SYSTEMS AND METHODS FOR ADDITIVE MANUFACTURING AND REPAIR OF METAL COMPONENTS

• US 20140163717A1
• Filed: 11/08/2013
• Published: 06/12/2014
• Est. Priority Date: 11/08/2012
• Status: Active Grant

• Current Assignee: Georgia Tech Research Corporation (University System of Georgia)
• Original Assignee: Suman Das
• Inventors: DAS, Suman, Bansal, Rohan, Gambone, Justin
• Granted Patent: US 9,522,426 B2
• Time in Patent Office: Days
• US Class Current: 700/119
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/36 of energy beam parameters
• CPC Class Codes: B22F 10/366 Scanning parameters, e.g. hatch distance or scanning strategy
• CPC Class Codes: B22F 12/41 characterised by the type, e.g. laser or electron beam
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B22F 2007/068 repairing articles
• CPC Class Codes: B22F 2203/03 for feed-back
• CPC Class Codes: B22F 2203/11 temperature, temperature profile
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 5/009 of turbine components other than turbine blades of turbine blades B22F5/04
• CPC Class Codes: B22F 5/04 of turbine blades
• CPC Class Codes: B22F 7/062 involving the connection or repairing of preformed parts
• CPC Class Codes: B23P 6/007 using only additive methods, e.g. build-up welding
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29L 2031/08 Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: C30B 13/24 : using electromagnetic waves
• CPC Class Codes: C30B 13/28 : Controlling or regulating
• CPC Class Codes: C30B 13/32 : Mechanisms for moving either the charge or the heater
• CPC Class Codes: C30B 19/08 : Heating of the reaction chamber or the substrate
• CPC Class Codes: C30B 19/10 : Controlling or regulating controlling or regulating in general G05
• CPC Class Codes: C30B 29/52 : Alloys
• CPC Class Codes: G01J 2005/0077 : Imaging
• CPC Class Codes: G01J 5/004 : by molten metals
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

Scanning Laser Epitaxy (SLE) is a layer-by-layer additive manufacturing process that allows for the fabrication of three-dimensional objects with specified microstructure through the controlled melting and re-solidification of a metal powders placed atop a base substrate. SLE can be used to repair single crystal (SX) turbine airfoils, for example, as well as the manufacture functionally graded turbine components. The SLE process is capable of creating equiaxed, directionally solidified, and SX structures. Real-time feedback control schemes based upon an offline model can be used both to create specified defect free microstructures and to improve the repeatability of the process. Control schemes can be used based upon temperature data feedback provided at high frame rate by a thermal imaging camera as well as a melt-pool viewing video microscope. A real-time control scheme can deliver the capability of creating engine ready net shape turbine components from raw powder material.

Claims

1. A system for manufacturing components by melting and resolidifiying powdered materials comprising:

a concentrated energy source for selectively melting a material; and

a control system comprising;

a control computer;

control software; and

one or more sensors providing feedback to the control system;

wherein the control system controls one or more parameters of the concentrated energy source.

2. The system of claim 1, wherein the concentrated energy source is a laser.

3. The system of claim 1, wherein the material comprises a powdered metal.

4. The system of claim 3, wherein the powdered metal is a nickel-based superalloy.

5. The system of claim 1, wherein the one or more sensors comprise a thermal imaging camera.