Methods of producing wrought products with internal passages

Abstract

Various methods are disclosed for additively manufacturing a feedstock material to create an AM preform, wherein the AM preform is configured with a body having an internal passage defined therein, wherein the internal passage further includes at least one of a void and a channel; inserting a filler material into the internal passage of the AM preform; closing the AM preform with an enclosure component such that the filler material is retained within the internal passage of the AM preform; and deforming the AM preform to a sufficient amount to create a product having an internal passage therein, wherein the product is configured with wrought properties for that material via the deforming step.

What is claimed is: 
     
       1. A method comprising:
 (a) additively manufacturing an additively manufactured (AM) preform, wherein the AM preform comprises an internal passage within a body of the AM preform, wherein the internal passage comprises at least one of a void and a channel; 
 (b) inserting a filler material into the internal passage of the AM preform; 
 (c) closing the AM preform with an enclosure component such that the filler material is retained within the internal passage of the AM preform; and 
 (d) creating a wrought product having the internal passage therein from the AM preform, wherein the creating comprises hot working the AM preform. 
 
     
     
       2. The method of  claim 1 , wherein the closing step comprises sealing the filler material within the AM preform via an enclosure component. 
     
     
       3. The method of  claim 1 , wherein the closing step comprises welding an opening of the internal passage, thereby enclosing the filler material within the AM preform. 
     
     
       4. The method of  claim 1 , wherein the internal passage comprises an opening, and wherein the closing step comprises pressing a plug into the opening to retain the filler material within the internal passage. 
     
     
       5. The method of  claim 1 , wherein the closing step comprises enclosing the filler material in the internal passage via successive additively manufactured build layers. 
     
     
       6. The method of  claim 1 , wherein the hot working comprises forging. 
     
     
       7. The method of  claim 6 , wherein the forging comprises using a single die forging. 
     
     
       8. The method of  claim 1 , wherein the hot working comprises rolling. 
     
     
       9. The method of  claim 1 , wherein the hot working comprises ring rolling. 
     
     
       10. The method of  claim 1 , wherein the hot working comprises extruding. 
     
     
       11. The method of  claim 1 , comprising:
 removing the filler material from the internal passage of the wrought product. 
 
     
     
       12. The method of  claim 11 , wherein the removing step comprises:
 melting the filler material; and 
 draining the filler material from the wrought product. 
 
     
     
       13. The method of  claim 1 , comprising annealing at least one of the AM preform and the wrought product. 
     
     
       14. The method of  claim 1 , comprising cold working at least one of the AM preform and the wrought product. 
     
     
       15. The method of  claim 1 , comprising at least one of (i) machining the wrought product, (ii) polishing the wrought product, and (iii) surface finishing the wrought product. 
     
     
       16. The method of  claim 15 , wherein the creating step comprises:
 prior to the hot working, preheating the AM preform, thereby melting the filler material within the internal passage. 
 
     
     
       17. The method of  claim 1 , comprising: solidifying the filler material and then completing the creating step (d). 
     
     
       18. The method of  claim 1 , wherein the filler material comprises a material different than the AM preform. 
     
     
       19. The method of  claim 18 , wherein the filler material comprises at least one of an oil, polymer, organic solvent, inorganic solvent, metal or metal alloy.