Additive manufacturing
AssigneeMaterials Solutions
InventorTrevor Illston
Life of this patent
Estimating the term…
Abstract
Methods of additive manufacturing a superalloy component are disclosed. In one method a powder bed of superalloy powder is selectively scanned with a focused laser beam in a line-by-line manner; and the spacing between adjacent scan lines is no more than twice the layer thickness being formed. In another method a compressive stress treatment is applied to the surface of the final component prior to separation of said component from the substrate. In a further method a superalloy component is formed on a substrate and the method includes Hot Isostatic Processing of the component wherein the mass of the substrate is reduced prior to the Hot Isostatic Processing. The methods may be combined in a multi-step process.
Claims25
A method of additive manufacturing a superalloy component, the method comprising the steps of:
- i. providing a powder bed of superalloy powder on a substrate;
- ii. scanning the powder with a laser to create a melt pool and thereby selectively fuse the powder into a desired shape, thereby forming a first layer of the component;
- iii. replenishing the powder bed and scanning the powder with the laser so as to form a subsequent layer of the component onto the first layer;
- and
- iv. repeating step (iii) as required until a final desired three dimensional component is formed;
- wherein scanning the powder with a laser comprises
- selective scanning of a focused laser beam across the surface of the powder bed in a line-by-line manner;
- and wherein
- the spacing between adjacent scan lines is no more than twice the layer thickness being formed.
A method of additive manufacturing a superalloy component, the method comprising:
- i. providing a powder bed of superalloy powder on a substrate;
- ii. scanning the powder with a laser to form a melt pool and there selectively fuse the powder into a desired shape, thereby forming a first layer of the component;
- iii. replenishing the powder bed and scanning the powder with the laser so as to form a subsequent layer of the component onto the first layer;
- and
- iv. repeating step (iii) as required until a final three dimensional component is formed;
- wherein the method further comprises:
- applying a compressive stress treatment to the surface of the final three dimensional component prior to separation of the final three dimensional component from the substrate.
A method of additive layer manufacturing a superalloy component on a substrate including Hot Isostatic Processing wherein the mass of the substrate is reduced prior to the Hot Isostatic Processing.
The method of 22, wherein the mass of the substrate is reduced by milling or drilling.
Dependencies are inferred from the claim text.