Title: Hybrid additive manufacturing methods using hybrid additively manufactured features for hybrid components

Abstract

A hybrid additive manufacturing method comprises building an additive structure on a pre-sintered preform base, wherein building the additive structure comprises iteratively fusing together a plurality of layers of additive material with at least a first layer of additive material joined to the pre-sintered preform base, and wherein the pre-sintered preform base comprises an initial shape. The hybrid additive manufacturing method further comprises modifying the initial shape of the pre-sintered preform base comprising the additive structure into a modified shape comprising the additive structure, and, joining the pre-sintered preform base in its modified shape to a component.

Inventors:

Lacy, Benjamin Paul; Kottilingam, Srikanth Chandrudu; Schick, David Edward

Issue Date:

2018-10-16

Research Org.:

General Electric Co., Schenectady, NY (United States)

Sponsoring Org.:

USDOE

OSTI Identifier:

1489784

Patent Number(s):

10099290

Application Number:

14/574,557

Assignee:

General Electric Company (Schenectady, NY)

Patent Classifications (CPCs):

B - PERFORMING OPERATIONS B22 - CASTING B22F - WORKING METALLIC POWDER

B - PERFORMING OPERATIONS B23 - MACHINE TOOLS B23K - SOLDERING OR UNSOLDERING

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B - PERFORMING OPERATIONS B22 - CASTING B22F - WORKING METALLIC POWDER

B22F2005/005 - {Article surface comprising protrusions}
B22F2301/15 - Nickel or cobalt
B22F3/24 - After-treatment of workpieces or articles {
B22F5/009 - {of turbine components other than turbine blades
B22F5/04 - of turbine blades
B22F7/06 - of composite workpieces or articles from parts, e.g. to form tipped tools {
B22F7/062 - {involving the connection or repairing of preformed parts}
B22F7/08 - with one or more parts not made from powder {

B - PERFORMING OPERATIONS B23 - MACHINE TOOLS B23K - SOLDERING OR UNSOLDERING

B23K10/027 - {Welding for purposes other than joining, e.g. build-up welding}
B23K2103/05 - {Stainless steel}
B23K2103/08 - Non-ferrous metals or alloys
B23K2103/10 - Aluminium or alloys thereof
B23K2103/14 - Titanium or alloys thereof
B23K2103/18 - Dissimilar materials
B23K2103/26 - {Alloys of Nickel and Cobalt and Chromium}
B23K26/0006 - {taking account of the properties of the material involved
B23K26/342 - Build-up welding

B - PERFORMING OPERATIONS B33 - ADDITIVE MANUFACTURING TECHNOLOGY B33Y - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING

B33Y10/00 - Processes of additive manufacturing
B33Y80/00 - Products made by additive manufacturing

C - CHEMISTRY C22 - METALLURGY C22C - ALLOYS

C22C19/057 - {with the maximum Cr content being less 10%}
C22C19/058 - {without Mo and W}
C22C19/07 - based on cobalt

F - MECHANICAL ENGINEERING F01 - MACHINES OR ENGINES IN GENERAL F01D - NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES

F01D9/02 - Nozzles

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02P - CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

Y02P10/25 - by increasing the energy efficiency of the process

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DOE Contract Number:  

FC26-05NT42643

Resource Type:

Patent

Resource Relation:

Patent File Date: 2014 Dec 18

Country of Publication:

United States

Language:

English

Subject:

36 MATERIALS SCIENCE; 42 ENGINEERING