US 5,038,014 AGranted

Fabrication of components by layered deposition

AssigneeGeneral Electric Company

InventorsVanon D. Pratt, Wilbur D. Scheidt, Eric J. Whitney

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Abstract

A component is fabricated by depositing a succession of overlying beads of a material, the pattern and position of the beads being assigned the proper characteristics of the corresponding section of the desired component. Shape definition is accomplished by characterizing the component as a series of sections or slices having the thickness of the bead, and programming a computer-controlled deposition head to deposit a succession of beads with the respective patterns and positions. Deposition is preferably by precision laser welding. Complex shapes having properties comparable to properties of forged or cast material are readily prepared. The material used in successive beads may be varied, producing a component of graded composition to achieve particular properties in various regions.

Claims22

Dependent claims

A process for fabricating an article using laser welding, the article having a preselected shape and characterized as a plurality of parallel cross sections, each cross section having a preselected pattern and thickness, comprising the steps of:

melting a powder material with a laser beam and depositing the molten material to form a first layer in the pattern of a first cross section of the article, the thickness of the first deposited layer corresponding to the thickness of the first cross section;
melting a powder material with a laser beam and depositing the molten material to form a second layer in the pattern of a second cross section of the article and at least partially overlying the first layer of deposited material, the thickness of the second deposited layer corresponding to the thickness of the second cross section;
and
melting a powder material with a laser beam and depositing the molten material to form successive layers in patterns of corresponding cross sections of the article, at least one of the successive cross sections partially overlying the underlying cross section and partially offset from the underlying cross section, so that a layer deposited in at least one of the cross sections is partially unsupported by the previously deposited material so as to form an overhang, and further, the thickness of each deposited layer and the thickness of the corresponding cross section in which the layer is deposited being about equal, the layers deposited in successive cross sections until the article is complete.

1 more element

A process for fabricating a compressor blade that is integral with a compressor disk using laser welding, the compressor blade having a preselected complex curved shape and characterized as a plurality of parallel cross sections, each cross section having a preselected pattern and thickness, comprising the steps of:

furnishing a compressor disk having a substrate surface at its periphery;
melting a powder material with a laser beam and depositing the molten material onto the substrate surface to form a first bead of material in the pattern of a first cross section of the blade, the thickness of the first deposited bead corresponding to the thickness of the first cross section;
and
melting a powder material with a laser beam and depositing the molten material as successive beads of material in successive deposition steps, each successive bead deposited in a pattern of a corresponding cross section of the blade, each cross section partially overlying the underlying cross section and partially offset from the underlying cross section so that each deposited bead after the first deposited bead is partially unsupported by the previously deposited material, the thickness of the deposited bead and the thickness of the corresponding cross section in which the material is deposited being about equal, the successive beads deposited in successive cross sections until the compressor blade is complete.

1 more element

Dependencies are inferred from the claim text.

Facts

Application: 07/443,830Filed 1 Dec 1989 · continuation
Priority: 8 Feb 1989
Granted: 6 Aug 1991
Term ends: Not estimatedThe source records don’t support an estimate.

Classification32 codes

F01D 5/005
Blades; Blade-carrying members ; Heating, heat-insulating, cooling or antivibration means on the blades or the members: repairing methods or devices
B22F 10/25
Direct sintering or melting: direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
B22F 10/385
To achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures: overhang structures
B23K 26/144
Using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor: the fluid stream containing particles, e.g. powder