Abstract: A method for forming a component includes estimating a dosing plan for powder of a powder bed fusion (PBF) system needed to form the component. The dosing plan includes powder dosing requirements needed per layer to form the component. The method includes providing the dosing plan to a controller of the PBF system. Further, the method includes regulating the powder being supplied to a build chamber of the PBF system from a supply chamber of the PBF system based on the dosing plan. In addition, the method includes additively manufacturing the component via the PBF system using the powder.

Abstract: A method for forming a component includes estimating a dosing plan for powder of a powder bed fusion (PBF) system needed to form the component. The dosing plan includes powder dosing requirements needed per layer to form the component. The method includes providing the dosing plan to a controller of the PBF system. Further, the method includes regulating the powder being supplied to a build chamber of the PBF system from a supply chamber of the PBF system based on the dosing plan. In addition, the method includes additively manufacturing the component via the PBF system using the powder.

Abstract: A method for additively manufacturing a component includes generating, via imaging software, a plurality of slices of a support structure of the component based on component geometry. The method also includes melting or fusing, via the additive manufacturing system, layers of material to a build platform of the component so as to form the support structure according to the plurality of slices. The support structure includes a lattice configuration having of a plurality of support members arranged together to form a plurality of cells. Further, the method includes melting or fusing, via the additive manufacturing system, a component body to the support structure. After the component body solidifies, the method includes removing all of the support structure from the component body to form the component.

Abstract: A method for additively manufacturing a component includes receiving, via an additive manufacturing system, a geometry of the component and melting and fusing, via an energy beam of the additive manufacturing system, material layer by layer atop a build platform according to the geometry so as to build up a plurality of layers that form the component. The method also includes determining a surface area change from one of the plurality of layers to the next based on the geometry. Further, the method includes temporarily discontinuing melting and fusing of the material by the energy beam between building of one or more of the plurality of layers so as to provide a delay after building one or more of the plurality of layers when the surface area change is above a predetermined threshold. As such, the delay allows for one or more previously built layers to at least partially cool so as to eliminate and/or reduce build failures from occurring in the final component.

Abstract: A method for forming a component includes estimating a dosing plan for powder of a powder bed fusion (PBF) system needed to form the component. The dosing plan includes powder dosing requirements needed per layer to form the component. The method includes providing the dosing plan to a controller of the PBF system. Further, the method includes regulating the powder being supplied to a build chamber of the PBF system from a supply chamber of the PBF system based on the dosing plan. In addition, the method includes additively manufacturing the component via the PBF system using the powder.

Abstract: A method for additively manufacturing a component includes generating, via imaging software, a plurality of slices of a support structure of the component based on component geometry. The method also includes melting or fusing, via the additive manufacturing system, layers of material to a build platform of the component so as to form the support structure according to the plurality of slices. The support structure includes a lattice configuration having of a plurality of support members arranged together to form a plurality of cells. Further, the method includes melting or fusing, via the additive manufacturing system, a component body to the support structure. After the component body solidifies, the method includes removing all of the support structure from the component body to form the component.

Abstract: A method for additively manufacturing a component includes receiving, via an additive manufacturing system, a geometry of the component and melting and fusing, via an energy beam of the additive manufacturing system, material layer by layer atop a build platform according to the geometry so as to build up a plurality of layers that form the component. The method also includes determining a surface area change from one of the plurality of layers to the next based on the geometry. Further, the method includes temporarily discontinuing melting and fusing of the material by the energy beam between building of one or more of the plurality of layers so as to provide a delay after building one or more of the plurality of layers when the surface area change is above a predetermined threshold. As such, the delay allows for one or more previously built layers to at least partially cool so as to eliminate and/or reduce build failures from occurring in the final component.

Abstract: A nozzle segment for a gas turbine engine may generally include an airfoil having an exterior surface defining a pressure side and a suction side extending between leading and trailing edges. The airfoil may define an open internal volume within its interior for receiving a cooling medium. The open internal volume may include a primary internal cavity and a plurality of internal cooling channels in flow communication with the primary internal cavity. The primary internal cavity may extend within the interior of the airfoil from a location adjacent to the leading edge to a forward end of each of the internal cooling channels. The internal cooling channels may extend within the interior of the airfoil from the primary internal cavity towards the trailing edge. In addition, the internal cooling channels may be spaced apart radially by a plurality of ribs extending within the interior of the airfoil.

Abstract: A gas turbine sealing assembly includes a first static gas turbine wall, a second static gas turbine wall, and a leaf seal having a first side and a second side. The first static gas turbine wall contacts the second side at a first position, and the second static gas turbine wall contacts the second side at a second position. A spring exerts force on the first side. The spring includes a first spring wall coupled to the first static gas turbine wall. A second spring wall extends radially outward from the first spring wall. A third spring wall extends axially away from the second spring wall. A fourth spring wall extends radially inward from the third spring wall and includes a radially inner end. The radially inner end of the fourth spring wall contacts the first side of the leaf seal between the first position and the second position.

Abstract: A nozzle segment for a gas turbine engine may generally include an airfoil having an exterior surface defining a pressure side and a suction side extending between leading and trailing edges. The airfoil may define an open internal volume within its interior for receiving a cooling medium. The open internal volume may include a primary internal cavity and a plurality of internal cooling channels in flow communication with the primary internal cavity. The primary internal cavity may extend within the interior of the airfoil from a location adjacent to the leading edge to a forward end of each of the internal cooling channels. The internal cooling channels may extend within the interior of the airfoil from the primary internal cavity towards the trailing edge. In addition, the internal cooling channels may be spaced apart radially by a plurality of ribs extending within the interior of the airfoil.

Abstract: A gas turbine sealing assembly includes a first static gas turbine wall, a second static gas turbine wall, and a leaf seal having a first side and a second side. The first static gas turbine wall contacts the second side at a first position, and the second static gas turbine wall contacts the second side at a second position. A spring exerts force on the first side. The spring includes a first spring wall coupled to the first static gas turbine wall. A second spring wall extends radially outward from the first spring wall. A third spring wall extends axially away from the second spring wall. A fourth spring wall extends radially inward from the third spring wall and includes a radially inner end. The radially inner end of the fourth spring wall contacts the first side of the leaf seal between the first position and the second position.