公开(公告)号：US20240390983A1

公开(公告)日：2024-11-28

申请号：US18201787

申请日：2023-05-25

Applicant: Raytheon Technologies Corporation

Inventor： Masoud Anahid ,  Matthew E. Lynch ,  Malcolm P. MacDonald ,  Ranadip Acharya ,  Brian A. Fisher

IPC: B22F10/85 ,  B22F10/28 ,  B22F10/37

Abstract: A process for uncertainty quantification for a predictive defect model for multi-laser additive manufacturing of a part including executing computational fluid dynamics modeling of a gas flow in an additive manufacturing machine manufacturing chamber; assigning a spatter particle size, velocity and direction relative to a melt pool on a powder bed disposed on a build plate within the manufacturing chamber; executing computational fluid dynamics post processing for spatter particle tracking; predicting a spatter particle landing pattern; feeding the spatter particle landing pattern prediction into a defect model; producing a layer thickness map, the layer thickness map configured to demonstrate a location of locally thicker layers on the part; and predicting defect location and density to accumulate lack-of-fusion risk as a function of part placement, orientation, and scan strategy.

公开(公告)号：US20230347452A1

公开(公告)日：2023-11-02

申请号：US18305628

申请日：2023-04-24

Applicant: Raytheon Technologies Corporation

Inventor： Brian A. Fisher

IPC: B23K26/70 ,  B23K26/342 ,  B22F10/28

CPC classification number: B23K26/705 ,  B23K26/342 ,  B22F10/28 ,  B33Y10/00

Abstract: Disclosed herein is a laser beam measurement system that includes a beam measurement device, a positioning apparatus, and a control system. The beam measurement device can include an imager and a plurality of optical elements configured to form an optical path to the imager within the beam measurement device. The positioning apparatus is configured to adjust a position of the beam measurement device relative to a build plate of a laser powder bed fusion system. The control system is configured to determine an intended measurement position to observe a laser beam profile of the laser powder bed fusion system, determine a target position of a beam measurement device to align with the intended measurement position, and command an adjustment of one or more aspects of the beam measurement device to achieve alignment of the target with the intended measurement position.

公开(公告)号：US20240408676A1

公开(公告)日：2024-12-12

申请号：US18332429

申请日：2023-06-09

Applicant: Raytheon Technologies Corporation

Inventor： Jesse R. Boyer ,  Brian A. Fisher ,  Alexandru Cadar ,  Joshua M. Norman

IPC: B22F10/73 ,  B22F10/28 ,  B22F10/80 ,  B29C64/153 ,  B29C64/357 ,  B29C64/386 ,  B33Y10/00 ,  B33Y40/00 ,  B33Y50/00

Abstract: A method for determining whether build powder is fit for reuse in a laser powder bed fusion additive manufacturing (LPBF) process includes constructing a model for determining a Powder Reuse Index indicative of whether build powder is fit for reuse in the LPBF process based upon LPBF process operating parameters. A build design is selected to be built using the LPBF process to collect data for constructing the model for determining the Powder Reuse Index. A plurality of test pieces the selected build design are built using a LPBF system with different layouts or set ups. Quality characteristics are determined for each of the plurality of test pieces and, using the quality characteristics for each of the plurality of test pieces, a relative importance of each LPBF process build parameter as to whether a batch of build powder is fit for reuse is determined.

公开(公告)号：US20240390987A1

公开(公告)日：2024-11-28

申请号：US18201790

申请日：2023-05-25

Applicant: Raytheon Technologies Corporation

Inventor： Masoud Anahid ,  Matthew E. Lynch ,  Amit Surana ,  Malcolm P. MacDonald ,  Brian A. Fisher

IPC: B22F12/90 ,  B22F10/28 ,  B22F10/31 ,  B22F10/322 ,  B22F10/366 ,  B22F10/85 ,  B22F12/41 ,  B22F12/45 ,  B22F12/70 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02

Abstract: A process for a laser plume interaction for a predictive defect model for multi-laser additive manufacturing of a part including executing computational fluid dynamics modeling of a gas flow in an additive manufacturing machine manufacturing chamber; approximating a laser plume relative to a melt pool on a powder bed disposed on a build plate within the manufacturing chamber; executing a space-time analysis to identify a laser plume interaction; creating a plume interaction zone map; feeding the plume interaction zone map prediction into a multi-laser defect model; and predicting defect location and density to accumulate lack-of-fusion risk as a function of part placement, orientation, and scan strategy.