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：US10583530B2

公开(公告)日：2020-03-10

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 ,  B33Y30/00 ,  B22F3/105 ,  B29C64/153 ,  B29C64/282 ,  B23K103/04

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：US20190283392A1

公开(公告)日：2019-09-19

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

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：US20190143406A1

公开(公告)日：2019-05-16

申请号：US15810308

申请日：2017-11-13

Applicant: General Electric Company

Inventor： William Thomas Carter ,  David Charles Bogdan, JR. ,  Jason Harris Karp ,  Justin John Gambone, JR. ,  Victor Petrovich Ostroverkhov ,  Marshall Gordon Jones ,  Kevin George Harding ,  Younkoo Jeong ,  Michael Robert Tucker ,  Subhrajit Roychowdhury

IPC: B22F3/00 ,  B22F3/105 ,  B29C64/153 ,  B29C64/245 ,  B29C64/386

Abstract: An additive manufacturing apparatus includes first and second spaced apart side walls defining a build chamber therebetween. The first and second spaced apart side walls are configured to rotate through an angle θ, about a z-axis along a pre-defined path. A build platform is defined within the first and second spaced apart side walls and is configured to rotate through an angle θ about the z-axis and vertically moveable along the z-axis. The apparatus further includes one or more build units mounted for movement along the pre-defined path. An additive manufacturing method is additionally disclosed.