公开(公告)号：US20240390984A1

公开(公告)日：2024-11-28

申请号：US18323875

申请日：2023-05-25

Applicant: Raytheon Technologies Corporation

Inventor： Parisa Farahmand ,  Masoud Anahid

IPC: B22F10/85 ,  B22F10/28 ,  B22F10/366 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02

Abstract: This disclosure is directed to a method for modeling additive manufacturing of a part, including a number of steps. The steps include constructing a model for estimating output of a simulated additive manufacturing process, followed by entering process operating parameters for an additive manufacturing system into the model to produce an output. The output is compared to acceptance criteria to determine whether the output is acceptable or unacceptable. Next regions of operating parameters that support production of the part with acceptable quality characteristics are determined based upon the output. Regions of operating parameters that support production of the part with acceptable quality characteristics are added to a process map for additive manufacturing the part. The steps are repeated for different operating parameters until the process map is complete.

公开(公告)号：US20240416424A1

公开(公告)日：2024-12-19

申请号：US18334179

申请日：2023-06-13

Applicant: Raytheon Technologies Corporation

Inventor： Sergei F. Burlatsky ,  Andreas Karl Roelofs ,  Masoud Anahid ,  Ranadip Acharya ,  Tahany El-Wardany ,  David U. Furrer

IPC: B22F10/85 ,  B22F10/28 ,  B22F12/20 ,  B33Y10/00 ,  B33Y40/20 ,  B33Y50/02

Abstract: The present disclosure provides improved additive manufacturing methods and systems. More particularly, the present disclosure provides advantageous additive manufacturing methods and systems for the production of hierarchical design optimized components (e.g., composite or composite-like materials). The present disclosure provides a methodology to produce hierarchical design optimized additively manufactured parts/materials that include an inhomogeneous structure with variable local mechanical properties across the entire volume. Hierarchical inhomogeneous structure/composite materials can be produced through a laser powder bed fusion (LPBF) process. A novel LPBF method can be used to obtain location-specific properties through in-situ controlling of the local cooling rate during the additive manufacturing process.

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.

公开(公告)号：US20240393765A1

公开(公告)日：2024-11-28

申请号：US18201786

申请日：2023-05-25

Applicant: Raytheon Technologies Corporation

Inventor： Masoud Anahid ,  Matthew E. Lynch ,  Tahany El-Wardany

IPC: G05B19/4099 ,  B22F10/85 ,  B29C64/393 ,  B33Y50/02

Abstract: An analysis tool for multi-laser additive manufacturing including a build file module; a preprocessor in operative communication with the build file module; a prime module in operative communication with the preprocessor; and a defect code module in operative communication with the prime module.

公开(公告)号：US20240254589A1

公开(公告)日：2024-08-01

申请号：US18162861

申请日：2023-02-01

Applicant: Raytheon Technologies Corporation

Inventor： Masoud Anahid ,  Matthew D. Mordasky ,  Anthony Patrick Ventura ,  David U. Furrer

IPC: C21D9/68 ,  C21D1/42 ,  C22F1/10

CPC classification number: C21D9/68 ,  C21D1/42 ,  C22F1/10

Abstract: The present disclosure provides assemblies, systems and methods for a single-step process for selective heat treatment of metals. More particularly, the present disclosure provides assemblies, systems and methods for a single-step process for selective heat treatment of metals using a coil-in-furnace configuration. A hybrid modeling-test approach can be used in the design process to improve or optimize the process parameters to achieve location specific and improved/optimal microstructure and residual stress to enhance the part performance. It is also noted that performing the selective heat treatment in a single step can reduce the cycle time significantly. Moreover, large thermal gradients can be avoided in the part as different volumes of the part are heated to their desired temperature simultaneously.

公开(公告)号：US20210334685A1

公开(公告)日：2021-10-28

申请号：US16859349

申请日：2020-04-27

Applicant: Raytheon Technologies Corporation

Inventor： Masoud Anahid ,  Tahany Ibrahim El-Wardany ,  Sergei F. Burlatsky ,  William K. Tredway

IPC: G06N7/00 ,  G05B19/4099

Abstract: A method of evaluating an additive manufacturing process includes receiving a set of additive manufacturing parameters and an additive manufacturing part design at an analysis module, receiving a set of random values at the analysis module, determining a probability distribution of stochastic flaws within a resultant additively manufactured article using at least one multidimensional space physics model, and categorizing the additive manufacturing part design as defect free when the probability distribution is below a predefined threshold. Each value in the set of random values corresponds to a distinct variable in a set of variables. Each variable in the set of variables at least partially defines at least one of an uncontrolled additive manufacturing parameter and an uncontrollable additive manufacturing parameter.

公开(公告)号：US20240391174A1

公开(公告)日：2024-11-28

申请号：US18201792

申请日：2023-05-25

Applicant: Raytheon Technologies Corporation

Inventor： Masoud Anahid ,  Matthew E. Lynch ,  Abdelilah Sakti

IPC: B29C64/393 ,  B33Y50/02

Abstract: A process for an external optimization framework utilizing a defect model for multi-laser additive manufacturing of a part including determining a scalar metric for the part; employing the scalar metric in the defect model; providing at least one output from the defect model to the external optimization framework; and optimizing the powder bed fusion additive manufacturing process for the part with the external optimization framework.

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：US20240254611A1

公开(公告)日：2024-08-01

申请号：US18162851

申请日：2023-02-01

Applicant: Raytheon Technologies Corporation

Inventor： Masoud Anahid ,  David U. Furrer ,  Matthew D. Mordasky ,  Anthony Patrick Ventura

IPC: C22F1/10 ,  C22F1/11

CPC classification number: C22F1/10 ,  C22F1/11

Abstract: The present disclosure provides assemblies, systems and methods for a single-step process for selective heat treatment of metals. More particularly, the present disclosure provides assemblies, systems and methods for a single-step process for selective heat treatment of metals using multiple heating sources. A hybrid modeling-test approach can be used in the design process to improve or optimize the process parameters to achieve location specific and improved/optimal microstructure and residual stress to enhance the part performance. It is also noted that performing the selective heat treatment in a single step can reduce the cycle time significantly. Moreover, large thermal gradients can be avoided in the part as different volumes of the part are heated to their desired temperature simultaneously.

公开(公告)号：US20240254578A1

公开(公告)日：2024-08-01

申请号：US18162860

申请日：2023-02-01

Applicant: Raytheon Technologies Corporation

Inventor： Masoud Anahid ,  Matthew D. Mordasky ,  Anthony Patrick Ventura ,  David U. Furrer

IPC: C21D1/42 ,  C21D11/00 ,  C22C19/05

CPC classification number: C21D1/42 ,  C21D11/00 ,  C22C19/05

Abstract: The present disclosure provides assemblies, systems and methods for a single-step process for selective heat treatment of metals. More particularly, the present disclosure provides assemblies, systems and methods for a single-step process for selective heat treatment of metals using multiple induction heating coils. A hybrid modeling-test approach can be used in the design process to improve or optimize the process parameters to achieve location specific and improved/optimal microstructure and residual stress to enhance the part performance. It is also noted that performing the selective heat treatment in a single step can reduce the cycle time significantly. Moreover, large thermal gradients can be avoided in the part as different volumes of the part are heated to their desired temperature simultaneously.