Sweep gas systems

Patent metadata

Field	Value
Publication number	US-11273606-B2
Application number	US-201916517026-A
Country	US
Kind code	B2
Filing date	Jul 19, 2019
Priority date	Jul 19, 2019
Publication date	Mar 15, 2022
Grant date	Mar 15, 2022

Abstract

A sweep gas system for an additive manufacturing machine can include a gas manifold having an outlet configured to effuse gas into a build area of the additive manufacturing machine. The gas manifold can be moveable across at least a portion of the build area. The sweep gas system can include a controller configured to control a position of the gas manifold.

First claim

What is claimed is:

1. A sweep gas system for an additive manufacturing machine, comprising:
a gas manifold having an outlet configured to effuse gas into a build area of the additive manufacturing machine, wherein the gas manifold is moveable across at least a portion of the build area, wherein the sweep gas system includes a controller configured to control a position of the gas manifold, wherein the controller is configured to position the outlet of the gas manifold relative to a laser spot position and/or a melt pool location a predetermined distance from the laser spot position and/or melt pool, wherein the controller is configured to maintain the predetermined distance from the laser spot position and/or melt pool as a laser scans over the build area such that the sweep gas manifold moves to follow the laser spot position and/or melt pool, wherein the controller is configured to determine the predetermined distance in real time as a function of a laser power, a scan speed, a melt pool size, and/or a sweep gas pressure.

2. The system of claim 1 , wherein the gas manifold includes a bellows connected to the outlet to allow the outlet to move relative to the build area while maintaining a sealed sweep gas path.

3. The system of claim 2 , wherein the outlet includes a width at least as wide as a build area width of the build area.

4. The system of claim 1 , wherein the outlet is angled and configured to effuse gas at a non-right angle relative to a plane defined by the build area.

5. The system of claim 3 , wherein the angled outlet is angled upward to effuse flow upward away from the build area.

6. A method of using a sweep gas system of an additive manufacturing machine, comprising:
moving a gas manifold across at least a portion of a build area of an additive manufacturing machine;
effusing gas from an outlet of the gas manifold into the build area, wherein moving the gas manifold includes positioning the outlet of the gas manifold relative to a laser spot position and/or a melt pool location a predetermined distance from the laser spot position and/or melt pool, wherein moving the gas manifold includes maintaining the predetermined distance from the laser spot position and/or melt pool as a laser scans over the build area to follow the laser spot position and/or melt pool; and
determining the predetermined distance in real time as a function of a laser power, a scan speed, a melt pool size, and/or a sweep gas pressure.

7. The method of claim 6 , wherein moving the gas manifold includes extending and/or contracting a bellows connected to the outlet to allow the outlet to move relative to the build area while maintaining a sealed sweep gas path.

8. The method of claim 6 , further comprising effusing gas from the outlet at a non-right angle relative to a plane defined by the build area.

9. An additive manufacturing machine, comprising:
a build area;
an energy applicator configured to melt powder in the build area; and
a sweep gas system, comprising:
a gas manifold having an outlet configured to effuse gas into the build area of the additive manufacturing machine, wherein the gas manifold is moveable across at least a portion of the build area; and
a controller configured to control a position of the gas manifold, wherein the controller is configured to position the outlet of the gas manifold relative to a laser spot position and/or a melt pool location a predetermined distance from the laser spot position and/or melt pool, wherein the controller is configured to maintain the predetermined distance from the laser spot position and/or melt pool as a laser scans over the build area such that the sweep gas manifold moves to follow the laser spot position and/or melt pool, wherein the controller is configured to determine the predetermined distance in real time as a function of a laser power, a scan speed, a melt pool size, and/or a sweep gas pressure.

Assignees

• Wigen Scott
• Hamilton Sundstrand Corp

Inventors

• Wigen Scott

Classifications

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title

• B29C64/20 Primary

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B22F10/322

  of the gas flow, e.g. rate or direction · CPC title

• B22F12/90

  Means for process control, e.g. cameras or sensors · CPC title

• B22F12/70

  Gas flow means · CPC title