公开(公告)号：US11478983B2

公开(公告)日：2022-10-25

申请号：US16565941

申请日：2019-09-10

Applicant: General Electric Company

Inventor： Gregory Muster Morris ,  Guenter Helmut Wilfert ,  Todd Jay Rockstroh

IPC: B29C64/153 ,  B29C64/245 ,  B29C64/241 ,  B29C64/255 ,  B29C64/264 ,  B29C64/343 ,  B29C64/329 ,  B29C64/35 ,  B29C64/205 ,  B33Y40/00 ,  B33Y10/00 ,  B33Y30/00

Abstract: An additive manufacturing apparatus includes: first and second spaced apart side walls extending along a pre-defined path and defining a build chamber therebetween; one or more build units mounted for movement along the pre-defined path, the one or more build units including at least one of: a powder dispenser positioned above the build chamber; an applicator configured to scrape powder dispensed into the build chamber; and a directed energy source configured to fuse the scraped powder.

公开(公告)号：US11446766B2

公开(公告)日：2022-09-20

申请号：US16798505

申请日：2020-02-24

Applicant: General Electric Company

Inventor： Todd Jay Rockstroh ,  Michael Francis Xavier Gigliotti ,  William Thomas Carter ,  David Henry Abbott ,  Rajendra Madhukar Kelkar

IPC: B33Y30/00 ,  B23K26/34 ,  B23K26/342 ,  C30B29/52 ,  B33Y10/00 ,  C30B11/00 ,  B22F10/20 ,  B33Y80/00 ,  B23K26/144 ,  B23K26/70 ,  B23K26/08 ,  C30B11/02 ,  C30B28/06 ,  H05B3/00 ,  H05B6/10 ,  B22F10/30

Abstract: A method of making a component includes: depositing a metallic powder on a workplane; directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a cross-sectional layer of the component; repeating in a cycle the steps of depositing and fusing to build up the component in a layer-by layer fashion; and during the cycle of depositing and melting, using an external heat control apparatus separate from the directed energy source to maintain a predetermined temperature profile of the component, such that the resulting component has a directionally-solidified or single-crystal microstructure.

公开(公告)号：US20210069967A1

公开(公告)日：2021-03-11

申请号：US16565941

申请日：2019-09-10

Applicant: General Electric Company

Inventor： Gregory Muster Morris ,  Guenter Helmut Wilfert ,  Todd Jay Rockstroh

IPC: B29C64/153 ,  B29C64/245 ,  B29C64/241 ,  B29C64/255 ,  B29C64/264 ,  B29C64/205 ,  B29C64/343 ,  B29C64/329 ,  B29C64/35

Abstract: An additive manufacturing apparatus includes: first and second spaced apart side walls extending along a pre-defined path and defining a build chamber therebetween; one or more build units mounted for movement along the pre-defined path, the one or more build units including at least one of: a powder dispenser positioned above the build chamber; an applicator configured to scrape powder dispensed into the build chamber; and a directed energy source configured to fuse the scraped powder.

公开(公告)号：US20200298341A1

公开(公告)日：2020-09-24

申请号：US16798505

申请日：2020-02-24

Applicant: General Electric Company

Inventor： Todd Jay Rockstroh ,  Michael Francis Xavier Gigliotti ,  William Thomas Carter ,  David Henry Abbott ,  Rajendra Machukar Kelkar

IPC: B23K26/342 ,  C30B29/52 ,  B33Y10/00 ,  B33Y30/00 ,  B22F3/105 ,  C30B11/00 ,  B33Y80/00 ,  B23K26/144 ,  B23K26/70 ,  B23K26/08 ,  C30B11/02 ,  C30B28/06 ,  H05B3/00 ,  H05B6/10

Abstract: A method of making a component includes: depositing a metallic powder on a workplane; directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a cross-sectional layer of the component; repeating in a cycle the steps of depositing and fusing to build up the component in a layer-by layer fashion; and during the cycle of depositing and melting, using an external heat control apparatus separate from the directed energy source to maintain a predetermined temperature profile of the component, such that the resulting component has a directionally-solidified or single-crystal microstructure.

公开(公告)号：US20170051386A1

公开(公告)日：2017-02-23

申请号：US14830759

申请日：2015-08-20

Applicant: General Electric Company

Inventor： William Thomas Carter ,  Todd Jay Rockstroh ,  Douglas Gerard Konitzer

IPC: C22F1/10 ,  B23K26/03 ,  B23K26/70 ,  B33Y80/00 ,  B23K26/14 ,  B23K26/00 ,  B33Y10/00 ,  B33Y30/00 ,  B23K26/342 ,  B23K26/144

Abstract: Methods for direct writing of single crystal super alloys and metals are provided. The method can include: heating a substrate positioned on a base plate to a predetermined temperature using a first heater; using a laser to form a melt pool on a surface of the substrate; introducing a superalloy powder to the melt pool; measuring the temperature of the melt pool; receiving the temperature measured at a controller; and using an auxiliary heat source in communication with the controller to adjust the temperature of the melt pool. The predetermined temperature is below the substrate's melting point. The laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition. An apparatus is also generally provided for direct writing of single crystal super alloys and metals.

Abstract translation: 提供了直接写入单晶超合金和金属的方法。 该方法可以包括：使用第一加热器将位于基板上的基板加热至预定温度; 使用激光在所述基板的表面上形成熔池; 在熔池中引入超合金粉末; 测量熔池的温度; 接收在控制器处测得的温度; 并使用与控制器通信的辅助热源来调节熔池的温度。 预定温度低于基板的熔点。 激光器和基板可相对于彼此移动，激光用于直接金属沉积。 通常还提供用于直接写入单晶超级合金和金属的装置。

公开(公告)号：US11135653B2

公开(公告)日：2021-10-05

申请号：US15643312

申请日：2017-07-06

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Todd Jay Rockstroh

IPC: B22F10/20 ,  B33Y10/00 ,  B33Y40/00 ,  C25D5/34 ,  C25F5/00 ,  B22F12/00 ,  B33Y30/00 ,  B29C64/245 ,  B22F10/10 ,  B33Y70/00

Abstract: A method for additive manufacturing utilizing a build plate with a release layer is provided. The method includes irradiating a first layer of powder in a powder bed to form a first fused region over a support. The first release layer is provided between the first fused region and the support. The method also includes providing a given layer of powder over the powder bed and irradiating the given layer of powder in the powder bed to form a given fused region. Providing the given layer of powder over the powder bed and irradiating the given layer of powder in the powder bed to form a given fused region are repeated until the object is formed in the powder bed. The object may be formed fusing individual layers with irradiation by laser or ebeam, or by binder jetting. The method further includes separating the object from the support by melting or dissolving the first release layer.

公开(公告)号：US20190240781A1

公开(公告)日：2019-08-08

申请号：US15888727

申请日：2018-02-05

Applicant: General Electric Company

Inventor： William Thomas Carter ,  Todd Jay Rockstroh ,  Brian Scott McCarthy ,  Subhrajit Roychowdhury ,  Younkoo Jeong ,  David Charles Bogdan, JR.

IPC: B23K26/342 ,  B33Y10/00 ,  B33Y30/00 ,  B23K26/082 ,  B23K26/08 ,  B23K26/06 ,  B23K26/144 ,  B23K26/16

CPC classification number: B23K26/342 ,  B23K26/0608 ,  B23K26/082 ,  B23K26/0823 ,  B23K26/144 ,  B23K26/16 ,  B33Y10/00 ,  B33Y30/00

Abstract: A direct metal laser melting (DMLM) system includes a rotatable base, and a build plate mounted on and supported by the rotatable base, where the build plate includes a build surface. The DMLM system also includes a first actuator assembly, a first powder dispenser disposed proximate the build plate and configured to deposit a weldable powder on the build surface of the build plate. In addition, the DMLM system includes a first powder spreader disposed proximate the build plate and configured to spread the weldable powder deposited on the build surface of the build plate, and a first laser scanner supported by the first actuator assembly in a position relative to the build plate, such that at least a portion of the build surface is within a field of view of the first laser scanner. The first laser scanner is configured to selectively weld the weldable powder. The first laser scanner is further configured to translate axially relative to the build surface on the first actuator assembly.

公开(公告)号：US10195692B2

公开(公告)日：2019-02-05

申请号：US15318088

申请日：2015-05-20

Applicant: General Electric Company

Inventor： Todd Jay Rockstroh ,  Daniel Curtis Gray ,  Mark Allen Cheverton ,  Victor Petrovich Ostroverkhov

IPC: B23K26/34 ,  B23K26/342 ,  B22F3/105 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B23K26/70 ,  B23K26/06 ,  B23K26/067 ,  B23K26/08 ,  B29C64/153

Abstract: A method of creating an article of manufacture is provided, which includes directing multiple laser beams to a single galvanometer; and dynamically repositioning the multiple laser beams in counterpart paths using the single galvanometer to shine the multiple laser beams on and melt a first powder material and, upon solidification of the melted first powder material, forming a first series of duplicate three dimensional structures, where each of the multiple laser beams is used to form at least one of the first series of duplicate three dimensional structures.

公开(公告)号：US20160258045A1

公开(公告)日：2016-09-08

申请号：US14836494

申请日：2015-08-26

Applicant: General Electric Company ,  The Regents of the University of Michigan

Inventor： William Thomas Carter, JR. ,  Todd Jay Rockstroh ,  Douglas Gerard Konitzer ,  Jyotirmoy Mazumder ,  Jeongyong Choi

IPC: C22F1/10 ,  B23K26/00 ,  B23K26/08 ,  B23K26/144 ,  B23K26/342 ,  B23K26/70

CPC classification number: B23K26/342 ,  B23K26/0006 ,  B23K26/034 ,  B23K26/083 ,  B23K26/0861 ,  B23K26/0869 ,  B23K26/0884 ,  B23K26/144 ,  B23K26/34 ,  B23K26/346 ,  B23K26/354 ,  B23K26/702 ,  B23K26/703 ,  B23K2101/001 ,  B23K2103/08 ,  B23K2103/26 ,  B23P15/04 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B33Y80/00 ,  C22F1/10

Abstract: Apparatus and methods for direct writing of single crystal super alloys and metals are provided. In one method, a substrate is heated to a pretermined temperature below its melting point, and a laser is used to form a melt pool on a surface of a substrate. The substrate is positioned on a base plate, and the laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition and the substrate is heated to a temperature below its melting point. A superalloy powder is introduced to the melt pool, and the temperature of the melt pool is controlled to maintain a predetermined thermal gradient on a solid and liquid interface of the melt pool so as to form a single crystal deposit on the substrate.

Abstract translation: 提供了用于直接写入单晶超级合金和金属的装置和方法。 在一种方法中，将衬底加热到​​低于其熔点的预制温度，并且使用激光器在衬底的表面上形成熔池。 基板定位在基板上，并且激光和基板可相对于彼此移动，激光用于直接金属沉积，并且将基板加热到低于其熔点的温度。 将超合金粉末引入到熔池中，并且控制熔池的温度以在熔池的固体和液体界面上保持预定的热梯度，以在衬底上形成单晶沉积物。

公开(公告)号：US20220362886A1

公开(公告)日：2022-11-17

申请号：US17878624

申请日：2022-08-01

Applicant: General Electric Company

Inventor： Todd Jay Rockstroh ,  Michael Francis Xavier Gigliotti ,  William Thomas Carter ,  David Henry Abbott ,  Rajendra Madhukar Kelkar

IPC: B23K26/342 ,  C30B29/52 ,  B33Y10/00 ,  B33Y30/00 ,  C30B11/00 ,  B22F10/20 ,  B33Y80/00 ,  B23K26/144 ,  B23K26/70 ,  B23K26/08 ,  C30B11/02 ,  C30B28/06 ,  H05B3/00 ,  H05B6/10

Abstract: A method of making a component includes: depositing a metallic powder on a workplane; directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a cross-sectional layer of the component; repeating in a cycle the steps of depositing and fusing to build up the component in a layer-by layer fashion; and during the cycle of depositing and melting, using an external heat control apparatus separate from the directed energy source to maintain a predetermined temperature profile of the component, such that the resulting component has a directionally-solidified or single-crystal microstructure.