# US 11,305,353 B2 · Method for additively manufacturing a tip structure on a pre-existing part

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- Number: US 11,305,353 B2
- Document ID: US11305353B2
- Status: Granted
- Kind: B2
- Application number: 16/630,112
- Filed: 2018-08-02
- Published: 2021-05-20
- Granted: 2022-04-19
- Earliest claimed: 2017-08-30
- Assignees: Siemens Energy Global GmbH & Co. KG
- Applicants: Siemens Energy Global GmbH & Co. KG
- Inventors: Ole Geisen; Yaroslav Lebed
- Web page: https://patentgrep.com/patent/US11305353B2

## CPC

- B23P 6/007: {using only additive methods, e.g. build-up welding}
- B22F 5/009: {of turbine components other than turbine blades (of turbine blades B22F5/04)}
- B22F 5/04: of turbine blades
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 10/31: Calibration of process steps or apparatus settings, e.g. before or during manufacturing
- B22F 12/22: {Driving means}
- B22F 12/222: {for motion along a direction orthogonal to the plane of a layer}
- B22F 12/224: {for motion along a direction within the plane of a layer}
- B22F 12/226: {for rotary motion}
- B22F 12/38: {Housings, e.g. machine housings}
- B23K 15/0086: {welding for purposes other than joining, e.g. build-up welding}
- B23K 26/342: Build-up welding
- B29C 70/76: Moulding on edges or extremities of the preformed part
- F01D 5/005: {Repairing methods or devices}
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- B23K 2101/001: {Turbines}
- B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- C04B 2235/6026: Computer aided shaping, e.g. rapid prototyping
- F05D 2230/31: Layer deposition
- F05D 2230/80: Repairing, retrofitting or upgrading methods
- F05D 2240/307: related to the tip of a rotor blade
- Y02P 10/25: Process efficiency
- B23P: METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS (arrangements for copying or controlling B23Q)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A method for additively manufacturing a tip structure on a pre-existing part includes: a) placing the part in a build space of a beam-assisted additive manufacturing setup and below a transparent aligning plate, b) engraving a top contour of the part onto the aligning plate with an energy beam of the setup, c) aligning a top surface of the part such that the top surface coincides with the engraved contour, d) removing the aligning plate from the setup, and e) additively manufacturing the tip structure according to a predefined geometry on the top surface.

## Claims

### Claim 1

A method for powder-bed-based additive manufacture of a tip structure on a pre-existing part comprising:
a) placing the pre-existing part in a build space of a beam-assisted additive manufacturing setup and below a transparent aligning plate,
b) engraving a top contour of the pre-existing part onto the transparent aligning plate with an energy beam of the setup,
c) aligning a top surface of the pre-existing part such that the top surface coincides with the engraved top contour,
d) removing the transparent aligning plate from the setup, and
e) additively manufacturing the tip structure according to a predefined geometry on the top surface, wherein the engraved top contour mates with the top surface, and with an initial layer of the tip structure,
wherein the aligning plate is made of an optically permeable material being susceptible to be engraved by an energy beam in order to image the contour of the tip structure.

### Claim 2 (depends on 1)

The method according to claim 1, wherein the pre-existing part is a pre-machined part, and wherein an extent of premachining is adjusted to the predefined geometry of the tip structure.

### Claim 3 (depends on 1)

The method according to claim 1, wherein the top surface of the pre-existing part is aligned horizontally.

### Claim 4 (depends on 1)

The method according to claim 1, wherein the tip structure is manufactured by selective laser melting or electron beam melting.

### Claim 5 (depends on 1)

The method according to claim 1, wherein the pre-existing part constitutes a section of a component, or a turbine blade or burner root, and wherein the tip structure constitutes a tip to be manufactured for the refurbishment of the component.