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：US10086567B2

公开(公告)日：2018-10-02

申请号：US14789350

申请日：2015-07-01

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Michael Evans Graham ,  John Broddus Deaton, Jr. ,  Mark Allen Cheverton ,  Thomas Charles Adcock ,  Andrew David Deal ,  Marshall Gordon Jones ,  Prabhjot Singh

IPC: B29C67/00 ,  B22F5/10 ,  B22F7/06 ,  B22F7/08 ,  G05B19/4099 ,  B29C64/153 ,  B29C64/386 ,  B29C64/40 ,  B22F3/105 ,  B23K101/04 ,  B33Y50/02

Abstract: A method that includes additively manufacturing with an additive manufacturing (AM) system a sub-component that has a locator element. Using a control system of the AM system for positioning a first location of the locator element. Selectively placing a portion of another sub-component adjacent to the locator element, based on the positioning. Then attaching the second sub-component to the first sub-component in a region, wherein the region is based on the positioning knowledge from the control system so as to make a component. A component that comprises a first sub-component that has an AM locator element; and a second sub-component attached to the first sub-component, wherein the locator element is attached to the second sub-component within the same additive manufacturing build chamber as the first sub-component.

公开(公告)号：US20210268789A1

公开(公告)日：2021-09-02

申请号：US17314606

申请日：2021-05-07

Applicant: General Electric Company

Inventor： Marshall Gordon Jones ,  William Thomas Carter ,  James William Sears

IPC: B33Y30/00 ,  B28B1/00 ,  B29C73/00 ,  B23K26/06 ,  B33Y10/00 ,  B23K26/073 ,  B23K26/34 ,  B29C73/34 ,  B22F5/00 ,  B29C64/153 ,  G02B6/42 ,  B29C64/277 ,  B29C64/268 ,  B29C64/282 ,  B29C64/20 ,  B22F12/00

Abstract: A method of forming a build in a powder bed includes emitting a plurality of laser beams from selected fibers of a diode laser fiber array onto the powder bed, the selected fibers of the array corresponding to a pattern of a layer of the build; and simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build. An apparatus for forming a build in a powder bed includes a diode laser fiber array including a plurality of diode lasers and a plurality of optical fibers corresponding to the plurality of diode lasers, each optical fiber configured to receive a laser beam from a respective diode laser and configured to emitting the laser beam; a support configured to support a powder bed or a component configured to support the powder bed at a distance from ends of the optical fibers; and a controller configured to control the diode laser fiber array to emit a plurality of laser beams from selected fibers of the diode laser fiber array onto the powder bed, the selected fibers of the array corresponding to a pattern of a layer of the build and simultaneously melt the powder in the powder bed corresponding to the pattern of the layer of the build.

公开(公告)号：US11027536B2

公开(公告)日：2021-06-08

申请号：US16743325

申请日：2020-01-15

Applicant: General Electric Company

Inventor： Marshall Gordon Jones ,  William Thomas Carter ,  James William Sears

IPC: B33Y30/00 ,  B28B1/00 ,  B29C73/00 ,  B23K26/06 ,  B33Y10/00 ,  B23K26/073 ,  B23K26/34 ,  B29C73/34 ,  B22F5/00 ,  B29C64/153 ,  G02B6/42 ,  B29C64/277 ,  B29C64/268 ,  B29C64/282 ,  B29C64/20 ,  B22F12/00 ,  B29K105/00 ,  B29L31/08 ,  B23P6/00 ,  B23K101/00 ,  B22F10/10

Abstract: A method of forming a build in a powder bed includes emitting a plurality of laser beams from selected fibers of a diode laser fiber array onto the powder bed, the selected fibers of the array corresponding to a pattern of a layer of the build; and simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build. An apparatus for forming a build in a powder bed includes a diode laser fiber array including a plurality of diode lasers and a plurality of optical fibers corresponding to the plurality of diode lasers, each optical fiber configured to receive a laser beam from a respective diode laser and configured to emitting the laser beam; a support configured to support a powder bed or a component configured to support the powder bed at a distance from ends of the optical fibers; and a controller configured to control the diode laser fiber array to emit a plurality of laser beams from selected fibers of the diode laser fiber array onto the powder bed, the selected fibers of the array corresponding to a pattern of a layer of the build and simultaneously melt the powder in the powder bed corresponding to the pattern of the layer of the build.

公开(公告)号：US20200223212A1

公开(公告)日：2020-07-16

申请号：US16743325

申请日：2020-01-15

Applicant: General Electric Company

Inventor： Marshall Gordon Jones ,  William Thomas Carter ,  James William Sears

IPC: B33Y30/00 ,  B28B1/00 ,  B29C73/00 ,  B23K26/06 ,  B33Y10/00 ,  B22F3/105 ,  B23K26/073 ,  B23K26/34 ,  B29C73/34 ,  B22F5/00 ,  B29C64/153 ,  B29C64/20 ,  G02B6/42 ,  B29C64/277

Abstract: A method of forming a build in a powder bed includes emitting a plurality of laser beams from selected fibers of a diode laser fiber array onto the powder bed, the selected fibers of the array corresponding to a pattern of a layer of the build; and simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build. An apparatus for forming a build in a powder bed includes a diode laser fiber array including a plurality of diode lasers and a plurality of optical fibers corresponding to the plurality of diode lasers, each optical fiber configured to receive a laser beam from a respective diode laser and configured to emitting the laser beam; a support configured to support a powder bed or a component configured to support the powder bed at a distance from ends of the optical fibers; and a controller configured to control the diode laser fiber array to emit a plurality of laser beams from selected fibers of the diode laser fiber array onto the powder bed, the selected fibers of the array corresponding to a pattern of a layer of the build and simultaneously melt the powder in the powder bed corresponding to the pattern of the layer of the build.

公开(公告)号：US10569525B2

公开(公告)日：2020-02-25

申请号：US16419657

申请日：2019-05-22

Applicant: General Electric Company

Inventor： Marshall Gordon Jones ,  William Thomas Carter ,  James William Sears

IPC: B33Y30/00 ,  B28B1/00 ,  B29C73/00 ,  B23K26/06 ,  B33Y10/00 ,  B22F3/105 ,  B23K26/073 ,  B23K26/34 ,  B29C73/34 ,  B22F5/00 ,  B29C64/153 ,  B29C64/20 ,  G02B6/42 ,  B29C64/277 ,  B29K105/00 ,  B29L31/08 ,  B23P6/00 ,  B23K101/00

Abstract: A method of forming a build in a powder bed includes emitting a plurality of laser beams from selected fibers of a diode laser fiber array onto the powder bed, the selected fibers of the array corresponding to a pattern of a layer of the build; and simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build. An apparatus for forming a build in a powder bed includes a diode laser fiber array including a plurality of diode lasers and a plurality of optical fibers corresponding to the plurality of diode lasers, each optical fiber configured to receive a laser beam from a respective diode laser and configured to emitting the laser beam; a support configured to support a powder bed or a component configured to support the powder bed at a distance from ends of the optical fibers; and a controller configured to control the diode laser fiber array to emit a plurality of laser beams from selected fibers of the diode laser fiber array onto the powder bed, the selected fibers of the array corresponding to a pattern of a layer of the build and simultaneously melt the powder in the powder bed corresponding to the pattern of the layer of the build.

公开(公告)号：US20180193955A1

公开(公告)日：2018-07-12

申请号：US15401643

申请日：2017-01-09

Applicant: General Electric Company

Inventor： Jason Harris Karp ,  Justin John Gambone, JR. ,  Michael Evans Graham ,  David Charles Bogdan, JR. ,  Victor Petrovich Ostroverkhov ,  William Thomas Carter ,  Harry Kirk Mathews, JR. ,  Kevin George Harding ,  Jinjie Shi ,  Marshall Gordon Jones ,  James William Sears

IPC: B23K26/342

CPC classification number: B23K26/342 ,  B22F3/1055 ,  B22F2003/1056 ,  B22F2301/00 ,  B23K2103/04 ,  B29C64/153 ,  B29C64/282 ,  B33Y30/00 ,  Y02P10/295

Abstract: A component is fabricated in a powder bed by moving a laser array across the powder bed. The laser array includes a plurality of laser devices. The power output of each laser device of the plurality of laser devices is independently controlled. The laser array emits a plurality of energy beams from a plurality of selected laser devices of the plurality of laser devices to generate a melt pool in the powder bed. A non-uniform energy intensity profile is generated by the plurality of selected laser devices. The non-uniform energy intensity profile facilitates generating a melt pool that has a predetermined characteristic.

公开(公告)号：US20170001374A1

公开(公告)日：2017-01-05

申请号：US14789350

申请日：2015-07-01

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Michael Evans Graham ,  John Broddus Deaton, JR. ,  Mark Allen Cheverton ,  Thomas Charles Adcock ,  Andrew David Deal ,  Marshall Gordon Jones ,  Prabhjot Singh

IPC: B29C67/00 ,  G05B19/4099

CPC classification number: B29C67/0088 ,  B22F3/1055 ,  B22F5/10 ,  B22F7/062 ,  B22F7/08 ,  B22F2003/1058 ,  B23K26/206 ,  B23K26/342 ,  B23K2101/04 ,  B23K2101/12 ,  B29C64/153 ,  B29C64/386 ,  B29C64/40 ,  B33Y50/02 ,  G05B19/4099 ,  G05B2219/35134 ,  G05B2219/49007 ,  Y02P10/295

Abstract: A method that includes additively manufacturing with an additive manufacturing (AM) system a sub-component that has a locator element. Using a control system of the AM system for positioning a first location of the locator element. Selectively placing a portion of another sub-component adjacent to the locator element, based on the positioning. Then attaching the second sub-component to the first sub-component in a region, wherein the region is based on the positioning knowledge from the control system so as to make a component. A component that comprises a first sub-component that has an AM locator element; and a second sub-component attached to the first sub-component, wherein the locator element is attached to the second sub-component within the same additive manufacturing build chamber as the first sub-component.

Abstract translation: 一种包括用附加制造（AM）系统对具有定位器元件的子部件进行附加制造的方法。 使用AM系统的控制系统来定位定位器元件的第一个位置。 基于定位，选择性地将另一个子部件的一部分与定位器元件相邻。 然后将第二子组件附接到区域中的第一子组件，其中该区域基于来自控制系统的定位知识，以便构成组件。 一种组件，包括具有AM定位器元素的第一子组件; 以及附接到所述第一子部件的第二子部件，其中所述定位元件在与所述第一子部件相同的添加剂制造构建室内附接到所述第二子部件。

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.