Method for fabricating a nozzle

Abstract

A system for machining a component with complex contour. The machining system includes a coolant flow nozzle with an interior passage with a first portion having a first cross-sectional shape, and a second portion having a second cross-sectional shape, with the second cross-sectional shape selected so that fluid discharged from the nozzle has a selected cross-sectional shape. A method of fabricating a coolant flow nozzle with an interior passage that has a varying cross sectional shape.

1 . A method for fabricating a nozzle including at least one piece, said method comprising:
 forming at least a portion of an exit aperture in at least one piece of the nozzle, wherein the at least a portion of the exit aperture has a first cross-sectional shape configured to discharge a fluid with a shape that substantially matches a portion of a contour of a component to be fabricated using the nozzle; and   forming at least a portion of an inlet aperture in the at least one piece of the nozzle, wherein the at least a portion of the inlet aperture has a second cross-sectional shape, and such that a fluid passage formed between the inlet and exit apertures transitions gradually between the first cross-sectional shape and the second cross-sectional shape.   
   
   
       2 . A method in accordance with  claim 1  wherein forming at least a portion of an exit aperture further comprises forming at least a portion of the exit aperture using an electro-discharge machining process. 
   
   
       3 . A method in accordance with  claim 1  wherein forming at least a portion of an inlet aperture further comprises forming the fluid passage using an electro-discharge machining process. 
   
   
       4 . A method in accordance with  claim 1  wherein forming at least a portion of an exit aperture further comprises extending a portion of the exit aperture along an axial length of the nozzle such that the second cross-sectional shape remains substantially constant for a distance. 
   
   
       5 . A method in accordance with  claim 1  further comprising forming a starter hole within a piece of stock material prior to forming the at least a portion of the exit aperture. 
   
   
       6 . A method in accordance with  claim 1  further comprising coupling a first piece of the nozzle to a second piece of the nozzle. 
   
   
       7 .- 20 . (canceled)