公开(公告)号：US12023860B2

公开(公告)日：2024-07-02

申请号：US17967391

申请日：2022-10-17

Applicant: General Electric Company

Inventor： Vipul Kumar Gupta ,  Natarajan Chennimalai Kumar ,  Anthony Joseph Vinciquerra ,  Laura Cerully Dial ,  Voramon Supatarawanich Dheeradhada ,  Timothy Hanlon ,  Lembit Salasoo ,  Xiaohu Ping ,  Subhrajit Roychowdhury ,  Justin John Gambone

IPC: B29C64/153 ,  B22F10/20 ,  B22F10/31 ,  B22F10/85 ,  B29C64/393 ,  B33Y50/00 ,  B22F3/24 ,  B22F10/28 ,  B22F10/30 ,  B22F10/366 ,  B22F12/90 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B33Y50/02

CPC classification number: B29C64/153 ,  B22F10/20 ,  B22F10/31 ,  B22F10/85 ,  B29C64/393 ,  B33Y50/00 ,  B22F2003/245 ,  B22F10/28 ,  B22F10/30 ,  B22F10/366 ,  B22F12/90 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00 ,  B33Y50/02

Abstract: According to some embodiments, system and methods are provided comprising receiving, via a communication interface of a parameter development module comprising a processor, a defined geometry for one or more parts, wherein the parts are manufactured with an additive manufacturing machine, and wherein a stack is formed from one or more parts; fabricating the one or more parts with the additive manufacturing machine based on a first parameter set; collecting in-situ monitoring data from one or more in-situ monitoring systems of the additive manufacturing machine for one or more parts; determining whether each stack should receive an additional part based on an analysis of the collected in-situ monitoring data; and fabricating each additional part based on the determination the stack should receive the additional part. Numerous other aspects are provided.

公开(公告)号：US20240113570A1

公开(公告)日：2024-04-04

申请号：US18467768

申请日：2023-09-15

Applicant: General Electric Company

Inventor： Shenyan Huang ,  Laura Cerully Dial ,  Wanming Zhang ,  Steve John Buresh

IPC: H02K1/02 ,  C22C38/00 ,  H01F1/147

CPC classification number: H02K1/02 ,  C22C38/001 ,  H01F1/14733

Abstract: Dual-phase magnetic components include an intermixed first region and second region formed from a single material, wherein the first region includes a magnetic ferrous composition, and wherein the second region includes a non-magnetic austenite composition and a dispersion of nitride precipitates.

公开(公告)号：US10801088B2

公开(公告)日：2020-10-13

申请号：US16221452

申请日：2018-12-15

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Laura Cerully Dial ,  Michael Francis Xavier Gigliotti, Jr.

IPC: C22C19/05 ,  C22F1/10 ,  B23K26/342 ,  B23K26/00 ,  C22C1/04 ,  B33Y80/00 ,  B22F3/105 ,  H01F1/147 ,  B33Y10/00 ,  B23K103/08

Abstract: Methods of forming an intermediate alloy and a Ni-base super alloy are disclosed along with the intermediate alloy and the Ni-base super alloy formed by the method. The method includes at least partially melting and solidifying a powder including about 5 to 15 wt. % of Co, 10 to 20 wt. % of Cr, 3 to 6 wt. % of Mo, 3 to 6 wt. % of W, 2 to 4 wt. % of Al, 4.2 to 4.7 wt. % of Ti, 0.01 to 0.05 wt. % of Zr, 0.015 to 0.060 wt. % of C, 0.001 to 0.030 wt. % of B and balance substantially Ni to form an intermediate alloy including a dendrite structure that includes columnar regions and intercolumnar regions and a primary dendrite arm spacing less than about 3 micrometers. The intermediate alloy is heat-treated to form the texture-free Ni-base super alloy.

公开(公告)号：US10190206B2

公开(公告)日：2019-01-29

申请号：US15460650

申请日：2017-03-16

Applicant: General Electric Company

Inventor： Laura Cerully Dial ,  Richard DiDomizio ,  Francis Johnson

IPC: H02K15/12 ,  H02K19/02 ,  H01F1/147 ,  H01F7/02 ,  C23C8/04 ,  C21D9/00 ,  C23C8/26 ,  H02K19/10 ,  C22C38/38 ,  C21D1/06 ,  C21D1/26

Abstract: A magnetic component having intermixed first and second regions, and a method of preparing that magnetic component are disclosed. The first region includes a magnetic phase and the second region includes a non-magnetic phase. The method includes mechanically masking pre-selected sections of a surface portion of the component by using a nitrogen stop-off material and heat-treating the component in a nitrogen-rich atmosphere at a temperature greater than about 900° C. Both the first and second regions are substantially free of carbon, or contain only limited amounts of carbon; and the second region includes greater than about 0.1 weight % of nitrogen.

公开(公告)号：US20180326712A1

公开(公告)日：2018-11-15

申请号：US15595178

申请日：2017-05-15

Applicant: General Electric Company

Inventor： Kamala Chakravarthy Raghavan ,  Meisam Salahshoor Pirsoltan ,  Laura Cerully Dial ,  Victor Petrovich Ostroverkhov

IPC: B33Y50/02 ,  B29C67/00

CPC classification number: B33Y50/02 ,  B29C64/153 ,  B29C64/214 ,  B29C64/393 ,  B29K2105/251 ,  B33Y10/00 ,  B33Y30/00

Abstract: A control system for use in an additive manufacturing system. A recoating device is configured to distribute powder for forming a component and a recoating motor is configured to move at least one of the powder bed and the recoating device relative to each other. The control system includes at least one vibration sensor configured to collect vibration data, a torque sensor coupled to the recoating motor and configured to collect the torque output data, and an optical sensor configured to collect reflected light data. The control system includes a controller configured to receive the vibration data, receive the torque output data, and receive the reflected light data, the controller further configured to determine at least one powder bed characteristic based on at least one of the data, and control at least one recoating parameter of the recoating device based on the at least one determined powder bed characteristic.

公开(公告)号：US20220001603A1

公开(公告)日：2022-01-06

申请号：US17477112

申请日：2021-09-16

Applicant: General Electric Company

Inventor： Scott Michael Oppenheimer ,  Anthony Joseph Vinciquerra ,  Laura Cerully Dial

IPC: B29C64/153 ,  B33Y10/00 ,  B33Y30/00 ,  B29C64/393 ,  B33Y70/00 ,  B29C64/295 ,  B33Y50/02 ,  B29C64/40 ,  B29C64/205 ,  B33Y40/00 ,  B29C64/336

Abstract: A method for fabricating a component of with an additive manufacturing system include entraining a first portion of first material particles in an airflow generated by a vacuum source and engaging the first portion of the first material particles against an air permeable screen. The first portion of the first material particles is deposited onto a build platform. The method also includes entraining a second portion of second material particles in the airflow and engaging the second portion of the second material particles against the air permeable screen. The second portion of the second material particles is deposited onto the build platform. An energy source transfers heat to at least a portion of at least one of the first portion of the first material particles or the second portion of the second material particles to facilitate consolidating material particles to fabricate the component.

公开(公告)号：US11118268B2

公开(公告)日：2021-09-14

申请号：US16205926

申请日：2018-11-30

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Wusheng Xu ,  Laura Cerully Dial ,  Lawrence Bernard Kool ,  Dalong Zhong ,  Hong Zhou

IPC: H01L21/3213 ,  H01L21/3205 ,  H01L21/02 ,  C23F1/20 ,  C23F1/16 ,  C23F1/14 ,  C23F1/10 ,  C23F1/00 ,  C23C26/00 ,  C23C10/60 ,  C23C10/48 ,  B33Y40/00

Abstract: A surface of an article is modified by aluminizing an initial surface at a first temperature to form a first aluminized layer and a sublayer, removing at least a portion of the first aluminized layer, aluminizing the sublayer at a second temperature to form a second aluminized layer, and finally removing at least a portion of the second aluminized layer to form a processed surface. The second temperature is less than the first temperature and a roughness of the processed surface is less than the roughness of the initial surface.

公开(公告)号：US10758976B2

公开(公告)日：2020-09-01

申请号：US15629313

申请日：2017-06-21

Applicant: General Electric Company

Inventor： Laura Cerully Dial ,  Andrew David Deal ,  Timothy Hanlon

IPC: B22F1/00 ,  B22F9/02 ,  B33Y70/00 ,  B33Y40/00 ,  B22F3/105 ,  B33Y10/00

Abstract: A method of processing a powdered feedstock to form a fabricated component is provided. The fabricated component includes a plurality of grains having a nominal grain size. The method includes providing the powdered feedstock material having a population of phase particulates with a first nominal size distribution disposed within a host matrix material. The method includes building a consolidated component from the powdered feedstock material in an additive manufacturing process, and fabricating the fabricated component from the consolidated component. The first nominal size distribution of the population of phase particulates is sized such that at least a portion of the population of phase particulates persists throughout the additive manufacturing process and is present as a processed population of phase particulates in the consolidated component. In addition, the processed population of phase particulates has a second nominal size distribution effective to produce the nominal grain size of the fabricated component.

公开(公告)号：US20180369907A1

公开(公告)日：2018-12-27

申请号：US15629313

申请日：2017-06-21

Applicant: General Electric Company

Inventor： Laura Cerully Dial ,  Andrew David Deal ,  Timothy Hanlon

IPC: B22F1/00 ,  B22F9/02 ,  B33Y70/00

Abstract: A method of processing a powdered feedstock to form a fabricated component is provided. The fabricated component includes a plurality of grains having a nominal grain size. The method includes providing the powdered feedstock material having a population of phase particulates with a first nominal size distribution disposed within a host matrix material. The method includes building a consolidated component from the powdered feedstock material in an additive manufacturing process, and fabricating the fabricated component from the consolidated component. The first nominal size distribution of the population of phase particulates is sized such that at least a portion of the population of phase particulates persists throughout the additive manufacturing process and is present as a processed population of phase particulates in the consolidated component. In addition, the processed population of phase particulates has a second nominal size distribution effective to produce the nominal grain size of the fabricated component.

公开(公告)号：US20180188144A1

公开(公告)日：2018-07-05

申请号：US15397520

申请日：2017-01-03

Applicant: General Electric Company

Inventor： Andrew David Deal ,  Timothy Hanlon ,  Vipul Kumar Gupta ,  Erica Elizabeth Sampson ,  Justin John Gambone, JR. ,  Scott Michael Oppenheimer ,  Laura Cerully Dial

IPC: G01N3/10 ,  G01N3/18 ,  B29C67/00 ,  B33Y40/00 ,  B33Y50/00

CPC classification number: G01N3/10 ,  B29C64/386 ,  B33Y40/00 ,  B33Y50/00 ,  G01N3/08 ,  G01N3/18 ,  G01N3/32

Abstract: An apparatus and method for rapid screening of material properties in a plurality of additively manufactured test specimens. The apparatus includes a build plate having the plurality of additively manufactured test specimens disposed on a first substantially planar surface. The plurality of additively manufactured test specimens are coupled to at least one actuator to one of individually or simultaneously translationally displace each of the test specimens along an axis “z”, and perpendicular to the build plane of the build plate to test material properties of each of the plurality of additively manufactured test specimens. A sensor is coupled to each of the plurality of additively manufactured test specimens. Load vs. displacement data may be used to monitor the progression of monotonic and/or cyclic tests of the plurality of additively manufactured test specimens.