Distortion mitigation in directed energy deposition
AssigneeNorsk Titanium AS
InventorsPedro Almeida, Dale Grigorenko, Steven Rondeau
Life of this patent
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Abstract
Provided are a mount system and systems and methods using the mount system for manufacturing objects, especially titanium and titanium alloy objects, by directed energy deposition. The methods include thermally pre-bending the substrate onto which the object is to be manufactured to form a pre-bent substrate, attaching the pre-bent substrate to a jig using the mount system as an underlying support, pre-heating the substrate, and forming the object on the pre-heated, pre-bent substrate using a directed energy deposition technique.
Claims20
A system for directed energy deposition, comprising:
- a welding jig for securing a pre-bent substrate;
- a pin support system configured to be positioned between the welding jig and the pre-bent substrate;
- clamps securing the pre-bent substrate to the welding jig;
- one or more melting tools comprising a DED thermal source to melt a source of metal into metallic molten material that is deposited on a surface of a base material;
- a gas jet device to direct a cooling gas to impinge upon the as-solidified material adjacent to a liquid-solid boundary of the liquid molten pool to influence temperature gradients;
- a supply of the cooling gas;
- and
- an actuator for positioning and moving the base material relative to the melting tool and the gas jet device,
- wherein the pin support system comprises one or more pins arranged on the welding jig defining a curved profile configured to interface with
- a surface of the pre-bent substrate.
A directed energy deposition method for producing a metal workpiece,
- comprising:
- bending a substrate of a metal material with thermal energy by forming a plurality of melting tracks on a first surface of the substrate using a melting tool to produce a pre-bent substrate;
- securing the pre-bent substrate to a pin support system coupled to a jig such that a first surface of the pre-bent substrate contacts the pin support system, the pin support system comprising one or more pins arranged on the welding jig and defining a curved profile;
- and
- forming the metal workpiece on a second surface of the substrate by an additive manufacturing process that comprises melting a metal feedstock to deposit a layer of molten metal on the second surface of the substrate to form a base material and deposits subsequent layers of molten metal on the base material to form the workpiece, the first surface of the substrate being opposite the second surface of the substrate.
Dependencies are inferred from the claim text.