US 12,759,045 B2Granted

Method of and apparatus using a split wiper for the repair of objects protruding above a powder bed

AssigneeSiemens Energy, Inc.

InventorGerald J. Bruck

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Abstract

A method of repairing a component using an additive manufacturing process is presented. The method includes submerging the component into a powder bed so that a portion of the component to be repaired is level with a surface of the powder bed and a protruding portion of the component protrudes above the surface of the powder bed, positioning a split wiper that includes a first wiper segment and a second wiper segment in the powder bed at the surface, advancing a quantity of powder by translating the first wiper segment and the second wiper segment across the surface of the powder bed, and directing a laser beam across the surface to fuse powder particles of the powder bed to the underlying substrate forming a layer of the component. Each of the first wiper segment and the second wiper segment follow a different contour of the protruding portion at the surface.

Claims18

Dependent claims

A system for repairing a component utilizing a powder bed fusion additive manufacturing process, comprising:

a vessel containing a powder bed having the component, with a portion to be repaired submerged to a position where the portion is at a surface of the powder bed defined by a pocket in the component and with a protruding portion of the component that protrudes above the powder bed;
a split wiper comprising a first wiper segment and a second wiper segment, the first wiper segment and the second wiper segment each configured to follow a different contour of the protruding portion at the surface of the powder bed, wherein the first wiper segment advances a quantity of powder into the pocket in the component;
and
a beam energy source operably configured to direct a beam energy towards the powder bed to fuse the quantity of powder into a layer of additive material on the component, and
a controller configured to control a translation of the first wiper segment and the second wiper segment so that each of the wiper segments follows the different contour of the protruding portion, respectively.

2 more elements

Dependencies are inferred from the claim text.

Facts

Application: 18/001,596Filed 28 Jul 2020
Published: US 2023/0234128 A127 Jul 2023
Granted: 13 Oct 2026
Term ends: Not estimatedThe source records don’t support an estimate.

Classification15 codes

B22F 5/04
Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product: of turbine blades
B22F 10/28
Direct sintering or melting: powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
B22F 10/38
Process control: to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
B22F 10/85
Data acquisition or data processing: for controlling or regulating additive manufacturing processes