公开(公告)号：US11679551B2

公开(公告)日：2023-06-20

申请号：US16289076

申请日：2019-02-28

Applicant: General Electric Company

Inventor： Brian Scott McCarthy ,  Dean Andrew Snelling, Jr. ,  Thomas Adcock ,  Donnell Crear ,  Michael Evans Graham

IPC: B33Y50/02 ,  B29C64/153 ,  B29C64/393 ,  B29C64/268 ,  B22F10/20 ,  B22F12/90 ,  B22F10/31 ,  B33Y10/00 ,  B33Y30/00 ,  B22F12/45 ,  B22F12/49 ,  B22F12/60

CPC classification number: B33Y50/02 ,  B22F10/20 ,  B22F10/31 ,  B22F12/90 ,  B29C64/153 ,  B29C64/268 ,  B29C64/393 ,  B22F12/45 ,  B22F12/49 ,  B22F12/60 ,  B33Y10/00 ,  B33Y30/00

Abstract: A system for additive manufacturing machine energy beam alignment error compensation includes, a calibration table having x-y planar offsets to correct laser alignment errors representing energy beam positional offsets between beam-steering commanded energy beam locations and fiducial marks generated on a burn-paper, a recoater mechanism that distributes successive layers of powder, one or more sensors monitoring the powderbed surface proximal to the beam scan unit, and a processor unit configured to perform a method. The method including collecting sensor data representing height variations across at least a portion of the powderbed surface, deriving dimensional data from the collected data, analyzing the dimensional data to determine a distribution of differences between the powderbed surface and a reference plane containing the burn-paper when the fiducial marks were generated, and calculating z-axis calibration offset points for inclusion in the calibration table x-y planar offsets. A method and a non-transitory medium are also disclosed.

公开(公告)号：US11090861B2

公开(公告)日：2021-08-17

申请号：US16046693

申请日：2018-07-26

Applicant: General Electric Company

Inventor： Michael Evans Graham ,  William Thomas Carter ,  John Broddus Deaton, Jr. ,  John Joseph Madelone, Jr. ,  Thomas Charles Adcock ,  Matthias Hoebel ,  Subhrajit Roychowdhury

IPC: B29C64/153 ,  B33Y10/00 ,  B33Y30/00 ,  B23K26/342 ,  B29C64/20 ,  B29C64/393 ,  B28B1/00 ,  B33Y50/02 ,  C03B19/01

Abstract: An additive manufacturing system includes a build platform, a plurality of particles positioned on the build platform defining a build layer, a first and second region within the build layer, and at least one consolidation device. The first region and the second region each including a portion of the plurality of particles. The at least one consolidation device is configured to consolidate the plurality of particles within the build layer into a solid, consolidated portion of said build layer. The consolidation device is further configured to consolidate at least one of the plurality of particles within the build layer and the solid, consolidated portion of the build layer into a molten volume of transfer material. The consolidation device is further configured to transfer a portion of the molten volume of transfer material within the first region from the first region to the second region.

公开(公告)号：US10821551B2

公开(公告)日：2020-11-03

申请号：US15881054

申请日：2018-01-26

Applicant: General Electric Company

Inventor： Subhrajit Roychowdhury ,  Matthias Hoebel ,  Michael Evans Graham ,  Robert John Filkins ,  Felix Martin Gerhard Roerig ,  Donnell Eugene Crear ,  Prabhjot Singh

IPC: B23K26/342 ,  B23K26/06 ,  B23K26/08 ,  B23K26/073 ,  B23K26/082 ,  B33Y50/02 ,  B33Y10/00 ,  B33Y30/00 ,  B22F3/105 ,  B22F3/00

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 simultaneously modulates the intensity of the laser beam to facilitate reducing spatter and to facilitate reducing a temperature of the melt pool to reduce overheating of the melt pool.

公开(公告)号：US10821508B2

公开(公告)日：2020-11-03

申请号：US13968184

申请日：2013-08-15

Applicant: General Electric Company

Inventor： Mark Allen Cheverton ,  Michael Evans Graham ,  John Broddus Deaton, Jr. ,  Prabhjot Singh

IPC: B22F3/105 ,  B23K26/342 ,  B23K26/03 ,  B23K26/34

Abstract: A direct metal laser melting (DMLM) system for enhancing build parameters of a DMLM component includes a confocal optical system configured to measure at least one of a melt pool size and a melt pool temperature. The DMLM system further includes a computing device configured to receive at least one of the melt pool size or the melt pool temperature from the confocal optical system. Furthermore, the DMLM system includes a controller configured to control the operation of a laser device based on at least one build parameter.

公开(公告)号：US10695865B2

公开(公告)日：2020-06-30

申请号：US15449536

申请日：2017-03-03

Applicant: General Electric Company

Inventor： Michael Evans Graham ,  Lang Yuan

IPC: B23K26/02 ,  B23K26/08 ,  B23K26/34 ,  B23K26/342 ,  B23K26/06 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B23K26/082 ,  B29C64/393 ,  B29C64/268 ,  B23K26/00 ,  B22F3/105 ,  B23K26/03

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：US20190232428A1

公开(公告)日：2019-08-01

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 ,  B23K26/082 ,  B23K26/08

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.

公开(公告)号：US20190232427A1

公开(公告)日：2019-08-01

申请号：US15881054

申请日：2018-01-26

Applicant: General Electric Company

Inventor： Subhrajit Roychowdhury ,  Matthias Hoebel ,  Michael Evans Graham ,  Robert John Filkins ,  Felix Martin Gerhard Roerig ,  Donnell Eugene Crear ,  Prabhjot Singh

IPC: B23K26/342 ,  B23K26/073 ,  B23K26/06 ,  B23K26/082 ,  B23K26/08

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 simultaneously modulates the intensity of the laser beam to facilitate reducing spatter and to facilitate reducing a temperature of the melt pool to reduce overheating of the melt pool.

公开(公告)号：US20190001658A1

公开(公告)日：2019-01-03

申请号：US15638966

申请日：2017-06-30

Applicant: General Electric Company

Inventor： Harry Kirk Mathews, JR. ,  Michael Evans Graham ,  Pinghai Yang ,  Tyler Nelson

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

Abstract: A computer-enabled device for dynamically creating or modifying at least a portion of an additive manufacturing build for making a part is provided. The device is in direct or indirect communication with one or more additive manufacturing machines that use one or more build parameters. The device is configured to analyze a plurality of build information pertaining to the part. The device is also configured to assess whether one or more differences between the pre-existing data and the non-pre-existing data will result in a deviation from, or improvement to, the part, the additive manufacturing build, or both and automatically create or modify, one or more of the build parameters of the part, at least a portion of the additive manufacturing build, or a combination thereof, based on the assessment of the one more differences.

公开(公告)号：US12103107B2

公开(公告)日：2024-10-01

申请号：US16515470

申请日：2019-07-18

Applicant: General Electric Company

Inventor： Brian Scott McCarthy ,  Eric Edward Halla ,  Thomas Charles Adcock ,  Michael Evans Graham ,  Andrea Marie Schmitz ,  Mark Samuel Bailey

IPC: B23K26/342 ,  B23K26/042 ,  B23K26/08 ,  B23K26/70 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02

CPC classification number: B23K26/342 ,  B23K26/042 ,  B23K26/0884 ,  B23K26/702 ,  B33Y30/00 ,  B33Y50/02 ,  B33Y10/00

Abstract: A method of aligning at least one laser beam of an additive manufacturing arrangement. The method includes measuring a surface of the calibration plate at a plurality of measurement points using the coordinate measuring machine. The method further includes generating a correction field based on the plurality of measurement points using the coordinate measuring machine. The method further includes writing at least one fiducial mark on the surface of the calibration plate using the at least one laser beam. The method further includes generating calibration data for the surface of the calibration plate using the calibration system. The method also includes aligning the laser beam within the additive manufacturing system based on the calibration data and the correction field using the computing device by comparing a position of the fiducial mark from the calibration data with the correction field to determine a corrected position of the laser beam.

公开(公告)号：US11247393B2

公开(公告)日：2022-02-15

申请号：US16426130

申请日：2019-05-30

Applicant: General Electric Company

Inventor： Juan Pablo Cilia ,  John Paul Davis ,  William Thomas Carter ,  Jared Micheal Iverson ,  Michael Robert Tucker ,  Michael Evans Graham ,  Edward James Nieters

IPC: B29C64/165 ,  B33Y10/00 ,  B33Y30/00 ,  B29C64/227 ,  B29C64/35 ,  B33Y40/00 ,  B29C64/214 ,  B29C64/393 ,  B33Y50/02

Abstract: Methods and systems for fabricating a component by consolidating a particulate include a build platform configured to receive a particulate, a particulate dispenser configured to deposit the particulate on the build platform, and at least one print head including at least one jet. The at least one print head is configured to dispense a binder through the at least one jet onto the particulate to consolidate at least a portion of the particulate and form a component. The methods and systems also include at least one actuator assembly configured to rotate at least one of the at least one print head and the build platform about a rotation axis extending through the build platform and move at least one of the at least one print head and the build platform in a build direction perpendicular to the build platform as part of a helical build process for the component.