ADDITIVE MANUFACTURING IN SITU STRESS RELIEF

• US 20130101728A1
• Filed: 01/31/2012
• Published: 04/25/2013
• Est. Priority Date: 10/21/2011
• Status: Abandoned Application

• Current Assignee: United Technologies Corporation (Rtx Corporation)
• Original Assignee: United Technologies Corporation (Rtx Corporation)
• Inventors: Matejczyk, Daniel Edward, Gao, Youping, Haynes, Jeffrey D., Keremes, John J.
• Application Number:
  US13/362,425
• Publication Number:
  US 20130101728A1
• Time in Patent Office: Days
• US Class Current: 427/8
• CPC Class Codes: B22F 10/32 of the atmosphere, e.g. composition or pressure in a building chamber
• CPC Class Codes: B22F 10/64 by thermal means control of energy beam parameters for post heating B22F10/364
• CPC Class Codes: B22F 12/60 Planarisation devices; Compression devices
• CPC Class Codes: B29C 2035/0211 resistance heating B29C2035/0811 takes precedence
• CPC Class Codes: B29C 2035/0811 using induction
• CPC Class Codes: B29C 2035/0838 using laser
• CPC Class Codes: B29C 2035/1666 dried air
• CPC Class Codes: B29C 2071/022 Annealing
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/295 Heating elements
• CPC Class Codes: B29C 64/371 using an environment other than air, e.g. inert gas
• CPC Class Codes: B29C 71/02 Thermal after-treatment B29C71/0063 and B29C71/0072 take precedence
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

An additive manufacturing process performed by an additive manufacturing machine includes strain gauges that detect stress within a part during fabrication within a defined workspace. When the detected stress is exceeds a desired level the fabrication steps are paused and a stress relieving process is performed within the chamber without moving the part. The additive manufacturing machine includes heaters and coolers for changing the temperature within the chamber to perform the desired stress relieving process in the same space as fabrication is performed. Once it is confirmed that stresses within the part are within acceptable limits the part fabrication process is resumed.

Claims

1. An additive manufacturing process comprising:

detecting stress within a part during fabrication within a defined workspace;

pausing fabrication steps responsive to a detected stress being within a predetermined range;

performing a stress relieving process on the part within the same workspace in which fabrication is performed; and

restarting part fabrication on the part within the defined work space once the stress relieving process is complete.

2. The additive manufacturing process as recited in claim 1, including heating the part within the workspace to a temperature determined to relieve built in stresses.

3. The additive manufacturing process as recited in claim 2, including a resistant heater surrounding the workspace for heating the part.

4. The additive manufacturing process as recited in claim 1, including the step of monitoring stress within the part during the stress relieving process.

5. The additive manufacturing process as recited in claim 1, including generating an atmosphere within the workspace and surrounding the part that prevents oxidation.

6. The additive manufacturing process as recited in claim 5, wherein the atmosphere comprises an argon gas.

7. The additive manufacturing process as recited in claim 1, including covering an energy directing device to prevent exposure to the workspace during the stress relieving process.

8. The additive manufacturing process as recited in claim 1, including cooling the workspace to a temperature desired for performing fabrication of the part.

9. An additive manufacturing device comprising:

a workspace defining an area for part fabrication;

a powder application device for spreading a powder within the workspace;

an energy transmitting device for generating a molten area of powder for forming a layer of a part;

a sensor mounted within the workspace that detects stresses within a part during fabrication; and

a stress relieving appliance supported proximate the workspace for relieving stress built up in the part during fabrication within the workspace.

12. The additive manufacturing device as recited in claim 9, including a cover movable to a position blocking exposure of the energy-transmitting device to the workspace.

13. The additive manufacturing device as recited in claim 9, including an atmosphere within the workspace comprising an argon gas.

14. The additive manufacturing device as recited in claim 9, including a cooler for cooling the workspace after performance of a stress relief process.

15. The additive manufacturing device as recited in claim 9 wherein the sensor comprises a strain gauge mounted within a support holding the part during fabrication.

10. The additive manufacturing device comprising a resistance heater disposed proximate the workspace for heating the workspace to a temperature determined to reduce stresses built up in the part.

11. The additive manufacturing device wherein the workspace includes walls and the resistant heater is supported within the walls of the workspace.