# US 2014/0190942 A1 · Forming a layered structure

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- Number: US 2014/0190942 A1
- Document ID: US20140190942A1
- Status: Published application
- Kind: A1
- Application number: 14/237,665
- Filed: 2012-08-08
- Published: 2014-07-10
- Earliest claimed: 2011-08-10
- Assignees: BAE SYSTEMS plc
- Inventors: Andrew David Wescott; Jagjit Sindhu
- Web page: https://patentgrep.com/patent/US20140190942A1

## CPC

- B23K 26/342: Build-up welding
- B22F 7/08: with one or more parts not made from powder {(B22F7/062 takes precedence)}
- B22F 10/25: Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
- B22F 12/41: characterised by the type, e.g. laser or electron beam
- B23K 9/042: {Built-up welding on planar surfaces}
- 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
- 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
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A method and apparatus for forming a layered structure. At least one raised area (202) is formed on a work piece (200), and a structure (302) is formed on the raised area using an Additive Layer Manufacturing (ALM) process.

## Claims

### Claim 1

A method of forming a layered structure, the method including:
forming at least one raised area on a work piece; and forming a structure on the raised area using an Additive Layer Manufacturing (ALM) process.

### Claim 2 (depends on 1)

A method according to claim 1 where the at least one raised area is of predetermined dimensions.

### Claim 3 (depends on 1)

A method according to claim 1, wherein a dimension of the raised area corresponds to a maximum design dimension of the structure to be formed by the ALM process.

### Claim 4 (depends on 3)

A method according to claim 3, wherein a width of the raised area corresponds to a maximum design width of the structure to be formed by the ALM process.

### Claim 5 (depends on 1)

A method according to claim 1, wherein a weld pool caused by deposition of at least one initial layer of the structure by the ALM process is contained/formed within the raised area, thereby reducing or eliminating distortion in a main body of the work piece.

### Claim 6 (depends on 1)

A method according to claim 1, wherein the at least one raised area is formed by machining the work piece.

### Claim 7 (depends on 1)

A method according to claim 1, wherein the at least one raised area is formed by casting, forging or a cold working process.

### Claim 8 (depends on 1)

A method according to claim 1, wherein the ALM process comprises a blown powder ALM process.

### Claim 9 (depends on 1)

A method according to claim 1, wherein the ALM process comprises a solid wire arc ALM process.

### Claim 10

Apparatus to form a layered structure, the apparatus including:
a work piece having at least one raised area;
an arrangement for holding the work piece in position; and forming apparatus configured to form a structure on the raised area using an ALM process.

### Claim 11 (depends on 10)

Apparatus according to claim 10, wherein the forming apparatus includes an Nd-YAG CW laser.

### Claim 12 (depends on 10)

Apparatus according to claim 10, wherein the forming apparatus includes a welding device.

### Claim 13

A work piece adapted for use in forming a layered structure using an ALM process, the work piece including at least one raised area.

### Claim 14 (depends on 13)

A work piece according to claim 13, wherein the at least one raised area is formed by machining the work piece.

### Claim 15 (depends on 13)

A work piece according to claim 13, wherein the at least one raised area is formed by casting, forging or a cold working process.