Additive manufacturing process for producing a structure

Patent metadata

Field	Value
Publication number	US-12509767-B2
Application number	US-202118019693-A
Country	US
Kind code	B2
Filing date	Jul 9, 2021
Priority date	Aug 6, 2020
Publication date	Dec 30, 2025
Grant date	Dec 30, 2025

Abstract

A method for manufacturing a structure by an additive manufacturing technique implementing a chemical vapor deposition assisted by focused energy radiation, includes the formation of a reinforcement which comprises a plurality of interconnected reinforcing elements made of ceramic or carbon, which define therebetween an interstitial volume having a tortuous shape along the deposition axis.

First claim

The invention claimed is:

1 . A method for manufacturing a structure by additive manufacturing, comprising:
forming a reinforcement by chemical vapor deposition assisted by focused energy radiation, the reinforcement being deposited along a deposition axis and comprising a plurality of interconnected reinforcing elements made of ceramic or carbon, said interconnected reinforcing elements being formed by chemical vapor deposition assisted by focused energy radiation from at least one gaseous precursor, and the interconnected reinforcing elements as formed by the chemical vapor deposition assisted by focused energy radiation from at least one gaseous precursor defining therebetween an interstitial volume having a tortuous shape along said deposition axis, said interstitial volume having a sinuous and non-rectilinear shape when moving along said deposition axis.

2 . The method according to claim 1 , wherein the reinforcement is a 4D reinforcement.

3 . The method according to claim 1 , wherein there is focusing of the energy radiation on a solid portion located in the vicinity of an area where the deposition is performed.

4 . The method according to claim 1 , wherein the reinforcement includes at least one of the following materials: a carbide ceramic, a nitride ceramic, a carbonitride ceramic, an oxide ceramic or a ceramic of eutectic composition.

5 . The method according to claim 1 , wherein the reinforcement is a reinforcement of a turbomachine part.

6 . The method according to claim 1 , wherein at least two layers each defining an interstitial volume with a different shape are deposited by chemical vapor deposition assisted by focused energy radiation to form the tortuous shape of the interstitial volume of the reinforcement.

7 . The method according to claim 1 , comprising an alternation between the deposition of a layer of the reinforcement and the deposition of a matrix by chemical vapor deposition assisted by focused energy radiation, the matrix being present in the interstitial volume of the reinforcement obtained.

8 . The method according to claim 7 , comprising:
depositing a first layer of the reinforcement, depositing a matrix in the interstitial volume of the first layer of the reinforcement in order to obtain a first layer of the densified reinforcement, and depositing a second layer of the reinforcement on the first layer of the densified reinforcement.

9 . The method according to claim 8 , further comprising forming an interphase on the reinforcing elements of the first layer of the reinforcement before the deposition of the matrix, the interphase being formed by chemical vapor deposition assisted by focused energy radiation.

10 . The method according to claim 1 , wherein the focused energy radiation is a focused laser beam.

11 . The method according to claim 10 , wherein a wavelength of the focused laser beam is comprised between 1,058 nm and 1,068 nm.

Assignees

• Safran Ceram

Inventors

• Delehouze Arnaud
• Bouillon Eric
• Goujard Stéphane Roger André
• Montaudon Marc

Classifications

• F01D5/147

  Construction, i.e. structural features, e.g. of weight-saving hollow blades (F01D5/148, F01D5/16 and F01D5/20 take precedence; blade shape F01D5/141; blades with cooling or heating channels or cavities F01D5/18; heating, heat-insulating or cooling means on blades F01D5/18) · CPC title

• F05D2230/22

  by sintering · CPC title

• F01D5/284

  Selection of ceramic materials · CPC title

• F05D2230/31

  Layer deposition · CPC title

• F01D5/28

  Selecting particular materials; {Particular measures relating thereto;} Measures against erosion or corrosion · CPC title