Additive manufacturing system utilizing an epitaxy process and method of operation
AssigneeUnited Technologies Corporation
InventorsThomas N. Slavens, Thomas J. Martin, Alexander Staroselsky, Sergey Mironets, Brooks E. Snyder, Mark F. Zelesky
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Abstract
An additive manufacturing system utilizing an epitaxy process, and method of manufacture, utilizes a heating source and a cooling source to control thermal gradients and a solidification rate of each slice of a workpiece manufactured from a seed having a directional grain microstructure. An energy gun is utilized to melt selected regions of each successive layer of a plurality layers of a powder in a powder bed to successively form each solidified slice of the workpiece.
Claims20
A method of additive manufacturing a workpiece comprising the steps of:
- providing a seed for propagating grain microstructure growth;
- covering the seed with a plurality of layers of a powder bed of a material capable of grain structure growth;
- melting at least in-part each successive layer of the plurality of layers utilizing an energy gun;
- controlling a solidification rate of each melted successive layer utilizing a cooling source located below the layer;
- forming a solidified slice of the workpiece such that a grain structure of the seed propagates through the solidified slice;
- and
- proceeding to the next successive layer.
An additive manufacturing system for manufacturing a workpiece in successive slices, the system comprising:
- a build table constructed and arranged to move vertically and support a powder bed and a seed for propagating microstructure grain growth;
- an energy gun for selectively melting a layer of the powder bed placed above the seed;
- a cooling source disposed below the layer and constructed and arranged to control at least a solidification rate of the melted layer;
- and
- a heating source disposed above the powder bed for at least controlling a temperature gradient of the melted layer.
Dependencies are inferred from the claim text.