Additive manufacturing on 3-d components

Patent metadata

Field	Value
Publication number	US-2016332251-A1
Application number	US-201514711816-A
Country	US
Kind code	A1
Filing date	May 14, 2015
Priority date	May 14, 2015
Publication date	Nov 17, 2016
Grant date	—

Abstract

A method of forming structure on a component includes: providing a component having a first surface; adhering powder to the first surface; and directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a layer of the structure.

First claim

What is claimed is:

1 . A method of forming structure on a component, comprising:
providing a component having a first surface; adhering powder to the first surface; and directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a layer of the structure.

2 . the method of claim 1 further comprising repeating in a cycle the steps of depositing and fusing to build up the structure in a layer-by layer fashion.

3 . The method of claim 2 wherein the repeating cycle of depositing and fusing results in the component including both fused and un-fused powder, the method further comprising removing the un-fused powder.

4 . The method of claim 1 wherein the first surface is non-planar.

5 . The method of claim 1 wherein the powder is adhered to the first surface by:
applying an adhesive to the first surface; and
applying powder to the adhesive.

6 . The method of claim 5 further comprising removing excess powder after the powder is applied to the adhesive.

7 . The method of claim 1 wherein the component comprises a metal alloy.

8 . The method of claim 1 wherein the powder comprises a metal alloy.

9 . A method of forming a cooling channel on a component, comprising:
providing a component having a first surface; adhering powder to the first surface; directing a beam from a directed energy source to fuse the powder in a predetermined pattern; and repeating in a cycle the steps of depositing and fusing to build up the structure in a layer-by layer fashion, wherein the structure includes spaced-apart walls which define at least one open channel therebetween.

10 . The method of claim 1 further comprising forming at least one coolant supply hole in the component communicating with the at least one open channel.

11 . The method of claim 9 further comprising forming a cover spanning the at least one open channel.

12 . The method of claim 11 further comprising:
leaving un-fused powder in the at least one open channel;
forming the cover; and
removing the un-fused powder.

13 . The method of claim 12 further comprising forming at least one exit film hole through the cover communicating with the channel.

14 . The method of claim 11 wherein the cover is formed by:
adhering powder over the channels;
directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a layer of the cover; and
repeating in a cycle the steps of depositing and fusing to build up the cover in a layer-by layer fashion.

15 . The method of claim 9 wherein the first surface is non-planar.

16 . The method claim 9 wherein the powder is adhered to the first surface by:
applying an adhesive to the first surface; and
applying powder to the adhesive.

17 . The method of claim 15 further comprising removing excess powder after the powder is applied to the adhesive.

18 . The method of claim 9 wherein the component comprises a metal alloy.

19 . The method of claim 9 wherein the powder comprises a metal alloy.

Assignees

• Gen Electric

Inventors

• Bunker Ronald Scott
• Carter William Thomas
• Hasz Wayne Charles

Classifications

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B22F10/28

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

• B22F5/04 Primary

  of turbine blades · CPC title

• B23K15/0086 Primary

  welding for purposes other than joining, e.g. build-up welding · CPC title

• B22F10/68

  Cleaning or washing · CPC title