公开(公告)号：US10646959B2

公开(公告)日：2020-05-12

申请号：US15680741

申请日：2017-08-18

Applicant: General Electric Company

Inventor： Brendon James Leary ,  Thomas Etter ,  Felix Martin Gerhard Roerig ,  Julius Andreas Schurb

IPC: B33Y80/00 ,  B33Y10/00 ,  B23K26/342 ,  B24C1/10 ,  B33Y99/00

Abstract: Additive manufactured components including sacrificial caps, and methods of forming components including sacrificial caps are disclosed. The additive manufactured components may include a body portion including a first surface, and a feature formed in the body portion. The feature may include an aperture formed through the first surface of the body portion. Additionally, the components may include a sacrificial cap formed integral with at least a portion of the first surface of the body portion. The sacrificial cap may include a conduit in fluid communication with the feature. The sacrificial cap including the conduit may be removed from the body portion to expose the first surface and the aperture of the feature, respectively, after performing one or more post-build processes, such as shot peening, on the component and the sacrificial cap.

公开(公告)号：US20180361502A1

公开(公告)日：2018-12-20

申请号：US15626413

申请日：2017-06-19

Applicant: General Electric Company

Inventor： Felix Martin Gerhard Roerig ,  Donnell Eugene Crear ,  Juan Vicente Haro Gonzalez ,  Mikhail Pavlov ,  Dean Andrew Snelling, JR.

IPC: B23K26/06 ,  B23K26/342 ,  B33Y30/00 ,  B33Y80/00 ,  B33Y50/02 ,  B22F3/105

CPC classification number: B23K26/0608 ,  B22F3/1055 ,  B22F5/10 ,  B22F2003/1057 ,  B23K15/0006 ,  B23K15/004 ,  B23K15/0086 ,  B23K15/0093 ,  B23K15/06 ,  B23K26/0006 ,  B23K26/0604 ,  B23K26/082 ,  B23K26/123 ,  B23K26/127 ,  B23K26/342 ,  B23K2101/001 ,  B23K2103/26 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B33Y80/00

Abstract: A component includes a body, and an interface in the body defining a first and second portion of the body made by different melting beam sources of a multiple melting beam source additive manufacturing system during a single build. The component also includes a channel extending through the body. The channel includes an interface-distant area on opposing sides of the interface, each interface-distant area having a first width. The channel also includes an enlarged width area fluidly communicative with the interface-distant areas and spanning the interface, the enlarged width area having a second width larger than the first width. Any misalignment of the melting beams at the interface is addressed by the enlarged width area, eliminating the problem of reduced cooling fluid flow in the channel.

公开(公告)号：US10974474B2

公开(公告)日：2021-04-13

申请号：US15619772

申请日：2017-06-12

Applicant: General Electric Company

Inventor： Donnell Eugene Crear ,  Mikhail Pavlov ,  Felix Martin Gerhard Roerig ,  Dean Andrew Snelling

IPC: B29C73/24 ,  B33Y40/00 ,  B29C64/30 ,  B29C73/26 ,  B33Y10/00 ,  B33Y30/00 ,  B29C73/16 ,  B29C73/34 ,  B32B43/00 ,  B22F3/105 ,  B33Y80/00

Abstract: An applicator repair system for an additive manufacturing (AM) system, and an AM system including the same are disclosed. The applicator repair system includes a repair device including a repair element configured to repair a damaged applicator element on an applicator of an AM system. The damaged applicator element is configured to distribute a layer of raw material on a build platform of the AM system. The repair device is positioned within a processing chamber of the AM system. A damaged applicator controller may be provided that is configured to cause repair of the damaged active applicator in response to the damaged applicator being identified as damaged.

公开(公告)号：US10814429B2

公开(公告)日：2020-10-27

申请号：US15881147

申请日：2018-01-26

Applicant: General Electric Company

Inventor： Subhrajit Roychowdhury ,  Matthias Hoebel ,  Lang Yuan ,  Prabhjot Singh ,  Michael Evans Graham ,  Robert John Filkins ,  Thomas Etter ,  Felix Martin Gerhard Roerig

IPC: B23K26/342 ,  B23K26/02 ,  B23K26/06 ,  B23K26/064 ,  B23K26/08 ,  B23K26/082 ,  B33Y50/02 ,  B33Y10/00 ,  B33Y30/00 ,  B22F3/105

Abstract: An additive manufacturing system includes a laser device, a build plate, and a scanning device. The laser device is configured to generate a laser beam with a variable intensity. The build plate is configured to support a powdered build material. The scanning device is configured to selectively direct the laser beam across the powdered build material to generate a melt pool on the build plate. The scanning device is configured to oscillate a spatial position of the laser beam while the laser device is configured to simultaneously modulate the intensity of the laser beam to thermally control the melt pool.

公开(公告)号：US10589353B2

公开(公告)日：2020-03-17

申请号：US15792928

申请日：2017-10-25

Applicant: General Electric Company

Inventor： Jan Vladimir Schwerdtfeger ,  Juan Vicente Haro Gonzalez ,  David Mazzolini ,  Felix Martin Gerhard Roerig ,  Steve Seifert

IPC: B22F3/105 ,  B33Y30/00 ,  B33Y10/00 ,  B23K26/342 ,  B29C64/379 ,  B22F3/10 ,  G05B19/4097 ,  B29C64/153 ,  B22F3/24

Abstract: An additively manufactured (AM) structure includes a removal plane extending therein defining an object thereabove. The AM structure also includes at least one datum structure coupled relative to the AM structure. Each datum structure includes a vertical reference plane for guiding a cutting element to remove the object from a remaining portion of the AM structure through the removal plane. The vertical reference plane is horizontally coplanar with the removal plane of the AM structure. The datum structures allow for accurate object cuts regardless of whether an AM build platform is horizontal or non-planar.

公开(公告)号：US20190275613A1

公开(公告)日：2019-09-12

申请号：US15915406

申请日：2018-03-08

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Thomas Etter ,  Matthias Hoebel ,  Felix Martin Gerhard Roerig

IPC: B23K26/342 ,  B23K26/082 ,  B23K26/06 ,  B23K26/0622 ,  B23K26/03 ,  B23K26/10

Abstract: Controlling microstructure in an object created by metal powder additive manufacturing is disclosed. During additive manufacturing of one or more objects using an irradiation beam source system, for each respective layer in a selected range of layers including a cross-sectional area of the one or more objects including the selected object, a duration controller controls actuation of each irradiation device to maintain constant a sum of: an irradiation device melting time, an irradiation device idle time, and a recoating time expended applying a new powder material layer, while otherwise maintaining all other operation parameters of each irradiation device constant.

公开(公告)号：US09889539B1

公开(公告)日：2018-02-13

申请号：US15680488

申请日：2017-08-18

Applicant: General Electric Company

Inventor： Julius Andreas Schurb ,  Thomas Etter ,  Brendon James Leary ,  Felix Martin Gerhard Roerig

IPC: B23P15/26 ,  B24C1/10 ,  C21D7/06

CPC classification number: B24C1/10 ,  B23P9/00 ,  B23P15/26 ,  C21D7/04 ,  C21D7/06 ,  C22F1/10

Abstract: Methods include converting a residual surface stress in a component made by a metal powder additive manufacturing process. The component includes a body having an external surface and an internal opening passing at least partially through the body, the internal opening including an unused metal powder from the additive manufacturing process therein. Residual surface stress is converted in at least a portion of a body about the internal opening by applying a pressure in the internal opening using a non-compressible fluid and the unused metal powder. The method is advantageous for use with gamma primed hardened superalloys. An additively manufactured component including the stress-converted internal opening is also disclosed.

公开(公告)号：US11524364B2

公开(公告)日：2022-12-13

申请号：US16776838

申请日：2020-01-30

Applicant: General Electric Company

Inventor： Felix Martin Gerhard Roerig ,  Juan Vicente Haro Gonzalez

IPC: B23K26/342 ,  B23K15/00 ,  B29C64/153 ,  B23K26/06 ,  B29C64/277 ,  B22F7/06 ,  B22F12/00 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B22F10/10

Abstract: A method for additive manufacturing an object is disclosed. The method includes, for a first portion of the object to be built in a first overlapping field region of a plurality of melting beams of a metal powder AM system, sequentially forming each layer of the first portion by: forming only a border section of the first portion of the object using a first melting beam of the plurality of melting beams in the first overlapping field region; and forming an internal section of the first portion of the object within the border section using at least one second, different melting beam from the first melting beam in the first overlapping field region. An entirety of an internal edge of the border section of the first portion of the object is overlapped with an entirety of an external edge of the internal section of the first portion of the object.

公开(公告)号：US10596802B2

公开(公告)日：2020-03-24

申请号：US15608154

申请日：2017-05-30

Applicant: General Electric Company

Inventor： Mikhail Pavlov ,  Donnell Eugene Crear ,  Felix Martin Gerhard Roerig ,  Dean Andrew Snelling, Jr.

IPC: B29C67/00 ,  B33Y40/00 ,  B33Y50/02 ,  B33Y30/00 ,  B29C64/153 ,  B29C64/393 ,  B29C64/268

Abstract: Additive manufacturing systems (AMS) are disclosed. The AMS may include a movable build platform, and a calibration system operably connected to the build platform. The calibration system may include a reflective element operably coupled to the build platform, a first calibration model positioned above and vertically offset from the reflective element, and a first camera substantially aligned with the first calibration model. The first camera may be visually aligned with the reflective element to capture a first reflective image of the first calibration model as reflected by the reflective element. The calibration system may also include at least one computing device operably connected to the build platform and the first camera, and configured to calibrate the build platform by: adjusting an actual inclination of the build platform in response to determining the first reflective image differs from a predetermined image of the first calibration model.

公开(公告)号：US10379063B2

公开(公告)日：2019-08-13

申请号：US15619775

申请日：2017-06-12

Applicant: General Electric Company

Inventor： Donnell Eugene Crear ,  Tiffany Muller Craft ,  Kassy Moy Hart ,  Mikhail Pavlov ,  Felix Martin Gerhard Roerig ,  Dean Andrew Snelling

IPC: G06K9/00 ,  G01N21/956 ,  B05C17/005 ,  B28B11/08 ,  B28B19/00 ,  G01N21/95 ,  G05D9/12 ,  G06T7/00 ,  B33Y40/00 ,  B29C64/30 ,  G01N21/88 ,  B33Y30/00 ,  B29C64/393 ,  B22F3/105

Abstract: A damaged applicator identifier system for an additive manufacturing (AM) system, and AM system including the same are disclosed. The damaged applicator identifier system may include a damaged applicator identifier determining whether the active applicator is damaged by identifying a non-planar surface in a layer of raw material on a build platform of the AM system after formation of the layer by the active applicator. A damaged applicator controller is configured to cause replacement or repair of the damaged, active applicator in response to the damaged applicator identifier identifying the damaged, active applicator.