Abstract: A method of forming an article includes forming a layer of a mixture of at least two distinct metal powders selected such that when combined they are chemically in the proportions of a superalloy containing a gamma prime phase, and fusing the powders locally without diffusion to define the shape of a part of the article such that the materials of the distinct metal powders remain substantially chemically segregated forming regions of different chemical composition. The method further includes repeating the forming and fusing until the derived article is formed, and heat treating the finished article such that at least one of the distinct separate materials diffuses to form a gamma prime phase containing superalloy with the other.

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.

Abstract: Apparatus is for additive layer manufacturing of an article from a material which can be rendered solid locally by application of a focused beam of laser radiation at a planar focal plane. The apparatus includes at least two laser beams, respective scanners for each laser beam for scanning the respective laser beams over a planar field, and a support movable stepwise to allow successive manufacturing layer cycles and for supporting material within the field. The entire planar field is common to each scanner and at least one scanner is tilted with respect to the planar field, and the at least one scanner is provided with a lens arranged to generate a focal plane tilted with respect to that scanner.

Abstract: A method of forming an article includes forming a layer of a mixture of at least two distinct metal powders selected such that when combined they are chemically in the proportions of a superalloy containing a gamma prime phase, and fusing the powders locally without diffusion to define the shape of a part of the article such that the materials of the distinct metal powders remain substantially chemically segregated forming regions of different chemical composition. The method further includes repeating the forming and fusing until the derived article is formed, and heat treating the finished article such that at least one of the distinct separate materials diffuses to form a gamma prime phase containing superalloy with the other.

Abstract: The invention relates to a method of verifying a scan speed in a laser scanning system. The method includes modulating the laser of the system to form a periodically modulated feature from which the actual scan speed can be read or deduced.

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.

Abstract: A method of forming an article in a layer wise manufacturing process from a computer software file representing the article includes dividing the file into sub files in dependence of the size or other characteristics of features of the article to be created, applying a process characteristic selected independence on a characteristic feature to each sub file and manufacturing the article in accordance with the subfiles.

Abstract: A method of forming an article includes forming a layer of a mixture of at least two distinct metal powders selected such that when combined they are chemically in the proportions of a superalloy containing a gamma prime phase, and fusing the powders locally without diffusion to define the shape of a part of the article such that the materials of the distinct metal powders remain substantially chemically segregated forming regions of different chemical composition. The method further includes repeating the forming and fusing until the derived article is formed, and heat treating the finished article such that at least one of the distinct separate materials diffuses to form a gamma prime phase containing superalloy with the other.

Abstract: A powder bed additive layer manufacturing system includes a linear traversing re-coater and a build plate. The build plate is mounted for rotation relative to the re-coater on an axis extending through the build plate.

Abstract: The invention relates to a method of verifying a scan speed in a laser scanning system. The method includes modulating the laser of the system to form a periodically modulated feature from which the actual scan speed can be read or deduced.

Abstract: A method of forming an article using a powder layer manufacturing process includes providing a first support, forming a part of an article up to a level at or beneath the lowest point of a to-be-formed part which has a base spaced from the first support, locating a preformed support beneath the location in which the to-be-formed part will lie so that part can be formed on the preformed support and wherein the preformed support does not project beyond the level, and removing the preformed support when the to-be-formed part and/or the article is completed.

Abstract: 1. A powder bed additive layer manufacturing system including a linear traversing re-coater and a build plate characterised in that the build plate is mounted for rotation, relative to the re-coater or movement about an axis.

Abstract: A method of making an article having at least one re-entrance surface includes the steps of (a) forming a layer of metal powder on a base, (b) selectively laser fusing portions of the layer, and (c) repeating steps (a) and (b) to form the article, each step (a) being performed on the preceding layer characterised in that prior to performing step (a) in a layer which will initiate the formation of a re-entrant feature reversibly bonding at least some of the unfused underlying powder such that it is stable under the application of the laser.

Abstract: This invention relates to methods and apparatus performing a part at a location on the workpiece. In particular the object is to form a bund to contain a powder around a forming part. In different aspects the retained powder may not be heated above half its melting point and/or the powder dispensing systems may include a delivery hopper which can be translated across a flat area and carries the recoater blade on the hopper.

Abstract: A method of forming an article in a layer wise manufacturing process from a computer software file representing the article includes dividing the file into sub files in dependence of the size or other characteristics of features of the article to be created, applying a process characteristic selected independence on a characteristic feature to each sub file and manufacturing the article in accordance with the subfiles.

Abstract: A method of making an article having at least one re-entrance surface includes the steps of (a) forming a layer of metal powder on a base, (b) selectively laser fusing portions of the layer, and (c) repeating steps (a) and (b) to form the article, each step (a) being performed on the preceding layer characterised in that prior to performing step (a) in a layer which will initiate the formation of a re-entrant feature reversibly bonding at least some of the unfused underlying powder such that it is stable under the application of the laser

Abstract: A method of making an article includes determining the greatest dimension of an article along a selected axis, and manufacturing a first part of the article between an end and a face lying in the laterally extending plane containing the dimension. The method further includes placing the article on the support of direct layer deposition (DLD) apparatus with the face upwards, and forming the remaining part of the article using the DLD apparatus.

Abstract: 1. A powder bed additive layer manufacturing system including a linear traversing re-coater and a build plate characterised in that the build plate is mounted for rotation, relative to the re-coater or movement about an axis.