US 2015/0306665 A1 · ADDITIVE LAYER MANUFACTURING

Abstract

Apparatus and a method for forming a metallic component by additive layer manufacturing are provided. The method includes the steps of mounting a work piece (3) to ALM manufacturing apparatus including measuring means in the form of load cells (13, 14) to measure stresses tending to distort the work piece, using a laser heat source (24) to apply heat to a surface (18) of the work piece (3) sufficient to melt it; adding metallic material to the melted surface (18) and moving the heat source (24) relative to the work piece (3) whereby progressively to form a layer (30) of metallic material on it; repeating the above steps as required, whereby progressively to form the component and, while doing so, measuring stresses tending to distort the component with the load cells (13, 14) and, if they are above a predetermined threshold, stress relieving the work piece with means such as a pulsed laser (27) while still mounted to the apparatus to reduce distortion to a predetermined level, and again repeating above steps as required to complete the component. A computer (16) may be included to control the whole process.

Claims24

Dependent claims

A method of forming a metallic component by additive layer manufacturing, the method comprising:

a) mounting a work piece to additive layer manufacturing (ALM) manufacturing apparatus including a stress measuring system adapted at least partly to clamp the work piece to the apparatus and to measure stresses tending to distort the work piece;
b) using a heat source to apply heat to a portion of a surface of the work piece sufficient to melt said portion;
c) adding metallic material to the melted portion and moving the heat source relative to the work piece whereby progressively to form a layer of metallic material on the work piece;
d) repeating b) and c) as required, whereby progressively to form the component;
e) while progressively forming the component, measuring stresses tending to distort the work piece with the stress measuring system and, if such stresses are measured to be above a predetermined threshold, stress relieving the work piece while mounted to the apparatus whereby to reduce distortion to a predetermined level;
and
repeating b) to e) as required whereby to form the component.

4 more elements

A computer program product containing a computer program instructions that when executed by one or more processors cause a process for forming a metallic component by additive layer manufacturing to be carried out the process comprising:

a) causing a heat source to apply heat to a portion of a surface of a work piece sufficient to melt said portion, the work piece to mounted to an additive layer manufacturing (ALM) manufacturing apparatus including a stress measuring system adapted at least partly to clamp the work piece to the apparatus and to measure stresses tending to distort the work piece;
b) causing metallic material to be added to the melted portion and further causing the heat source to move relative to the work piece whereby progressively to form a layer of metallic material on the work piece;
c) repeating a) and b) as required, whereby progressively to form the component;
d) while progressively forming the component, causing stresses tending to distort the work piece to be measured with the stress measuring system and, if such stresses are measured to be above a predetermined threshold, further causing stress relieving the work piece while mounted to the apparatus whereby to reduce distortion to a predetermined level;
and
repeating b) to d) as required whereby to form the component.

3 more elements

Dependencies are inferred from the claim text.

Additive layer manufacturing

Life of this patent

Additive layer manufacturing

Life of this patent

Abstract

Claims24