Additive manufacturing based multi-layer fabrication/repair

Patent metadata

Field	Value
Publication number	US-11583928-B2
Application number	US-201916385177-A
Country	US
Kind code	B2
Filing date	Apr 16, 2019
Priority date	Apr 16, 2019
Publication date	Feb 21, 2023
Grant date	Feb 21, 2023

Abstract

A method of additively manufacturing includes generating a thermal model driven scan map that identifies an equiaxed cap region, a single crystal (SX) region, and a columnar to equiaxed transition (CET) region; and forming an active melt pool with respect to the thermal model driven scan map such that a depth of the active melt pool is greater than a thickness of the equiaxed transition (CET) region.

First claim

What is claimed:

1. A method of additively manufacturing, comprising:
generating a thermal model driven scan map;
maintaining an active melt pool of an active melt pool scan pattern with respect to the thermal model driven scan map such that a depth of the active melt pool is greater than a thickness of a columnar to equiaxed transition (CET) region;
restricting a scan rotation to zero and unidirectional movement of the active melt pool scan pattern to assure columnar single crystal (SX) growth;
utilizing the thermal model driven scan map to model residual stress to simulate and prevent residual stress and a propensity of hot cracking; and
utilizing the thermal model driven scan map to define a morphology, wherein the morphology includes a directionally solidified (DS) microstructure; wherein the thermal model driven scan map identifies the columnar to equiaxed transition (CET) region.

2. The method as recited in claim 1 , further comprising initiating formation of the active melt pool in a cast single crystal (SX) baseplate.

3. The method as recited in claim 1 , further comprising maintaining the active melt pool of the active melt pool scan pattern with a lesser power than a conventional melt pool of a conventional scan pattern.

4. The method as recited in claim 3 , further comprising arranging the active melt pool scan pattern with a closer line spacing and higher velocity than the conventional scan pattern.

5. A method of additively manufacturing, comprising:
locating a cast single crystal (SX) baseplate in an additively manufacturing machine;
initiating formation of an active melt pool in the cast single crystal (SX) baseplate via an active melt pool scan pattern;
generating a thermal model driven scan map that identifies an equiaxed cap region, a single crystal (SX) region, and a columnar to equiaxed transition (CET) region;
maintaining the active melt pool with the active melt pool scan pattern in accords with the thermal model driven scan map such that a depth of the active melt pool is greater than a thickness of a columnar to equiaxed transition (CET) region;
restricting a scan rotation to zero and unidirectional movement of the active melt pool scan pattern to assure columnar single crystal (SX) growth;
utilizing the thermal model driven scan map to model residual stress to simulate and prevent residual stress and a propensity of hot cracking; and
utilizing the thermal model driven scan map to define a morphology, wherein the morphology includes a directionally solidified (DS) microstructure.

6. The method as recited in claim 5 , further comprising maintaining the active melt pool of the active melt pool scan pattern with a lesser power than a conventional melt pool of a conventional scan pattern.

7. The method as recited in claim 6 , further comprising arranging the active melt pool scan pattern with a closer line spacing and higher velocity than the conventional scan pattern.

Assignees

• United Technologies Corp
• Raytheon Tech Corp

Inventors

• Acharya Ranadip
• Jagdale Vijay Narayan

Classifications

• B22F10/73

  of powder · CPC title

• B22F10/32

  of the atmosphere, e.g. composition or pressure in a building chamber · CPC title

• Y02P10/25

  Process efficiency · CPC title

• B22F10/38

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

• B22F10/28

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