公开(公告)号：US20180250770A1

公开(公告)日：2018-09-06

申请号：US15449536

申请日：2017-03-03

Applicant: General Electric Company

Inventor： Michael Evans Graham ,  Lang Yuan

IPC: B23K26/342 ,  B33Y50/02 ,  B33Y30/00 ,  B33Y10/00 ,  B23K26/06 ,  B23K26/082

Abstract: A controller for use in an additive manufacturing system including at least one laser device configured to generate at least one melt pool in powdered material including a processing device and a memory device. The controller is configured to generate at least one control signal to control a power output of the at least one laser device throughout at least one scan path across the layer of powdered material, the scan path generated at least partially based on a functional relationship between a plurality of points of a generating path and each point of a plurality of points of the scan path. The controller is further configured to generate a non-uniform energy intensity profile for the scan path, and transmit the control signal to the laser device to emit at least one laser beam to generate at least one melt pool.

公开(公告)号：US20180193954A1

公开(公告)日：2018-07-12

申请号：US15400525

申请日：2017-01-06

Applicant: General Electric Company

Inventor： Lang Yuan ,  Ning Zhou

IPC: B23K26/342 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B33Y70/00 ,  B22F3/105 ,  B23K26/08 ,  B23K26/10 ,  B23K26/70

Abstract: An additive manufacturing system includes a powder bed and at least one energy source configured to produce at least one energy beam for forming a build layer of a component from the powder bed. The additive manufacturing system further includes a computing device coupled to the at least one energy source. The computing device includes a processor and a memory device. The memory device includes instructions configured to cause the computing device to execute a manufacturing plan for manufacturing the component, receive component thermal data corresponding to at least a portion of the component during manufacturing of the component, and control the at least one energy beam in response to receiving the component thermal data to produce a predetermined microstructure within the portion of the component.

公开(公告)号：US20230030701A1

公开(公告)日：2023-02-02

申请号：US17964366

申请日：2022-10-12

Applicant: General Electric Company

Inventor： William Thomas Carter ,  Justin John Gambone, JR. ,  Lang Yuan ,  David Charles Bogdan, JR. ,  Marshall Gordon Jones

IPC: B23K26/142 ,  B33Y10/00 ,  B33Y30/00 ,  B23K26/342 ,  B29C64/371 ,  B29C64/153 ,  B23K26/06 ,  B22F12/00

Abstract: An additive manufacturing system including a housing configured to contain a powder bed of material, and an array of laser emitters having a field of view. The array is configured to melt at least a portion of the powder bed within the field of view as the array translates relative to the powder bed. The system further includes a spatter collection device including a diffuser configured to discharge a stream of gas across the powder bed, and a collector configured to receive the stream of gas and contaminants entrained in the stream of gas. The collector is spaced from the diffuser such that a collection zone is defined therebetween, and the spatter collection device is configured to translate relative to the powder bed such that the collection zone overlaps with the field of view of the array.

公开(公告)号：US20180281113A1

公开(公告)日：2018-10-04

申请号：US15476498

申请日：2017-03-31

Applicant: General Electric Company

Inventor： William Thomas Carter ,  Jason Harris Karp ,  Justin John Gambone, JR. ,  Lang Yuan ,  David Charles Bogdan, JR. ,  Victor Petrovish Ostroverkhov ,  Marshall Gordon Jones ,  Michael Evans Graham ,  Kevin George Harding

IPC: B23K26/342 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B23K26/082 ,  B23K26/08 ,  B23K26/144

Abstract: An additive manufacturing system configured to manufacture a component including scan strategies for efficient utilization of one or more laser arrays. The additive manufacturing system includes at least one laser device, each configured as a laser array, and a build platform. Each laser device is configured to generate a plurality of laser beams. The component is disposed on the build platform. The at least one laser device is configured to sweep across the component and the build platform in at least one of a radial direction, a circumferential direction or a modified zig-zag pattern and simultaneously operate the one or more of the plurality of individually operable laser beams corresponding to a pattern of the layer of a build to generate successive layers of a melted powdered material on the component and the build platform corresponding to the pattern of the layer of the build. A method of manufacturing a component with the additive manufacturing system is also disclosed.

公开(公告)号：US12059748B2

公开(公告)日：2024-08-13

申请号：US17964366

申请日：2022-10-12

Applicant: General Electric Company

Inventor： William Thomas Carter ,  Justin John Gambone, Jr. ,  Lang Yuan ,  David Charles Bogdan, Jr. ,  Marshall Gordon Jones

IPC: B23K26/142 ,  B22F10/10 ,  B22F10/28 ,  B22F10/322 ,  B22F10/36 ,  B22F10/37 ,  B22F10/77 ,  B22F12/00 ,  B22F12/45 ,  B22F12/46 ,  B22F12/70 ,  B23K26/06 ,  B23K26/342 ,  B29C64/153 ,  B29C64/371 ,  B33Y10/00 ,  B33Y30/00

CPC classification number: B23K26/142 ,  B22F10/28 ,  B22F10/322 ,  B22F10/37 ,  B22F10/77 ,  B22F12/00 ,  B22F12/45 ,  B22F12/46 ,  B22F12/70 ,  B23K26/0604 ,  B23K26/342 ,  B29C64/153 ,  B29C64/371 ,  B33Y10/00 ,  B33Y30/00 ,  B22F10/10 ,  B22F10/36 ,  B22F2201/00 ,  B22F2201/10 ,  B22F2999/00 ,  Y02P10/25 ,  B22F2999/00 ,  B22F12/45 ,  B22F12/46 ,  B22F12/70 ,  B22F2201/00

Abstract: An additive manufacturing system including a housing configured to contain a powder bed of material, and an array of laser emitters having a field of view. The array is configured to melt at least a portion of the powder bed within the field of view as the array translates relative to the powder bed. The system further includes a spatter collection device including a diffuser configured to discharge a stream of gas across the powder bed, and a collector configured to receive the stream of gas and contaminants entrained in the stream of gas. The collector is spaced from the diffuser such that a collection zone is defined therebetween, and the spatter collection device is configured to translate relative to the powder bed such that the collection zone overlaps with the field of view of the array.

公开(公告)号：US11484970B2

公开(公告)日：2022-11-01

申请号：US15438326

申请日：2017-02-21

Applicant: General Electric Company

Inventor： William Thomas Carter ,  Justin John Gambone, Jr. ,  Lang Yuan ,  David Charles Bogdan, Jr. ,  Marshall Gordon Jones

IPC: B23K26/142 ,  B33Y10/00 ,  B33Y30/00 ,  B23K26/342 ,  B29C64/371 ,  B29C64/153 ,  B23K26/06 ,  B22F12/00 ,  B22F10/10

Abstract: An additive manufacturing system including a housing configured to contain a powder bed of material, and an array of laser emitters having a field of view. The array is configured to melt at least a portion of the powder bed within the field of view as the array translates relative to the powder bed. The system further includes a spatter collection device including a diffuser configured to discharge a stream of gas across the powder bed, and a collector configured to receive the stream of gas and contaminants entrained in the stream of gas. The collector is spaced from the diffuser such that a collection zone is defined therebetween, and the spatter collection device is configured to translate relative to the powder bed such that the collection zone overlaps with the field of view of the array.

公开(公告)号：US11020955B2

公开(公告)日：2021-06-01

申请号：US16704831

申请日：2019-12-05

Applicant: General Electric Company

Inventor： William Thomas Carter ,  Marshall Gordon Jones ,  Lang Yuan ,  Ning Zhou ,  Steven Jude Duclos

IPC: B33Y80/00 ,  B23K26/00 ,  B23P6/00 ,  B33Y10/00 ,  B29C73/34 ,  B33Y30/00 ,  B23K26/06 ,  B29C73/00 ,  B23K26/073 ,  B23K26/34 ,  B22F5/00 ,  B28B1/00 ,  F01D5/00 ,  B22F5/04 ,  C30B11/00 ,  C30B13/06 ,  C30B29/52 ,  C30B13/30 ,  C30B13/24 ,  C30B13/32 ,  B29C64/153 ,  G02B6/42 ,  B22F12/00 ,  B29L31/08 ,  B29K105/00 ,  B23K101/00 ,  B23K103/18 ,  B22F10/10

Abstract: A method of method of forming or repairing a superalloy article having a columnar or equiaxed or directionally solidified or amorphous or single crystal microstructure includes emitting a plurality of laser beams from selected fibers of a diode laser fiber array corresponding to a pattern of a layer of the article onto a powder bed of the superalloy to form a melt pool; and controlling a temperature gradient and a solidification velocity of the melt pool to form the columnar or single crystal microstructure.

公开(公告)号：US10906132B2

公开(公告)日：2021-02-02

申请号：US15476498

申请日：2017-03-31

Applicant: General Electric Company

Inventor： William Thomas Carter ,  Jason Harris Karp ,  Justin John Gambone, Jr. ,  Lang Yuan ,  David Charles Bogdan, Jr. ,  Victor Petrovish Ostroverkhov ,  Marshall Gordon Jones ,  Michael Evans Graham ,  Kevin George Harding

IPC: B23K26/00 ,  B23K26/342 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B23K26/082 ,  B23K26/08 ,  B23K26/144 ,  B23K26/12 ,  B23K26/06 ,  B23K103/02 ,  B23K103/10 ,  B23K103/14 ,  B23K103/18

Abstract: An additive manufacturing system configured to manufacture a component including scan strategies for efficient utilization of one or more laser arrays. The additive manufacturing system includes at least one laser device, each configured as a laser array, and a build platform. Each laser device is configured to generate a plurality of laser beams. The component is disposed on the build platform. The at least one laser device is configured to sweep across the component and the build platform in at least one of a radial direction, a circumferential direction or a modified zig-zag pattern and simultaneously operate the one or more of the plurality of individually operable laser beams corresponding to a pattern of the layer of a build to generate successive layers of a melted powdered material on the component and the build platform corresponding to the pattern of the layer of the build. A method of manufacturing a component with the additive manufacturing system is also disclosed.

公开(公告)号：US10821512B2

公开(公告)日：2020-11-03

申请号：US15400525

申请日：2017-01-06

Applicant: General Electric Company

Inventor： Lang Yuan ,  Ning Zhou

IPC: B22F3/105 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02

Abstract: An additive manufacturing system includes a powder bed and at least one energy source configured to produce at least one energy beam for forming a build layer of a component from the powder bed. The additive manufacturing system further includes a computing device coupled to the at least one energy source. The computing device includes a processor and a memory device. The memory device includes instructions configured to cause the computing device to execute a manufacturing plan for manufacturing the component, receive component thermal data corresponding to at least a portion of the component during manufacturing of the component, and control the at least one energy beam in response to receiving the component thermal data to produce a predetermined microstructure within the portion of the component.

公开(公告)号：US10814429B2

公开(公告)日：2020-10-27

申请号：US15881147

申请日：2018-01-26

Applicant: General Electric Company

Inventor： Subhrajit Roychowdhury ,  Matthias Hoebel ,  Lang Yuan ,  Prabhjot Singh ,  Michael Evans Graham ,  Robert John Filkins ,  Thomas Etter ,  Felix Martin Gerhard Roerig

IPC: B23K26/342 ,  B23K26/02 ,  B23K26/06 ,  B23K26/064 ,  B23K26/08 ,  B23K26/082 ,  B33Y50/02 ,  B33Y10/00 ,  B33Y30/00 ,  B22F3/105

Abstract: An additive manufacturing system includes a laser device, a build plate, and a scanning device. The laser device is configured to generate a laser beam with a variable intensity. The build plate is configured to support a powdered build material. The scanning device is configured to selectively direct the laser beam across the powdered build material to generate a melt pool on the build plate. The scanning device is configured to oscillate a spatial position of the laser beam while the laser device is configured to simultaneously modulate the intensity of the laser beam to thermally control the melt pool.