Abstract: The present disclosure generally relates to additive manufacturing systems and methods involving a mechanism for feeding in a desired amount of fresh recoater blade. This can be accomplished by, for example, spooling the fresh blade material from a spool. This helps prevent work stoppage when a portion of a recoater blade becomes damaged. As such, the present disclosure also relates to a system and method for detecting whether a recoater blade is damaged, and if there is damage, then causing a fresh blade portion to be fed in.

Abstract: Methods for direct writing of single crystal super alloys and metals are provided. The method can include: heating a substrate positioned on a base plate to a predetermined temperature using a first heater; using a laser to form a melt pool on a surface of the substrate; introducing a superalloy powder to the melt pool; measuring the temperature of the melt pool; receiving the temperature measured at a controller; and using an auxiliary heat source in communication with the controller to adjust the temperature of the melt pool. The predetermined temperature is below the substrate's melting point. The laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition. An apparatus is also generally provided for direct writing of single crystal super alloys and metals.

Abstract: A method of making a component includes: depositing a metallic powder on a workplane; directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a cross-sectional layer of the component; repeating in a cycle the steps of depositing and fusing to build up the component in a layer-by layer fashion; and during the cycle of depositing and melting, using an external heat control apparatus separate from the directed energy source to maintain a predetermined temperature profile of the component, such that the resulting component has a directionally-solidified or single-crystal microstructure.

Abstract: An additive manufacturing apparatus includes: first and second spaced apart side walls extending along a pre-defined path and defining a build chamber therebetween; one or more build units mounted for movement along the pre-defined path, the one or more build units including at least one of: a powder dispenser positioned above the build chamber; an applicator configured to scrape powder dispensed into the build chamber; and a directed energy source configured to fuse the scraped powder.

Abstract: A method of making a component includes: depositing a metallic powder on a workplane; directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a cross-sectional layer of the component; repeating in a cycle the steps of depositing and fusing to build up the component in a layer-by layer fashion; and during the cycle of depositing and melting, using an external heat control apparatus separate from the directed energy source to maintain a predetermined temperature profile of the component, such that the resulting component has a directionally-solidified or single-crystal microstructure.

Abstract: The present disclosure generally relates to additive manufacturing systems and methods involving a mechanism for feeding in a desired amount of fresh recoater blade. This can be accomplished by, for example, spooling the fresh blade material from a spool. This helps prevent work stoppage when a portion of a recoater blade becomes damaged. As such, the present disclosure also relates to a system and method for detecting whether a recoater blade is damaged, and if there is damage, then causing a fresh blade portion to be fed in.

Abstract: The present disclosure generally relates to additive manufacturing systems and methods involving a mechanism for feeding in a desired amount of fresh recoater blade. This can be accomplished by, for example, spooling the fresh blade material from a spool. This helps prevent work stoppage when a portion of a recoater blade becomes damaged. As such, the present disclosure also relates to a system and method for detecting whether a recoater blade is damaged, and if there is damage, then causing a fresh blade portion to be fed in.

Abstract: A direct metal laser melting (DMLM) system includes a rotatable base, and a build plate mounted on and supported by the rotatable base, where the build plate includes a build surface. The DMLM system also includes a first actuator assembly, a first powder dispenser disposed proximate the build plate and configured to deposit a weldable powder on the build surface of the build plate. In addition, the DMLM system includes a first powder spreader disposed proximate the build plate and configured to spread the weldable powder deposited on the build surface of the build plate, and a first laser scanner supported by the first actuator assembly in a position relative to the build plate, such that at least a portion of the build surface is within a field of view of the first laser scanner. The first laser scanner is configured to selectively weld the weldable powder. The first laser scanner is further configured to translate axially relative to the build surface on the first actuator assembly.

Abstract: A method for additive manufacturing utilizing a build plate with a release layer is provided. The method includes irradiating a first layer of powder in a powder bed to form a first fused region over a support. The first release layer is provided between the first fused region and the support. The method also includes providing a given layer of powder over the powder bed and irradiating the given layer of powder in the powder bed to form a given fused region. Providing the given layer of powder over the powder bed and irradiating the given layer of powder in the powder bed to form a given fused region are repeated until the object is formed in the powder bed. The object may be formed fusing individual layers with irradiation by laser or ebeam, or by binder jetting. The method further includes separating the object from the support by melting or dissolving the first release layer.

Abstract: A method of manufacturing an object by additive manufacturing is provided. The method includes lowering a build platform having a given layer of build material to powder provided on a window. The powder is irradiated to form a subsequent layer that corresponds to the given layer. The method then includes solidifying the subsequent layer, and raising the build platform and the subsequent layer away from the window. The steps are repeated until the desired object is formed.

Abstract: An additive manufacturing apparatus includes: first and second spaced apart side walls extending along a pre-defined path and defining a build chamber therebetween; one or more build units mounted for movement along the pre-defined path, the one or more build units including at least one of: a powder dispenser positioned above the build chamber; an applicator configured to scrape powder dispensed into the build chamber; and a directed energy source configured to fuse the scraped powder.

Abstract: A method of making an annular component includes forming sheet feedstock into an annular shape disposed about a central axis; and bonding one portion of the feedstock to another portion of the feedstock using ultrasonic welding, so as to fix the annular shape.

Abstract: A method of making a component includes: depositing a metallic powder on a workplane; directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a cross-sectional layer of the component; repeating in a cycle the steps of depositing and fusing to build up the component in a layer-by layer fashion; and during the cycle of depositing and melting, using an external heat control apparatus separate from the directed energy source to maintain a predetermined temperature profile of the component, such that the resulting component has a directionally-solidified or single-crystal microstructure.

Abstract: A method of making a component includes depositing a metallic powder on a workplane; directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a cross-sectional layer of the component; repeating in a cycle the steps of depositing and fusing to build up the component in a layer-by layer fashion; and during the cycle of depositing and melting, using an external heat control apparatus separate from the directed energy source to maintain a predetermined temperature profile of the component, such that the resulting component has a directionally-solidified or single-crystal microstructure.

Abstract: Methods for direct writing of single crystal super alloys and metals are provided. The method can include: heating a substrate positioned on a base plate to a predetermined temperature using a first heater; using a laser to form a melt pool on a surface of the substrate; introducing a superalloy powder to the melt pool; measuring the temperature of the melt pool; receiving the temperature measured at a controller; and using an auxiliary heat source in communication with the controller to adjust the temperature of the melt pool. The predetermined temperature is below the substrate's melting point. The laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition. An apparatus is also generally provided for direct writing of single crystal super alloys and metals.

Abstract: An additive manufacturing apparatus includes: first and second spaced apart side walls extending along a pre-defined path and defining a build chamber therebetween; one or more build units mounted for movement along the pre-defined path, the one or more build units including at least one of: a powder dispenser positioned above the build chamber; an applicator configured to scrape powder dispensed into the build chamber; and a directed energy source configured to fuse the scraped powder.

Abstract: Methods for direct writing of single crystal super alloys and metals are provided. The method can include: heating a substrate positioned on a base plate to a predetermined temperature using a first heater; using a laser to form a melt pool on a surface of the substrate; introducing a superalloy powder to the melt pool; measuring the temperature of the melt pool; receiving the temperature measured at a controller; and using an auxiliary heat source in communication with the controller to adjust the temperature of the melt pool. The predetermined temperature is below the substrate's melting point. The laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition. An apparatus is also generally provided for direct writing of single crystal super alloys and metals.

Abstract: A direct metal laser melting (DMLM) system includes a rotatable base, and a build plate mounted on and supported by the rotatable base, where the build plate includes a build surface. The DMLM system also includes a first actuator assembly, a first powder dispenser disposed proximate the build plate and configured to deposit a weldable powder on the build surface of the build plate. In addition, the DMLM system includes a first powder spreader disposed proximate the build plate and configured to spread the weldable powder deposited on the build surface of the build plate, and a first laser scanner supported by the first actuator assembly in a position relative to the build plate, such that at least a portion of the build surface is within a field of view of the first laser scanner. The first laser scanner is configured to selectively weld the weldable powder. The first laser scanner is further configured to translate axially relative to the build surface on the first actuator assembly.

Abstract: A turbine component includes: a metallic wall having opposed interior and exterior surfaces, the wall configured for directing a combustion gas stream in a gas turbine engine; and a metallic negative CTE structure rigidly attached to one of the surfaces.

Abstract: A method of manufacturing an object by additive manufacturing is provided. The method includes lowering a build platform having a given layer of build material to powder provided on a window. The powder is irradiated to form a subsequent layer that corresponds to the given layer. The method then includes solidifying the subsequent layer, and raising the build platform and the subsequent layer away from the window. The steps are repeated until the desired object is formed.