Duct with additive manufactured seal

Abstract

A method of making a component includes creating a computer file defining the component in layers, the component including: a body including a sealing portion; and an abradable seal extending from the sealing portion; and building the component using an additive manufacturing process that builds the component on a layer-by-layer basis such that the abradable seal is integral to the body.

1 . A method of making a component, the method comprising:
 creating a computer file defining the component in layers, the component comprising:
 a body including a sealing portion; and 
 an abradable seal extending from the sealing portion; and 
   building the component using an additive manufacturing process that builds the component on a layer-by-layer basis such that the abradable seal is integral to the body.   
     
     
         2 . The method of  claim 1 , wherein building the component comprises:
 building a tangential on-board injector including a plurality of vanes configured to be incorporated into a gas turbine engine.   
     
     
         3 . The method of  claim 1 , wherein building the component comprises:
 building a plurality of walls to form the abradable seal.   
     
     
         4 . The method of  claim 3 , wherein building the component comprises:
 building a plurality of walls arranged to form a plurality of hexagonal cells to form the abradable seal.   
     
     
         5 . The method of  claim 3 , wherein building the component comprises:
 building a plurality of walls with a plurality of joints with the body at the sealing portion, wherein each joint is uniform.   
     
     
         6 . The method of  claim 5 , wherein building the component comprises:
 building each of the plurality of joints with a radiused shape.   
     
     
         7 . The method of  claim 1 , wherein building the component comprises:
 building a protective layer on the abradable seal;   modifying the component after building the component; and   removing the protective layer from the abradable seal after the component has been modified.   
     
     
         8 . The method of  claim 1 , wherein the abradable seal is configured to interact with a knife edge seal that travels through a pathway in the abradable seal. 
     
     
         9 . A monolithic component having a first end and a second end, the component comprising: a body including a sealing portion; and an abradable seal integral to and extending from the sealing portion; the component being made by the steps of:
 selectively sintering a first layer of pulverulent material within a frame to make a partially built component;   lowering the partially built component;   adding a second layer of pulverulent material on top of the partially built component; and   selectively sintering the second layer of pulverulent material to the partially built component.   
     
     
         10 . The component of  claim 9 , wherein the component is a tangential on-board injector including a plurality of vanes configured to be incorporated into a gas turbine engine. 
     
     
         11 . The component of  claim 9 , wherein the abradable seal is comprised of a plurality of walls. 
     
     
         12 . The component of  claim 11 , wherein the plurality of walls are arranged to form a plurality of hexagonal cells. 
     
     
         13 . The component of  claim 9 , wherein each joint between each of the plurality of walls and the body is uniform. 
     
     
         14 . The component of  claim 13 , wherein each joint between each of the plurality of walls and the body is filleted. 
     
     
         15 . The component of  claim 9 , wherein the abradable seal is built with a protective layer, and wherein the component is made by the further steps of:
 modifying the component after building the component; and   removing the protective layer from the abradable seal after the component has been modified.   
     
     
         16 . A component comprising:
 a body including a sealing portion; and   an abradable seal extending from the sealing portion, the abradable seal having a plurality of walls;   wherein the abradable seal is comprised of the same material as the body and is integral to the body; and   wherein each joint between each of the plurality of walls and the body is uniform.   
     
     
         17 . The component of  claim 16 , wherein the component is a tangential on-board injector including a plurality of vanes configured to be incorporated into a gas turbine engine. 
     
     
         18 . The component of  claim 16 , wherein each joint between each of the plurality of walls and the body is filleted. 
     
     
         19 . The component of  claim 16 , and further comprising:
 a protective layer that covers the abradable seal.   
     
     
         20 . The component of  claim 19 , wherein the protective layer extends from at least one of the plurality of walls.