Porous structures
AssigneeROLLS-ROYCE plc
InventorsAndrew D. NORTON, Moataz M. ATTALLAH, Khamis E. ESSA, Sheng LI
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Abstract
Method of forming porous structures which are permeable in two or more dimensions. The method comprises forming successive layers of material on top of one another and, for each layer, selectively fusing powdered material according to a geometry having voids to be permeable in one or more dimensions, and selectively eroding material from the layer to create additional permeability.
Claims16
A method of forming a porous structure which is permeable in two or more dimensions, the method comprising forming successive layers of a metal or alloy material on top of one another, including, for each layer:
- selectively fusing powdered material according to a geometry, said geometry defining voids such that it is permeable in one or more dimensions, wherein said fusing is performed at an energy density which is sufficient to fully fuse said material;
- and
- selectively eroding material from the layer to thereby create additional permeability.
Apparatus for forming a porous structure which is permeable in two or more dimensions, comprising:
- a powder delivery system configured to deliver powdered metal or alloy material to a powder bed;
- a powder fusion system including an energy source;
- and
- a control system configured to:
- selectively fuse powdered material on the powder bed with the energy source according to a geometry, said geometry defining voids such that it is permeable in one or more dimensions, and
- selectively erode material from the layer with the energy source to thereby create additional permeability.
Dependencies are inferred from the claim text.