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公开(公告)号：US11571743B2
公开(公告)日：2023-02-07
申请号：US15810783
申请日：2017-11-13
发明人： Michael Evans Graham , William Monaghan , Thomas Charles Adcock , Andrew J. Martin , John Joseph Madelone, Jr. , David Charles Bogdan, Jr. , John Broddus Deaton, Jr. , William Thomas Carter
IPC分类号： B22F10/20 , B22F3/12 , B33Y10/00 , B33Y50/02 , B33Y30/00 , B22F10/28 , B22F10/47 , B22F10/25 , B22F12/33 , B22F12/44 , B22F12/46 , B22F12/49
摘要： In one aspect, an additive manufacturing system is provided. The additive manufacturing system includes a build platform, a first plurality of particles positioned on the build platform, and a particle containment system positioned on the build platform. The particle containment system includes a particle containment wall. The particle containment wall at least partially surrounds the first plurality of particles and includes a second plurality of particles consolidated together. The particle containment wall includes a top end spaced apart from the build platform, an inner face positioned against the first plurality of particles and extending between the build platform and the top end, and an outer face that faces a substantially particle-free region, the outer face positioned opposite the inner face and extending between the build platform and the top end.
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公开(公告)号：US11325207B2
公开(公告)日：2022-05-10
申请号：US15411718
申请日：2017-01-20
IPC分类号： B23K26/342 , B33Y30/00 , B29C64/153 , B29C64/386 , B29C64/282 , B29C64/268 , B29C64/277 , B33Y50/02 , B22F12/00 , B33Y10/00 , B23K26/082 , B23K26/03 , B23K26/06 , B28B1/00 , B22F10/10
摘要： An additive manufacturing system includes a plurality of laser devices, a plurality of first scanning devices, and an optical system. The optical system includes an optical detector and a second scanning device. The plurality of laser devices are each configured to generate a laser beam. The plurality of first scanning devices is each configured to selectively direct the laser beam from a laser device of the plurality of laser devices across a powder bed. The laser beam generates a melt pool in the powder bed. The optical detector is configured to detect electromagnetic radiation generated by the melt pool. The second scanning device is configured to direct electromagnetic radiation generated by the melt pool to the optical detector. The optical system is configured to detect a position of the laser beams in the melt pool.
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公开(公告)号：US11154956B2
公开(公告)日：2021-10-26
申请号：US15439643
申请日：2017-02-22
IPC分类号： B23P6/04 , B23K26/34 , F01D5/00 , B22F5/04 , B23P6/00 , B23K20/22 , B23K35/02 , F01D5/14 , C30B29/66 , C30B13/24 , B22F7/06 , B22F7/08 , B22F5/00 , C30B29/52 , C30B29/60 , B22F10/20 , B22F3/105 , B23K26/0622 , B23K101/00 , B23K103/08 , B23K103/18 , F01D9/06 , F01D5/18 , B22F3/24
摘要： Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.
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公开(公告)号：US11084132B2
公开(公告)日：2021-08-10
申请号：US15794225
申请日：2017-10-26
IPC分类号： B23P6/00 , H01S5/40 , G02B6/42 , B33Y10/00 , B33Y30/00 , B29C64/153 , B28B1/00 , C03B19/01 , F01D5/00 , B23K26/342 , B23K26/10 , B23K26/06 , B23K26/08 , B23K26/0622 , B23K26/00 , B29C64/277 , B33Y80/00 , B29C64/393 , B33Y50/02 , B23K103/00 , B23K103/18
摘要： A method of forming a build in a powder bed includes providing a first diode laser fiber array and a second diode laser fiber array, emitting a plurality of laser beams from selected fibers of the second diode laser fiber array onto the powder bed, corresponding to a pattern of a layer of the build, simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build, scanning a first diode laser fiber array along an outer boundary of the powder bed and emitting a plurality of laser beams from selected fibers of the first diode laser fiber array and simultaneously melting powder in the powder bed corresponding to the outer boundary of the layer of the build to contour the layer of the build. An apparatus for forming a build in a powder bed including a first diode laser fiber array and a second diode laser fiber array is also disclosed. The first diode laser fiber array configured to contour the layer of the build.
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公开(公告)号：US10569364B2
公开(公告)日：2020-02-25
申请号：US15400592
申请日：2017-01-06
IPC分类号： B29C64/214 , B23K26/342 , B33Y10/00 , B29C64/153 , B29C64/20 , B22F3/105 , B22F3/00 , B33Y30/00 , B29K105/00 , B23K103/10 , B23K103/14
摘要： A recoating device for an additive manufacturing system includes a plurality of recoater blades which include a first stage and a second stage. The first stage includes a plurality of rows of the plurality of recoater blades and extends in the transverse dimension. The second stage includes a plurality of recoater blades and is configured substantially similar to the first stage of the plurality of recoater blades. The second stage of recoater blades is displaced from the first stage of recoater blades in the vertical dimension.
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公开(公告)号：US20190240781A1
公开(公告)日：2019-08-08
申请号：US15888727
申请日：2018-02-05
发明人： William Thomas Carter , Todd Jay Rockstroh , Brian Scott McCarthy , Subhrajit Roychowdhury , Younkoo Jeong , David Charles Bogdan, JR.
IPC分类号： B23K26/342 , B33Y10/00 , B33Y30/00 , B23K26/082 , B23K26/08 , B23K26/06 , B23K26/144 , B23K26/16
CPC分类号： B23K26/342 , B23K26/0608 , B23K26/082 , B23K26/0823 , B23K26/144 , B23K26/16 , B33Y10/00 , B33Y30/00
摘要： 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.
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7.发明申请公开(公告)号：US20190240773A1
公开(公告)日：2019-08-08
申请号：US15888770
申请日：2018-02-05
IPC分类号： B23K26/08 , B33Y30/00 , B23K26/342
CPC分类号： B23K26/083 , B23K26/342 , B33Y30/00
摘要： A customizable powder bed containment system for use with a direct metal laser melting (DMLM) system includes a plurality of interlinkable containment walls mechanically couplable on a build plate of the DMLM system as well as mechanically coupleable to another interlinkable containment wall of the plurality of interlinkable containment walls, and at least one actuator mechanically coupled to at least one interlinkable containment wall of the plurality of interlinkable containment walls. The at least one actuator is operable to selectively raise the at least one interlinkable containment wall of the plurality of interlinkable containment walls axially relative to a build surface of the build plate.
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公开(公告)号：US20190202101A1
公开(公告)日：2019-07-04
申请号：US15861072
申请日：2018-01-03
IPC分类号： B29C47/00 , B29C64/241 , B29C64/209 , B29C64/153 , B29C64/223 , B33Y50/02 , B33Y30/00
CPC分类号： B29C48/04 , B29C64/153 , B29C64/209 , B29C64/223 , B29C64/241 , B33Y30/00 , B33Y50/02
摘要： An additive manufacturing system is provided. The additive manufacturing system includes a build platform and at least one workstation. The build platform defines a continuous workflow path and is configured to rotate about a build platform axis. The workstation is spaced apart from the build platform along the third direction and at least one of the build platform and the workstation is configured to move along the third direction. The workstation includes at least one particle delivery device, at least one recoating device, and at least one consolidation device. The particle delivery device is configured to deposit particles on the build platform. The recoating device is configured to distribute the deposited particles to form a build layer on the build platform. The consolidation device is configured to consolidate at least a portion of the build layer.
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公开(公告)号：US20190126413A1
公开(公告)日：2019-05-02
申请号：US15794225
申请日：2017-10-26
IPC分类号： B23P6/00 , H01S5/40 , G02B6/42 , B33Y10/00 , B33Y30/00 , B33Y50/02 , B29C64/153 , B29C64/393 , B28B1/00 , C03B19/01 , F01D5/00 , B23K26/342
摘要： A method of forming a build in a powder bed includes providing a first diode laser fiber array and a second diode laser fiber array, emitting a plurality of laser beams from selected fibers of the second diode laser fiber array onto the powder bed, corresponding to a pattern of a layer of the build, simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build, scanning a first diode laser fiber array along an outer boundary of the powder bed and emitting a plurality of laser beams from selected fibers of the first diode laser fiber array and simultaneously melting powder in the powder bed corresponding to the outer boundary of the layer of the build to contour the layer of the build. An apparatus for forming a build in a powder bed including a first diode laser fiber array and a second diode laser fiber array is also disclosed. The first diode laser fiber array configured to contour the layer of the build.
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公开(公告)号：US20180194074A1
公开(公告)日：2018-07-12
申请号：US15400592
申请日：2017-01-06
摘要： A recoating device for an additive manufacturing system includes a plurality of recoater blades which include a first stage and a second stage. The first stage includes a plurality of rows of the plurality of recoater blades and extends in the transverse dimension. The second stage includes a plurality of recoater blades and is configured substantially similar to the first stage of the plurality of recoater blades. The second stage of recoater blades is displaced from the first stage of recoater blades in the vertical dimension.
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