# US 11,999,012 B2 · Method and system for additive manufacturing or repair with in-situ manufacturing and feeding of a sintered wire > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,999,012 B2 - Document ID: US11999012B2 - Status: Granted - Kind: B2 - Application number: 17/040,559 - Filed: 2018-03-27 - Published: 2021-03-11 - Granted: 2024-06-04 - Earliest claimed: 2018-03-27 - Assignees: Siemens Energy, Inc. - Applicants: Siemens Energy, Inc. - Inventors: Bernd Burbaum; Kazim Ozbaysal; Ahmed Kamel - Web page: https://patentgrep.com/patent/US11999012B2 ## CPC - B23K 1/0018: {Brazing of turbine parts} - B23K 26/342: Build-up welding - B23K 1/0056: {soldering by means of beams, e.g. lasers, electron beams [EB]} - B23K 3/063: {for wire feeding} - B23K 26/1464: {Supply to, or discharge from, nozzles of media, e.g. gas, powder, wire} - B23K 26/34: Laser welding for purposes other than joining - B23K 35/0227: {Rods or wires (B23K35/0244 takes precedence)} - B23K 35/3033: {Ni as the principal constituent} - B23K 35/3046: {Co as the principal constituent} - B33Y 10/00: Processes of additive manufacturing - B23K 35/24: Selection of soldering or welding materials proper (B23K35/34 takes precedence) - B23K 35/40: Making wire or rods for soldering or welding - B23K 2101/001: {Turbines} - B23K 2103/08: Non-ferrous metals or alloys - Y02P 10/25: Process efficiency - 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 - 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 - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract A system for manufacturing of a sintered wire and in-situ feeding to a laser wire welding system is presented. The system includes a pressure vessel connected to a powder feed system for delivering at least two powders to a powder mixing zone of the pressure vessel. The at least two powders are mixed via a rotating cone in the pressure vessel. After mixing, a heating device contained within the pressure vessel heats the mixture so that liquid phase sintering occurs and a sintered rod is created. The sintered wire is continuously fed to a laser metal deposition system for depositing a layer of additive material on a base material. A method of additively manufacturing or repairing a superalloy component is also presented. ## Claims ### Claim 1 A system for additively manufacturing and/or repairing a superalloy component via laser metal deposition utilizing a sintered wire, comprising: a pressure vessel connected to a powder feed system for delivering at least two powders to a powder mixing zone of the pressure vessel; a heating device contained within the pressure vessel, the heating device configured to heat a mixture of the at least two different powders mixed in the powder mixing zone so that liquid phase sintering occurs creating a sintered wire; a laser wire welding system, comprising: a laser energy source operably configured to direct a laser energy towards a base material for forming a melt pool thereon and for laser processing the sintered wire deposited into the melt pool for forming a layer of additive material on the base material, and a welding head for receiving the sintered wire directly from the pressure vessel, wherein the sintered wire is continuously fed from the pressure vessel to the laser wire welding system. ### Claim 2 (depends on 1) The system as claimed in claim 1, wherein the additive material comprises a similar or a same composition as the base material. ### Claim 3 (depends on 1) The system as claimed in claim 1, wherein the at least two powders include a first powder comprising a base metal powder and a second powder comprising a braze alloy powder. ### Claim 4 (depends on 3) The system as claimed in claim 3, wherein the base metal powder is a nickel-based superalloy powder. ### Claim 5 (depends on 4) The system as claimed in claim 4, wherein the mixture comprises a ratio of (in a wt. %) nickel-based superalloy powder to (in a wt. %) braze alloy powder, and wherein the nickel-based superalloy powder lies in a range of 60-100% (in a wt. %) and the braze alloy powder lies in a range of 0-40% (in a wt. %). ### Claim 6 (depends on 4) The system as claim in claim 4, wherein the nickel-based superalloy powder is selected from the group consisting of CM247, Rene 80, IN738, and IN792. ### Claim 7 (depends on 3) The system as claimed in claim 3, wherein the braze alloy powder comprises the composition selected from the group consisting of: Amdry BRB, Amdry DR-4B, Ni—Cr—Ti, Ni—Cr—Zr—Ti, Ni—Ti—Zr, Ni—Cr—Hf—Zr, Ni—Cr—Ti—Hf, and Ni—Cr—Hf—Zr—Ti. ### Claim 8 (depends on 1) The system as claimed in claim 1, wherein the system further comprises at least two rollers for receiving the hot sintered wire from pressure vessel and for continuously feeding the sintered wire to the laser wire welding system. ### Claim 9 (depends on 3) The system as claimed in claim 3, wherein a successive layer is built on top of the deposited layer of additive material via the laser wire welding system. ### Claim 10 (depends on 9) The system as claimed in claim 9, wherein a first proportion of the first powder to the second powder of the deposited layer is different from a second proportion of the first powder to the second powder of the successive layer. ### Claim 11 (depends on 1) The system as claimed in claim 1, wherein the pressure vessel includes a rotating cone in a container for mixing the at least two powders. ### Claim 12 A method additively manufacturing and/or repairing a superalloy component comprising: sintering of at least two different powders in a pressure vessel by a heating process so that a sintered wire is created; continuous in-situ feeding of the sintered wire to a weld head of a laser wire welding system; directing a laser beam from the laser wire welding system towards a base material of the superalloy component for forming a melt pool thereon and for processing the sintered wire deposited into the melt pool to form a layer of additive material on the base material. ### Claim 13 (depends on 12) The method as claimed in claim 12, wherein the at least two powders include a first powder comprising a base metal powder and a second powder comprising a braze alloy powder. ### Claim 14 (depends on 13) The method as claimed in claim 13, wherein the first powder is a nickel-based superalloy powder. ### Claim 15 (depends on 12) The method as claimed in claim 12, wherein the continuous in-situ feeding is accomplished utilizing a pair of rollers. ### Claim 16 (depends on 12) The method as claimed in claim 12, further comprising traversing the component comprising the base material relative to the laser wire welding system so that the layer of additive material is disposed on the base material as desired.