; a second base connected to the second surface and extending toward the first surface, and a jumper that connects the first base to the second base, can selectively be destroyed by thermal stress and has a main part and a weakened zone formed in the specified main part.

[0008] Illustrated by the drawings, aspects of the present invention provide a solution to the described in this document and / or other problems not discussed in this document.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] These and other features of the present invention will become more apparent from the following detailed description of its various aspects, made with reference to the accompanying drawings, showing various embodiments of the invention. In the drawings:

[0010] FIG. 1 is a flowchart of an additive manufacturing process including a non-volatile computer readable information medium in which an object code is stored, according to embodiments of the invention.

[0011] FIG. 2 is a sectional view of a fuel injector which is an object formed in the additive manufacturing process illustrated in FIG. 1, according to embodiments of the invention.

[0012] FIG. 3 is an enlarged sectional perspective view of a spray portion of a fuel injector of FIG. 2, comprising a collapsible support structure according to embodiments of the invention.

[0013] FIG. 4 is an enlarged perspective view of a collapsible support structure located in the spray portion of FIG. 3, according to embodiments of the invention.

[0014] FIG. 5 is a side elevational view of a collapsible support structure according to embodiments of the invention.

[0015] FIG. 6 is an enlarged front view of a weakened area of a collapsible support structure according to embodiments of the invention.

[0016] FIG. 7 is a perspective view of the fuel injector of FIG. 2 illustrating stress generation according to embodiments of the invention.

[0017] FIG. 8 is an enlarged sectional perspective view of a spray portion of a fuel injector of FIG. 2, comprising a series of collapsible supporting structures, illustrating the generation of thermal stresses by means of these structures, according to embodiments of the invention.

[0018] It should be noted that the drawings are not to scale. The drawings depict only typical aspects of the invention and therefore should not be considered as delimiting its scope. In the drawings, like reference numbers indicate like elements.

DETAILED DESCRIPTION OF THE INVENTION

[0019] First of all, for a clear description of the invention, it is necessary to determine the terminology used when referring to an object manufactured in accordance with this document and its characteristic. Whenever possible, a unified industry terminology is used, applied in accordance with its generally accepted meaning. Unless otherwise indicated, this terminology implies an expanded interpretation in accordance with the context of this application and the scope of the attached claims. Those skilled in the art will recognize that often a particular object may be referred to using several different or partially matching terms. An object that can be described as a single part in this document, in another context, may include several components and may be referred to as consisting of several components. Alternatively, an item that can be described in this document as consisting of several components may in some cases be indicated as a single part.

[0020] In addition, some descriptive terms may be used regularly in this document, and it will be useful to determine their meaning at the beginning of this section. These terms, as well as their meanings, provided that no special reservation is made, are given below. As used herein, the word “collapse” means that the corresponding supporting structure 200 or its jumper 210 breaks down, is no longer integral, or is otherwise damaged, so that at least its ability to support the corresponding structure is impaired. As used herein, the expression “metal object” can include any physical object containing metal or a metal alloy and formed in the process of additive production using metal powder, and the word “object” can include any physical object formed in the process of additive production, possibly with the use of other, non-metallic materials, such as polymers and ceramic composite materials, but not limited to. The wording used throughout the description and claims of the invention indicating approximate correspondence in this document can be used to vary any quantitative designation, which may change without leading to a change in the basic function on which it depends. Therefore, a value defined by an expression or expressions such as “about”, “about”, and “essentially” is not limited to the exact value indicated. In at least some cases, formulations indicating approximate conformity may correspond to the accuracy of a measurement tool. In this case, and throughout the description and claims, the boundaries of the range can be combined and / or replaced, while these ranges are set and include all their sub-ranges, unless otherwise specified in the context or text. The expression “about”, used when referring to a specific value from a range of values, refers to both values and, regardless of the accuracy of the instrument used to measure the specified value, may include +/- 10% of the set value (s). The expression “substantially vertical” may imply a deviation of +/- 5 ° from vertical, the expression “substantially horizontal” may imply a deviation of +/- 5 ° from horizontal, and the expression “substantially perpendicular”, referring to two structures, may imply an angle between them, comprising 85 ° -95 °. The expression “substantially triangular” may refer to a configuration having three main surfaces, but there is a slight deviation in the shape of the surfaces or a change in the number of additional, secondary surfaces. The expression “substantially round” may refer to a configuration having the form of a circle, but some inconstancy of its diameter is permissible. Indications of singular elements in this document also include the plural, unless the context clearly indicates otherwise. It should also be understood that the expressions "contains" and / or "containing", when used in this description indicate the presence of the claimed features, integrity, steps, operations, elements and / or objects, but do not exclude the presence or addition of one or more other features , integrity, steps, operations, elements, objects and / or their groups. The expression “possible” or “possible” means that the following event or situation may or may not occur, and that the description includes cases when the event occurs and cases when the event does not occur.

[0021] As indicated above, the invention provides an object formed by an additive manufacturing method including a collapsible supporting structure for vertically opposed first and second surfaces of the object. Also described is a method of manufacturing an object containing destructible supporting structure, and the specified structure.

[0022] As an example of the additive manufacturing process in FIG. 1 is a block diagram of an illustrative computerized additive manufacturing system 100 that provides for the formation of an object 102. In this example, the system 100 is designed to perform a DMLM process using an additive technology using metal powder. It should be understood that the basic ideas of the invention are equally applicable to other types of additive manufacturing. Object 102 is depicted as a fuel injector. However, it is clear that additive manufacturing technology may in fact involve the manufacture of any object. The AM system 100 typically includes a computerized additive manufacturing (AM) management system 104 and an AM printer 106. As described below, the AM system 100 provides code 120 that includes a set of computer-executable instructions defining object 102 to physical embodiment by the AM printer 106. In each AM process, different starting materials can be used, for example, in the form of a fine-grained metal powder, the stock of which can be stored in the AM chamber 110 of the printer 106. In this case, the object 102 can be made of metal or a metal alloy. As shown in the drawing, the application device 112 can create a thin layer of the source material 114 distributed in the form of a continuous web from which each subsequent layer of the final object will be created. In the illustrated example, a laser or electron beam 116 melts the particles of each formation in accordance with code 120. Different parts of the AM of the printer 106 can be moved to allow each new layer to grow, for example, the forming platform 118 can be lowered, and / or a camera can rise after the formation of each layer. 110 and / or device 112.

[0023] The AM production control system 104 depicted in the drawing is implemented in computer 130 as computer program code. In this case, a computer 130 is shown including a memory 132, a processor 134, an input / output (I / O) interface 136 and a bus 138. Moreover, the computer 130 is shown in communication with an external (I / O) device / resource 140 and a system 142 data storage. Typically, processor 134 provides execution of computer program code, for example, AM production control system 104, which is stored in memory 132 and / or data storage system 142, according to instructions received from code 120 specifying object 102. During execution of computer program code processor 134 may read and / or write information coming into / from memory 132, data storage system 142, (I / O) device 140 and / or AM of printer 106. Bus 138 provides a communication channel between each of the objects in computer 130, and The (I / O) device 140 may comprise any device capable of allowing a user to interact with a computer 130 (e.g., a keyboard, pointing device, display, etc.). Computer 130 is merely various possible combinations of hardware and software. For example, processor 134 may contain only one data processing unit, or may be distributed among several data processing units at one or more locations, for example, for a client and a server. Similarly, the memory 132 and / or the storage system 142 may comprise any combination of various types of non-volatile computer readable media including optical media, random access memory (RAM), read only memory (ROM), etc. The computer 130 may comprise any type of computing device, such as a network server, a desktop computer, a compact portable computer, a mobile device, a cellular telephone, a paging device, a handheld computer, etc.

[0024] The additive manufacturing process begins with non-volatile computer-readable storage media (eg, memory 132, data storage system 142, etc.) in which object display code 120 is stored 102. As noted above, code 120 includes a set of computer-executable instructions, providing the formation of the object 102, which can be used for the physical embodiment of the object after the code is executed by the system 100. For example, code 120 may include a strictly defined 3D model of the object 102 and may consist of a number of any well-known complex computer-aided design (CAD) programs, such like AutoCAD®, TurboCAD®, DesignCAD 3D Mach, etc. Based on the foregoing, code 120 may have any unknown or future file format. For example, code 120 may correspond to the Standard Tessellation Language (STL) format that was created for computer-aided design programs (CAD) of 3D stereolithographic systems, or the additive production file format (AMF), which is a standard of the American Society of Mechanical Engineers (ASME), presenting a format based on extensible markup language (XML), which provides, using any (CAD) software, a description of the shape and composition of any three-dimensional object produced on any AM printer. Code 120, if necessary, can be translated between different formats, converted to a set of information signals and transmitted, received as a set of information signals and converted to code, stored in memory, etc. Code 120 may be input to system 100 and may come from a designer, intellectual property (IP) provider, design organization, operator or customer of system 100, or from other sources. In any case, the AM production control system 104 provides code 120 by dividing the object 102 into a series of thin sections that are collected using an AM printer 106 from successive layers of powder. In the example of direct laser melting of metals (DMLM), each layer is melted or sintered, achieving the exact geometric configuration specified by code 120, and alloyed with the previous layer. Subsequently, the object 102 can be subjected to any various finishing processes, for example, secondary machining, sealing, polishing, assembling with another part, etc.

[0025] In FIG. 2 depicts a typical object 102 in which a destructible support structure 200 may be used in accordance with the teachings of the invention. In the example shown in the drawings, the object 102 includes a fuel injector 144 formed by the AM production technology shown in the flowchart of FIG. 1. It should be noted that the fuel injector is given as an example and it is clear that the production process AM may include the manufacture of any object, which may also include a destructible support structure 200 according to the invention. Fuel injector 144 includes a system of three concentric pipelines 146, 148, 150 (outer 146, inner middle 148, inner central 150) forming chambers 152, 154, 156 for fuel and / or air. It should be noted that the fuel injector 144 may include any number of pipelines and chambers, which is considered predominant. In addition, it should be noted that the cross-section of the pipelines 146, 148, 150 can be of any shape, for example, substantially round, in the form of a drop, etc. Fuel injector 144 includes a first portion 160 that is substantially horizontal and a second portion 162 that is substantially vertical (as shown). The first part 160 and the second part 162 include sections of pipelines 146, 148, 150 and chambers 152, 154, 156. It should be noted that the fuel nozzle 144 can be formed by AM production technology when fixed at a point 164 connecting one or more pipelines 146, 148, 150 to ensure alignment during the AM process. The first portion 160 of the fuel injector 144 also includes a spray portion 166 containing a collapsible support structure 200 according to the invention. As used herein, the term “spray portion” includes the inside of the fuel nozzle 144, at least partially inaccessible to the outside of said nozzle and having two surfaces opposing in the vertical direction. Fuel nozzle 144 may be formed by AM technology and using conventional, removable vertical support structures 168 supporting one or more external conduits 146. In addition, fuel nozzle 144 may be formed by AM technology and using conventional, detachable vertical support structures 170 supporting one or more internal pipelines 148, 150.

[0026] In FIG. 3 is an enlarged perspective view of a spray nozzle portion 166 of the fuel injector of FIG. 2 including a collapsible support structure 200. Section 166 includes a portion of the outer pipe 146 and a portion of the inner middle pipe 148. The outer pipe 146 has a first surface 172 that is vertically opposed to a second surface 174 of the inner middle pipe 148. As used herein, the expression “opposite to vertical direction "indicates that one surface has at least a portion that is located vertically above at least a portion of the other surface.

[0027] Vertically opposed surfaces 172, 174 may extend horizontally or at an angle relative to the horizontal. In this example, the spray portion 166 extends approximately at an angle of 5 ° relative to the horizontal (see FIG. 2). Therefore, the first surface 172 includes a first vertically inclined surface 176, and the second surface 174 includes a second vertically inclined surface 178, which is vertically opposite to the first surface 176 and extends at an angle of 5 °. As used herein, the expression “tilted from vertical” indicates that the surface is neither vertical nor horizontal, but extends relative to the horizontal at an angle other than 90 °. As is known from the field of AM technology, for reasons related to suitability for printing, the angle of inclination of most surfaces tilted from the vertical relative to the horizontal does not exceed 45 °. Accordingly, the first vertical inclined surface 176 can be inclined relative to the horizontal at an angle not exceeding 45 °, and the second vertical inclined surface can be inclined relative to the horizontal at an angle not exceeding 45 °. It should be emphasized that in this document the fuel injector 144 (see Fig. 2) is provided solely as an illustration and it is clear that the ideas of the invention are applicable to surfaces tilted vertically and other vertically opposed surfaces, one or more of which may be horizontal.

[0028] The vertically opposite surfaces 172, 174 and the surfaces 176, 178 inclined from the vertical may have any shape, for example, flat, rounded, uneven, etc. As shown in sectional view of the spraying portion 166 shown in perspective view of FIG. 3, a substantially circular piping arrangement has a first vertically inclined surface 176 including an inner rounded surface 180, and a second vertically inclined surface 178 including an outer rounded surface 182 that vertically resists said surface 180.

[0029] Despite the fact that the pipelines 146, 148, 150 at the end of the nozzle are connected to the fixation point 164 (see Fig. 2) in order to maintain alignment, it is advantageous to provide additional support for them. The destructible support structure 200 according to the embodiments of the invention, which is shown in FIG. 2 - FIG. 3. Destructible structure 200 is stable during the AM process, for example, DMLM, and can provide reliable support for surfaces 172, 174. As described in detail below, the structure of structure 200 allows its destruction under the influence of thermal stresses generated by the forces induced by the gradient temperatures in the specified structure. It should be noted that the stability of the structure 200 may also suggest its stability during the additional processing (for example, milling of the external supporting structures 168, 170 of the fuel nozzle 144 shown in Fig. 2) of the object 102 after the AM process. Although in FIG. 2 - FIG. 3, the structure 200 is depicted at one specific location, it should be emphasized that this structure can be performed anywhere in the fuel injector 144 or object 102, formed as a result of AM production, which is considered preferable. Despite the fact that in FIG. 2 - FIG. 3 shows a specific amount of collapsible support structures 200; any number of them can be used. Each structure 200 may be further included in code 120 (or any previous or subsequent code format) for object 102 at any given location and may be printed with the specified object. Structure 200 may be located on the left.

[0030] In FIG. 4 is an enlarged perspective view of a structure 200, and FIG. 5 is a side view of the indicated structure in a perspective view. According to embodiments of the invention, the collapsible support structure 200 includes a first base 202 connected to the first surface 172 and extending toward the second surface 174. Structure 200 also includes a second base 204 connected to the second surface 174 and extending toward the first surface 172. Jumper 210 connects the first base 202 to the second base 204 and provides support between the surfaces 172, 174. For example, in FIG. 5, the jumper 210 extends substantially vertically between the first base 202 and the second base 204. As described in detail below, the jumper 210 includes a main part 212 and an attenuated zone 214 formed in said main part, which ensures the destruction of the jumper under sufficient thermal stress. It should be emphasized that in FIG. 4 and FIG. 5 illustrates an example of a collapsible support structure 200. The structure 200 may have various other forms, selected based on a number of factors, such as, but not limited to: any number of characteristics of the first and second surfaces 172, 174, for example, the distance between them, the mutual angles of inclination, tilt angles of each of them, etc .; a specified number of necessary supporting structures; the specified location of the destruction of the weakened zone 214; and / or a predetermined voltage required to destroy the structure 200.

[0031] Each base 202, 204 may be of any shape that provides a support function or position of structure 200 in which it is necessary to provide support for surfaces during the additive manufacturing process. For example, in the presented embodiments, each base has a substantially triangular cross-section (with the exception of the area where the main part 212 departs from it).

[0032] FIG. 6 is an enlarged front view of the weakened area 214 of structure 200. Zone 214 may include any kind of physical structure capable of destroying the main body 212 under the influence of a predetermined force. In the example shown in FIG. 6, the weakened zone 214 includes a region 216 thinned in cross section in the main body 212 (compared to the remaining regions of the main body). The weakened zone 214 formed in the main body 212 of the web 210 may provide destruction at any advantageous location along the length of the collapsible supporting structure 200. In one example, the zone 214 may provide destruction approximately in the middle of the length of the structure 200. The weakened zone 214 may include any variety of shapes, e.g. corners, curves, etc. According to embodiments of the invention, in contrast to conventional technologies, the configuration of the weakened zone 214 provides destruction due to the formation of a temperature gradient in the structure 200 after performing the additive manufacturing process. Namely, the destruction of the structure 200 occurs through thermal stresses in this structure, created as a result of deformation under the action of thermal expansion caused by the temperature gradient formed in the specified structure.

[0033] FIG. 7 is a perspective view of a fuel injector 144 of FIG. 2, illustrating the formation of a temperature gradient in the destructible support structure 200 of FIG. 4, according to one embodiment of the invention. In the example shown in FIG. 7, the destruction of the structure 200 can occur, for example, after the completion of the additive manufacturing process of the fuel injector 144, but before its operation, as a result of the temperature of the spray section 166 (see Fig. 2) of the external pipe 146, for example, reaches values of about 750 ° C - 850 ° C, using, for example, a blowtorch, and / or (if necessary) by reducing the temperature in the inner middle pipe 148, for example, by flowing a cooling medium, for example, water, through the specified pipe. That is, in the example shown in FIG. 7, the material of the first surface 172 (see Fig. 3 expands due to an increase in its temperature, and the material of the second surface 174 (see Fig. 3 is contracted due to a decrease in the temperature of this surface, which leads to the formation of a heat-induced shear exerted on the destructible supporting structure 200 ( see Fig. 6), which transfers the shear stress to the jumper 210. The shear stress on the jumper leads to the fact that the main part 212 is destroyed in approximately the weakened zone 214. It should be understood that the time for the selectively destructible structure 200 is not limited to the interval starting after completion the process of additive production of the fuel nozzle 144 and ending before its operation, as described for the example shown in Fig. 7. For example, the fuel nozzle 144 can be made as a result of two processes of additive production, for example, one of them is performed for the first part 160, and the other for the second part 162, and with the structure 200 can be destroyed, for example, by forming a temperature gradient after completing the additive manufacturing process of the first part 160 and before starting the additive manufacturing of the second part 162. It should be emphasized that the method of forming the temperature gradient in the destructible supporting structure 200 is not limited to the illustration of FIG. 7. Alternatively, a temperature gradient can be obtained, for example, only as a result of an increase in temperature of either the first surface 172 or the second surface 174; only as a result of a decrease in temperature of either the first surface 172 or the second surface 174; etc. Moreover, the mechanism for heating or cooling surfaces is not limited to the use of a blowtorch or cooling medium, as shown in FIG. 7. The temperature rise mechanism may include, for example, the use of a blowtorch, air, water, etc. The temperature lowering mechanism may include, for example, the use of cooling media such as air, water, etc. Although in the example shown in FIG. 7, a blowtorch is used for the outer pipe 146, and a cooler is supplied to the inner middle pipe 148, it should be noted that the place of cooling and / or heating is not limited to the first surface 172 and the second surface 174. In addition, we note that the temperature to which the first surface 172 or second surface 174 is either heated or cooled, not limited to the values of the example depicted in FIG. 7. Surfaces 172, 174, or bases 202, 204 may be heated and / or cooled to any temperature that provides a temperature gradient leading to the destruction of the supporting structure 200.

[0034] FIG. 8 is a cross-sectional view of a spray portion 166 of a fuel injector 144 including a series of collapsible support structures 200, illustrating the generation of forces caused by heating and through said structure 200 made in accordance with embodiments of the invention. Although in FIG. 8 depicting a portion of the fuel injector 144, shear forces Fs exerted on a collapsible support structure 200 are shown, it is understood that the heat-induced forces acting on the structure are not limited by shear. For example, the weakened zone 214 may be destroyed by tensile force Ft and / or compressive force Fc. Moreover, it should be noted that in addition to the formation of the thermal gradient, other mechanisms of applying force to the destructible supporting structure 200 can also be used. For example, in addition to the formation of the thermal gradient, vibrational forces can be applied, leading to the combination of tensile, compressive and shear forces, causing the destruction of the specified structure 200.

[0035] A method of manufacturing an object 102 according to embodiments of the invention may include forming the object 102 together with the collapsible support structure 200 described herein using additive manufacturing technology (which is depicted in FIG. 1). As already noted, the first base 202 can be connected to the first surface 172 of the object and extends towards the second surface 174 of the object, which is opposed in the vertical direction of the first surface. The second base 204 can be connected to the second surface 174 and extends toward the first surface 172. Moreover, the first base 202 and the second base 204 can be connected by a jumper 210 including the main part 212 and the weakened area 214 located in the indicated part. The method may include maintaining the integrity of the jumper 210 during the formation of the object 102 by the additive manufacturing method, and the destruction of the jumper 210 as a result of the application of forces to the destructible supporting structure 200 caused by heating due to the formation of a temperature gradient in the specified structure after completion of the AM process of forming this object. For example, the method may include raising the temperature of the first base 202 and the first surface 172 by heating the outer pipe 146, and reducing the temperature of the second base 204 and the second surface 174 by cooling the interior of the middle inner pipe 148. Alternatively, the method may include destroying the jumper 210 as a result applications to the destructible support structure 200 of tensile and / or compressive forces. The method may include the destruction of the structure 200, for example, as a result of only heating any surface 172, 174 or as a result of only cooling any of these surfaces. The structure 200 may additionally provide for the impact on it of compressive and / or tensile forces, for example, formed as a result of vibration of the object 102, while exerting a shearing force on the structure due to the formation of a thermal gradient in it. The method may include the destruction of the weakened zone 214 approximately in the middle of the length of the structure 200. Moreover, the method may include the destruction of the bridge 210 due to thermal forces exerted after removal of external supporting structures 168, 170 from the object 102. In addition, the method may include finding the structure 200 inside the object 102 during its operation.

[0036] In the following claims, the corresponding constructions, materials, actions and equivalents of all elements of “means plus function” or “step plus function” include any structure, material or action to perform a function in combination with other elements claimed in the specific claims inventions. The description of the invention is given for illustrative and descriptive purposes, but is not limited or not limited to the scope. Numerous modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the invention. The selected and described embodiment best describes the basic principles and practical application of the invention and enables other specialists to conclude that various modified versions of the proposed specific field of application correspond.

Claims (34)

1. A fuel injector made by additive manufacturing and containing: first surface a second surface located opposite the specified first surface in a vertical direction, and a destructible support structure that contains: a first base connected to said first surface and extending toward said second surface, a second base connected to said second surface and extending toward said first surface, and the jumper that connects the specified first base with the specified second base, can selectively collapse under the influence of thermal stress and contains the main part and the weakened zone formed in the specified main part. 2. The fuel injector according to claim 1, which is made of metal, the weakened zone of the destructible supporting structure being made to ensure its destruction under the action of thermal stress applied after the manufacture of the metal nozzle by additive manufacturing using metal powder. 3. The fuel injector according to claim 1, in which the weakened zone of the destructible supporting structure is made to ensure its destruction essentially in the middle of the length of the specified structure. 4. The fuel injector according to claim 1, wherein each of said first and second bases of a collapsible support structure has a substantially triangular cross section. 5. The fuel injector according to claim 1, comprising a first part and a second part, which comprises a spray portion containing said destructible support structure. 6. The fuel injector according to claim 1, wherein said first surface comprises a first vertically inclined surface, and said second surface comprises a second vertically inclined surface, which is in a vertical direction opposite said first vertically inclined surface. 7. The fuel injector according to claim 6, wherein the angle of inclination of said first inclined surface from a vertical does not exceed 45 ° with respect to the horizontal, and the angle of inclination of said second inclined from vertical with a surface does not exceed 45 ° with respect to the horizontal. 8. The method of additive production of a fuel injector, including: molding a fuel injector with a destructible support structure using an additive manufacturing process, wherein the destructible support structure comprises: a first base connected to a first surface of said nozzle and extending toward its second surface, which is in a vertical direction opposite said first surface, a second base connected to said second surface and extending toward said first surface, and a jumper connecting the specified first base with the specified second base and containing the main part and the weakened zone formed in the specified main part, and the destruction of the specified jumper under the influence of thermal stress after molding the specified nozzle using the additive manufacturing process. 9. The method according to p. 8, in which when the specified jumper is destroyed, it is destroyed essentially approximately in the middle of its length. 10. The method according to p. 8, in which when forming said nozzle, external supporting structures are formed, said method comprising removing said external structures until said jumper is destroyed. 11. The method of claim 8, wherein the destructible support structure is stored inside said nozzle. 12. The method according to p. 8, in which when the specified jumper is destroyed under the influence of thermal stress exerted after the formation of the specified nozzle, the weakened zone is destroyed by either tensile or compressive forces. 13. The method of claim 8, wherein said first surface comprises a first vertically inclined surface, and said second surface comprises a second vertically inclined surface, which is vertically opposed to said first vertically inclined surface. 14. The method according to p. 13, in which the angle of inclination of the specified first inclined surface from the vertical does not exceed 45 ° relative to the horizontal, and the angle of inclination of the specified second inclined from the vertical surface does not exceed 45 ° relative to the horizontal. 15. The method according to p. 8, in which when exposed to thermal stress, the temperature of the specified first base is destroyed destructible supporting structure. 16. The method according to p. 15, in which when exposed to thermal stress, reduce the temperature of the specified second base destructible supporting structure. 17. The method according to p. 16, in which, when the temperature of said first base of destructible supporting structure is increased, the temperature of said first surface of said nozzle is increased, and when the temperature of said second base of said structure is decreased, the temperature of said second surface of said nozzle is decreased. 18. The method according to p. 8, in which when exposed to thermal stress, the temperature of said first base of the destructible supporting structure is reduced. 19. The method according to p. 18, in which when the temperature of the specified second base of the destructible supporting structure is reduced, the temperature of the specified second surface of the specified nozzle is reduced by supplying a cooling medium to it. 20. Destructible support structure for the manufacture of a fuel injector by the method according to any one of paragraphs. 8-19, containing a first base connected to a first surface of the fuel nozzle and extending toward its second surface, a second base connected to said second surface and extending toward said first surface, and the jumper that connects the specified first base with the specified second base, can selectively collapse under the influence of thermal stress and contains the main part and the weakened zone formed in the specified main part.

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