Turbine disk fabrication with in situ material property variation

Patent metadata

Field	Value
Publication number	US-10710161-B2
Application number	US-201414202195-A
Country	US
Kind code	B2
Filing date	Mar 10, 2014
Priority date	Mar 11, 2013
Publication date	Jul 14, 2020
Grant date	Jul 14, 2020

Abstract

A method of fabricating a functionally graded turbine engine component is disclosed and includes the step of depositing layers of powder onto a base and solidifying/fusing each layer with a first directed energy beam to define a component. The method further includes varying a process parameter between deposited layers to define different material properties within the component. The method also proposes surface enhancement approach that can be used after depositing each layer to locally customize the material properties. The method also proposes machining the different internal surfaces to achieve the proper surface finishing required.

First claim

What is claimed is:

1. A method of fabricating a functionally graded turbine engine component comprising:
depositing layers of powder onto a base;
solidifying and fusing each layer with a first directed energy beam to define a component; and
varying a process parameter between deposited layers to define different material properties within the component, further comprising varying the energy level from the first directed energy beam to vary a density of a solidified layer of powder.

2. The method as recited in claim 1 , further comprising using a second directed energy beam for heat treating the deposited layers of powder to locally generate a desired microstructure.

3. The method as recited in claim 1 , further comprising laser shock peening of a solidified layer prior to depositing a subsequent layer of powder to induce compressive residual stress.

4. The method as recited in claim 1 , further comprising utilizing a deep rolling tool to induce cold working at a surface of a solidified layer prior to depositing a subsequent layer of powder material.

5. The method as recited in claim 1 , further comprising deep rolling a solidified layer to obtain a desired strength of material and surface microstructure.

6. The method as recited in claim 1 , further comprising varying a powder size between layers to define different material properties within the component.

7. The method as recited in claim 1 , further comprising varying a composition of the powder between layers to define material properties within the component.

8. The method as recited in claim 1 , further comprising the step of finish machining an internal surface of the component and sealing the internal surface within the component with subsequent solidified and fused layers of powder.

9. The method as recited in claim 1 , wherein the component comprises a turbine disk including a hub and a rim and the method comprises the step of machining the deposited layers to provide a desired surface finish.

10. The method as recited in claim 1 , wherein layer specifications are determined utilizing a structural optimization methodology.

11. A method of fabricating a turbine disk comprising:
depositing layers of powder onto a base;
solidifying and fusing each layer with a first directed energy beam to define the turbine disk;
varying a process parameter between deposited layers to define different material properties within the turbine disk; and
heat treating a solidified layer using a second directed energy beam to induce compressive residual stress into solidified layers of powder.

12. The method as recited in claim 11 , further comprising depositing layers along a plane transverse to an intended axis of rotation of the turbine disk.

13. The method as recited in claim 11 , further comprising deep rolling a solidified layer to obtain a desired microstructure and enhance the surface properties by inducing compressive residual stress.

14. The method as recited in claim 11 , further comprising varying one of an energy level from the first directed energy beam, a powder size and powder compositions to vary a density between solidified layers of powder.

15. The method as recited in claim 11 , wherein layer specifications are determined utilizing a structural optimization methodology.

Assignees

• United Technologies Corp
• Raytheon Tech Corp

Inventors

• El-Wardany Tahany Ibrahim
• Lynch Matthew E
• Viens Daniel V
• Grelotti Robert A

Classifications

• B22F12/45

  Two or more · CPC title

• B22F10/50

  Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up · CPC title

• B22F10/38

  to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures · CPC title

• B22F10/36

  of energy beam parameters · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title