By Electric Arc Patents (Class 219/76.14)
  • Patent number: 10994370
    Abstract: In a track determination device, a CAD data acquisition unit acquires shape data that represents a shape of a three-dimensional formed object. A deposition direction setting unit generates control information for controlling a lamination device that laminates the molten metal in order to form a formed object, based on the shape data acquired by the CAD data acquisition unit. The control information is information indicating at least a specific deposition direction of the molten metal such that an error between a first deposition position set in advance and a second deposition position in accordance with an actual laminated state is reduced. A control program output unit outputs the control information generated by the deposition direction setting unit.
    Type: Grant
    Filed: February 6, 2018
    Date of Patent: May 4, 2021
    Assignee: Kobe Steel, Ltd.
    Inventor: Takemasa Yamasaki
  • Patent number: 10835982
    Abstract: A sprocket wheel, which is a machine component configured to slide relative to a bushing while being in contact with the bushing in an outer peripheral surface, includes a base made of a first metal, and an overlay that covers the base so as to constitute the outer peripheral surface. The surface of the overlay constituting the outer peripheral surface has been smoothed. Such a smoothed surface of the overlay makes the sprocket wheel less damaging to the bushing.
    Type: Grant
    Filed: November 18, 2014
    Date of Patent: November 17, 2020
    Assignee: KOMATSU LTD.
    Inventors: Masayuki Ohishi, Masaharu Amano
  • Patent number: 10816963
    Abstract: An automated welding system includes a mounting platform, a welding tool, an imaging device configured to acquire data associated with an object, and a controller. The controller is configured to receive the acquired data, determine an area to be welded in the acquired data, retrieve stored master model data associated with the object, and compare the acquired data to the stored master model data to identify a master model area in the acquired data. The controller is also configured to mask the master model area in the acquired data, such that the master model area is excluded from the area to be welded, and generate control instructions for controlling at least one of the mounting platform and the welding tool to weld the area to be welded.
    Type: Grant
    Filed: June 23, 2017
    Date of Patent: October 27, 2020
    Assignee: General Electric Company
    Inventors: Richard Roy Worthing, Jr., Mark Dean Pezzutti, Lyle Timothy Rasch
  • Patent number: 10669602
    Abstract: A manufacturing process includes depositing a clad layer having a thickness greater than about 0.5 mm (0.02 in) on a surface of the component by hardfacing, and creating a heat affected zone directly below the clad layer due to the depositing. The heat affected zone may be a region of the component where a lowest hardness is lower than a base hardness of the component below the heat affected zone. The method may also include heat treating the component after the deposition such that the lowest hardness in the heat affected zone is restored to within about 15% of the base hardness of the component.
    Type: Grant
    Filed: May 27, 2016
    Date of Patent: June 2, 2020
    Assignee: Caterpillar Inc.
    Inventors: Daniel Sordelet, Robert L. Meyer, Fernando Martinez Diez
  • Patent number: 10654132
    Abstract: A laser machining system includes: a scanner that scans a laser beam L along a predetermined radiation path and at a predetermined radiation speed; a robot that moves the scanner along a predetermined moving path and at a predetermined move speed; a robot controller that controls the moving path and the move speed of the robot; and a scanner controller that controls the radiation path and the radiation speed of the scanner. The scanner controller determines whether the predetermined radiation path exceeds a radiation range of the scanner within a radiation time of the predetermined radiation path and transmits a determination result to the robot controller as radiation range determination information. The robot controller changes the predetermined move speed to be decelerated on the basis of the radiation range determination information received from the scanner controller.
    Type: Grant
    Filed: October 4, 2018
    Date of Patent: May 19, 2020
    Inventor: Takayoshi Matsumoto
  • Patent number: 10639745
    Abstract: This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensing system that monitors two discrete wavelengths associated with a blackbody radiation curve of the layer of powder; determining temperature variations for an area of the build plane traversed by the scans based upon a ratio of sensor readings taken at the two discrete wavelengths; determining that the temperature variations are outside a threshold range of values; and thereafter, adjusting subsequent scans of the energy source across or proximate the area of the build plane.
    Type: Grant
    Filed: February 21, 2019
    Date of Patent: May 5, 2020
    Assignee: SIGMA LABS, INC.
    Inventors: Darren Beckett, Scott Betts, Martin Piltch, R. Bruce Madigan, Lars Jacquemetton, Glenn Wikle, Mark J. Cola, Vivek R. Dave, Alberto M. Castro, Roger Frye
  • Patent number: 10619513
    Abstract: Embodiments of the present invention relate to an inner casing component configured to form part of a steam flow path of a last stage of an axial flow steam turbine, the steam turbine inner casing component having a base made of nodular cast iron and a coating, on the base, in a region exposed to the steam flow path, consisting of manganese austenitic steel.
    Type: Grant
    Filed: February 16, 2017
    Date of Patent: April 14, 2020
    Assignee: General Electric Technology GmbH
    Inventor: Kornelia Weidemann
  • Patent number: 10569368
    Abstract: A wire feed control system includes an anti-twist mechanism and a controller programmed to operate the anti-twist mechanism, responsive to a measured degree of twist of a wire on a trajectory between a feed for the wire and a plasma transfer wire arc (PTWA) torch, to maintain the degree of twist within a predetermined range defined by natural rotation introduced to the wire by the PTWA torch.
    Type: Grant
    Filed: July 13, 2017
    Date of Patent: February 25, 2020
    Inventors: Clifford E. Maki, Antony George Schepak, James Maurice Boileau
  • Patent number: 10174617
    Abstract: The present application provides a method of repairing a turbine blade. The method may include the steps of removing an existing tip cap from the turbine blade in whole or in part, machining the turbine blade to form a machined groove, positioning an insert in the machined groove, welding the insert to the turbine blade, and brazing the turbine blade.
    Type: Grant
    Filed: December 10, 2015
    Date of Patent: January 8, 2019
    Assignee: General Electric Company
    Inventors: Lawrence James Whims, James Ryan Connor, Daniel James Dorriety, Andrea Booher Kretschmar, Paul A. Cook, Brian Leslie Henderson
  • Patent number: 10173290
    Abstract: Embodiments of an alloy that can be resistant to cracking. In some embodiments, the alloy can be advantageous for use as a hardfacing alloys, in both a diluted and undiluted state. Certain microstructural, thermodynamic, and performance criteria can be met by embodiments of the alloys that may make them advantageous for hardfacing.
    Type: Grant
    Filed: June 8, 2015
    Date of Patent: January 8, 2019
    Assignee: Scoperta, Inc.
    Inventor: Justin Lee Cheney
  • Patent number: 10045008
    Abstract: Disclosed an apparatus for processing images in a stereo vision system including: an image capturing unit including first and second cameras for obtaining image information by capturing a subject, and a lighting unit for emitting a flash during the image capturing; and a camera controller for controlling the image information to be obtained by cross-acquiring images of the subject in a predetermined time interval without the synchronization of the first and second cameras.
    Type: Grant
    Filed: December 30, 2011
    Date of Patent: August 7, 2018
    Assignee: GOLFZON CO., LTD.
    Inventors: Gee Hwan Kwon, Yong Won Sung
  • Patent number: 9759612
    Abstract: A welding portion inspection system includes a sensing head, and first and second electrodes that are disposed a predetermined distance from each other at one side of the sensing head, where front end portions of the first and second electrodes contact both sides of a welding portion to apply current such that a temperature of the welding portion is heated, and an infrared camera is disposed on the sensing head and detects a temperature distribution of the welding portion.
    Type: Grant
    Filed: October 24, 2014
    Date of Patent: September 12, 2017
    Assignee: Hyundai Motor Company
    Inventor: Jae Hun Song
  • Patent number: 9656354
    Abstract: During the repair of welded two-stage or multi-stage compressor or turbine drums, which after welding are machined in the weld area down to a height A, a first material coating with a height B extending on both sides from the root face is applied to the machined weld area, and a second and lesser material coating is applied by laser welding to the area of plasma pockets formed on the intact rotor disk, with the sum of the heights A and B corresponding to an original height C in the weld area prior to its final machining. Then the defective rotor disk is detached in the root face and through the middle of the first material coating, and after that a new rotor disk already validated in the new construction with the root face validated in the new construction is welded on using appropriate welding parameters, and the weld area is machined, in line with the parameters already used for the new construction, down to the original height A.
    Type: Grant
    Filed: January 4, 2012
    Date of Patent: May 23, 2017
    Assignee: Rolls-Royce Deutschland Ltd & Co KG
    Inventors: Elke Weiss, Gregor Kappmeyer, Florian Stappenbeck
  • Patent number: 9393636
    Abstract: Systems and methods for facilitating the starting and stopping of arc welding processes, as well as for responding to events in mid-weld. Specially designed signals may be briefly applied between a welding electrode and a welding workpiece at the start and end of a welding process to gracefully and properly start and stop a weld. Furthermore, specially designed signals may be briefly applied in the middle of a welding process, if determined events occur, to counter the undesirable effects of the events.
    Type: Grant
    Filed: February 26, 2013
    Date of Patent: July 19, 2016
    Assignee: Lincoln Global, Inc.
    Inventors: Judah Benjamin Henry, James E. Hearn, Daniel P. Fleming
  • Patent number: 9347138
    Abstract: A coating steel component with a pattern of an iron based matrix with crystalline particles metallurgically bound to the surface of a steel substrate for use as disc cutters or other components with one or more abrading surfaces that can experience significant abrasive wear, high point loads, and large shear stresses during use. The coated component contains a pattern of features in the shape of freckles or stripes that are laser formed and fused to the steel substrate. The features can display an inner core that is harder than the steel substrate but generally softer than the matrix surrounding the core, providing toughness and wear resistance to the features. The features result from processing an amorphous alloy where the resulting matrix can be amorphous, partially devitrified or fully devitrified.
    Type: Grant
    Filed: January 16, 2014
    Date of Patent: May 24, 2016
    Assignee: UT-BATTELLE, LLC
    Inventors: Craig A. Blue, Frank Wong, Louis F. Aprigliano, Peter G. Engleman, William H. Peter, Tibor G. Rozgonyi, Levent Ozdemir
  • Patent number: 9328421
    Abstract: An organic vapor jet printing system includes a pump for increasing the pressure of an organic flux.
    Type: Grant
    Filed: September 18, 2012
    Date of Patent: May 3, 2016
    Assignee: The Regents of the University of Michigan
    Inventor: Stephen R. Forrest
  • Patent number: 9321117
    Abstract: Arc welding systems, apparatus and methods are for hardfacing are provided, including particle feeding apparatus. In one aspect the workpiece is moved in an oscillatory fashion while keeping the welding torch and the particulate delivery system stationary during at least a portion of welding pass. The welding torch and particulate delivery system may also be moved in a non-oscillatory fashion. Process speeds of about 18-30 in/min can be obtained with carbide incorporation of greater than 30% and uniform distribution.
    Type: Grant
    Filed: May 29, 2015
    Date of Patent: April 26, 2016
    Inventors: Scott W. Beary, Michael J. Proffitt, Clint A. Weinberg, Wanti Muchtar, David Landon, Bjorn Johnson
  • Patent number: 9278404
    Abstract: A system and method is provided in which at least two welding power supplies are coupled to respective weld torches where the power supplies each provide a pulse welding waveform to their respective weld torches such that the welding pulses are out of phase with each other such that the respective welding pulses do not overlap during welding. The system also includes a ground current switch which switches the ground current path during welding to minimize arc interference and arc blow.
    Type: Grant
    Filed: February 3, 2012
    Date of Patent: March 8, 2016
    Assignee: LINCOLN GLOBAL, INC.
    Inventors: Timothy O'Donnell, Elmar Schwill
  • Patent number: 9144857
    Abstract: A welding torch includes a torch housing and, preferably, a tube bend fastenable thereto. A drive unit for feeding a welding wire is arranged in the torch housing and is formed by at least a drive roller and a pressure roller, as well as a drive motor. Part of the torch housing is designed as a component of the drive unit. A rotor, in particular a motor shaft, of the drive motor is fastened to the torch housing via a bearing or bearings to stabilize and position the rotor. A welding wire feed drive motor includes bearings, a rotor, in particular a motor shaft and a rotor winding or rotor magnets, and a stator pack, in particular stator winding or stator magnets. At least a part of the motor shaft, in particular the retention zone of a drive roller, is electrically insulated from the stator housing or base body.
    Type: Grant
    Filed: December 11, 2013
    Date of Patent: September 29, 2015
    Assignee: Fronius International GmbH
    Inventors: Guenther Flattinger, Manfred Schoerghuber, Karin Himmelbauer
  • Patent number: 9126287
    Abstract: A method of build-up welding including depositing of a weld material on a substrate in a series of weld passes in side-by-side relation to form a first weld layer, wherein substantially all weld passes forming the first weld layer are deposited in a first pass direction. Subsequently, a series of weld passes are deposited in side-by-side relation on the first layer to form a second weld layer, wherein substantially all weld passes forming the second weld layer are deposited in a second pass direction opposite to the first pass direction. Each weld pass of each layer may be deposited at a location where it is restrained on no more than one lateral side extending parallel to the weld pass.
    Type: Grant
    Filed: March 12, 2012
    Date of Patent: September 8, 2015
    Assignee: Siemens Energy, Inc.
    Inventors: Gerald J. Bruck, Petya M. Georgieva, Brandon W. Shinn
  • Patent number: 9109449
    Abstract: A turbine rotor has suitable strength and toughness without causing soaring manufacturing costs and prolonged manufacturing time. The turbine rotor is constructed by welding a rotor member for high temperature made of high Cr steel to a rotor member for low temperature made of low Cr steel. The high temperature rotor member is formed from high Cr steel of which the nitrogen content is 0.02% or higher by mass %. A filler material welds the high temperature rotor member and the low temperature rotor member together, and is a 9% Cr-based filler material of which the nitrogen content is 0.025% or lower by mass %.
    Type: Grant
    Filed: July 15, 2009
    Date of Patent: August 18, 2015
    Inventors: Takashi Shige, Shin Nishimoto, Kimmitsu Maruyama, Kenji Kawasaki, Yoshiaki Fukunaga, Takashi Nakano
  • Publication number: 20150147585
    Abstract: A method and an apparatus (10) for generating a three-dimensional work piece containing an information code are provided. The method comprises the steps of applying a raw material powder (18) onto a carrier (14) by means of a powder application device (16), irradiating electromagnetic or particle radiation (22) onto the raw material powder (18) applied onto the carrier (14) by means of an irradiation device (20), and controlling the operation of the powder application device (16) and the irradiation device (20) so as to generate an information code pattern (36) on or in the work piece (12), wherein the information code pattern (36) is defined by the microstructure (34) of the work piece (12).
    Type: Application
    Filed: November 25, 2014
    Publication date: May 28, 2015
    Inventors: Dieter Schwarze, Thomas Niendorf, Mirko Schaper, Florian Brenne, Wadim Reschetnik, Stefan Leuders, Andre Riemer
  • Publication number: 20150136908
    Abstract: A manufacturing method for passenger door corner components of aircraft or spacecraft includes using additive layer manufacturing, ALM, to form an integral passenger door corner component. The integral passenger door corner component includes a substantially cruciform shape having a frame coupling member with two frame couplings as end pieces. The frame coupling member intersect with a beam coupling member with two beam couplings as end pieces.
    Type: Application
    Filed: November 10, 2014
    Publication date: May 21, 2015
    Applicant: Airbus Operations GmbH
    Inventors: Matthias Hegenbart, Wolfgang Eilken
  • Publication number: 20150140239
    Abstract: A method for modifying an aperture in a component, a system for modifying flow through a component, and a turbine component are disclosed. The method includes providing a substrate having at least one aperture having an electrically-conductive surface, providing a deposition device including an ESD torch, the ESD torch including an aperture penetrating electrode including a conductive material, inserting the aperture penetrating electrode at least partially into the aperture, and generating an arc between the aperture penetrating electrode and the electrically-conductive surface to deposit electrode material within the aperture. The system includes the ESD torch removably supported in an electrode holder. The turbine component includes at least one aperture having an electrospark deposited material along an electrically-conductive surface, the electrospark deposited material providing modified fluid flow through the turbine component.
    Type: Application
    Filed: November 18, 2013
    Publication date: May 21, 2015
    Applicant: General Electric Company
    Inventors: Thomas Robert REID, Jonathan Matthew LOMAS, Gary Charles SHUBERT
  • Publication number: 20150135897
    Abstract: The disclosure relates to the manufacture of metal articles, more specifically the manufacture of metal articles by additive manufacturing techniques, and in particular to the manufacture of metal articles by an additive manufacturing technique that may involve the selective melting or sintering of a metal powder. Examples of such techniques may include selective laser melting (SLM), selective laser sintering (SLS) and techniques that use an electron beam rather than a laser. Exemplary embodiments include a method of manufacture of an article including selective melting and/or sintering of a powder including an alloy containing aluminium, wherein the alloy contains bismuth.
    Type: Application
    Filed: May 28, 2013
    Publication date: May 21, 2015
    Inventors: Christopher John Sutcliffe, Peter Fox
  • Publication number: 20150141234
    Abstract: A manufacturing method for reinforced structural elements includes providing a reinforcement structure including a first material, and embedding the reinforcement structure in an encasing matrix comprising a second material using additive layer manufacturing, ALM. A manufacturing tool for reinforced structural elements includes a positioning component including a jig for clamping a reinforcement structure including a first material and an ALM robot configured to embed a reinforcement structure clamped in the jig in an encasing matrix including a second material.
    Type: Application
    Filed: November 10, 2014
    Publication date: May 21, 2015
    Applicant: Airbus Operations GmbH
    Inventors: Peter Sander, Matthias Hegenbart, Carlos Weinbuch, Helene-Hedwig Koenig
  • Publication number: 20150139849
    Abstract: acting on a powder layer in a working zone, containing a device for layering said powder, said device including: means for storing powder, means for distributing powder that travel over the working zone to distribute powder in a layer having a final thickness for additive manufacturing, feeding means that transfer powder from storage means to distributing means, metering means that control the quantity of powder transferred from storage means to distributing means, said machine being wherein: storage means are positioned higher than the working zone, feeding means utilize gravity, feeding means and the metering means move with the distributing means, the machine has two separate working zones and two separate working trays that move independently of one another, each of the working trays is associated with only one working zone, and the layering device is common to both working zones.
    Type: Application
    Filed: June 3, 2013
    Publication date: May 21, 2015
    Inventors: Frederic Pialot, JR., Gilles Walrand, Pierre Wiel
  • Publication number: 20150128603
    Abstract: The present invention relates to a gas-turbine combustion chamber having a head plate and an outer and an inner combustion chamber wall, characterized in that the combustion chamber is designed in one piece by means of a DLD method, or is assembled from segments which are welded to one another and manufactured in one piece by means of a DLD method, as well as to a method for manufacturing the gas-turbine combustion chamber.
    Type: Application
    Filed: November 11, 2014
    Publication date: May 14, 2015
    Inventors: Carsten CLEMEN, Miklós GERENDÁS, Michael EBEL, Stefan PENZ
  • Publication number: 20150132601
    Abstract: A method of depositing a multi-layer cladding (40) of superalloy material and an apparatus so formed. A first layer of material (20) is deposited on a substrate (22) such as by laser cladding of superalloy powder (54). The deposited material includes a directionally solidified region (24) and a topmost equiaxed region (26). The topmost region is removed such as by grinding to expose a flat surface (28) of directionally solidified material. A second layer of material (32) deposited onto the exposed flat surface will again have a directionally solidified region (34) and a topmost equiaxed region (36). The process is repeated until a desired thickness of cladding material is achieved, the multi-layer cladding having no equiaxed material between its layers throughout its thickness.
    Type: Application
    Filed: November 8, 2013
    Publication date: May 14, 2015
    Inventors: Gerald J. Bruck, Ahmed Kamel
  • Publication number: 20150132173
    Abstract: An additive manufacturing apparatus (10) and process including selectively heating a processing plane of a bed of powdered material (14) that includes a powdered metal material (14?), and may also include a powdered flux material (14?). The heating may be accomplished by directing an energy beam, such as a laser beam (20), toward a processing plane (27) of the bed. One or more masking elements (61, 62) are disposed between a source (18) of the beam and the processing plane; and the masking elements are variable to change a beam pattern at the processing plane according to a predetermined shape of a component (22) to be formed or repaired.
    Type: Application
    Filed: November 5, 2014
    Publication date: May 14, 2015
    Inventors: Gerald J. Bruck, Ahmed Kamel
  • Publication number: 20150114938
    Abstract: A method for hard-surfacing metal parts for an aircraft turbofan, the method involving the use of a nozzle outputting a laser beam or an electron beam, which is to heat a sprayed powder for hard-surfacing the metal part, the method including positioning the metal part to be hard-surfaced in an enclosure, the top portion of which has an opening; positioning a mobile cover covering the opening of the top portion, the mobile cover having an opening; positioning the nozzle at the opening of the mobile cover; feeding an inert gas into the enclosure; spraying metal powders and emitting the laser or electron beam for hard-surfacing the metal part; moving the nozzle relative to the enclosure along a path for hard-surfacing the metal part, the movement of the nozzle causing the movement of the mobile cover on the top surface of the enclosure.
    Type: Application
    Filed: May 7, 2013
    Publication date: April 30, 2015
    Inventor: Jean-Baptiste Mottin
  • Publication number: 20150113993
    Abstract: A fuel injector assembly includes a fuel injector and a fuel injector shroud housing the fuel injector. The fuel injector includes a body and a nozzle coupled to the body. The fuel injector shroud includes a swirler device defining a center opening proximate to the nozzle of the fuel injector and a plurality of swirler holes surrounding the center opening, a body section with an air inlet configured to admit a flow of air into the fuel injector shroud and a dome section defining a mount for securing the swirler device to the body section, and at least one interior rib positioned on an interior surface of the dome section configured to direct the flow of air to the swirler holes of the swirler device such that the flow of air exiting through the swirler is mixed with the flow of fuel exiting the nozzle.
    Type: Application
    Filed: October 30, 2013
    Publication date: April 30, 2015
    Inventors: Nagaraja S. Rudrapatna, Thomas J. Bronson, Donald G. Godfrey
  • Publication number: 20150108098
    Abstract: By way of the targeted selection of method parameters in laser welding, namely feed rate, laser power beam diameter and powder mass flow, the temperature gradient can be set in a targeted manner, which temperature gradient is decisive for the single crystal growth during laser build-up welding.
    Type: Application
    Filed: October 1, 2014
    Publication date: April 23, 2015
    Inventors: Nikolai ARJAKINE, Georg BOSTANJOGLO, Bernd BURBAUM, Andres GASSER, Torsten JAMBOR, Torsten JOKISCH, Stefanie LINNERBRINK, Selim MOKADEM, Michael OTT, Norbert PIRCH, Rolf WILKENHÖNER
  • Publication number: 20150108095
    Abstract: A method and apparatus for depositing metals and metal-like substances in two and three dimensional form without a substrate in a safe, rapid and economical fashion using gas shielded arc welding equipment and programmable robotic motion. The method and apparatus includes the use and application of robotic controls, temperature and position feedback, single and multiple material feeds, and semi liquid deposition thereby creating near net shape parts particularly well suited to rapid prototyping and lower volume production.
    Type: Application
    Filed: October 20, 2014
    Publication date: April 23, 2015
  • Publication number: 20150108097
    Abstract: In order to obtain crack-free, homogeneous welds in nickel-based superalloys, laser parameters in respect of the power, the beam diameter, the mass feed rate, and the speed of advancement, are specifically selected.
    Type: Application
    Filed: December 4, 2012
    Publication date: April 23, 2015
    Inventors: Nikolai Arjakine, Bernd Burbaum, Andres Gasser, Torsten Jokisch, Stefanie Linnenbrink, Frank Mentzel, Michael Ott, Norbert Pirch
  • Publication number: 20150102017
    Abstract: A device for surfacing a metal alloy part by laser welding, the part including a recess to be surfaced and located at an overall planar area of the part, the device including a first protective element and a second protective element arranged on either side of the recess, the first protective element and the second protective element each having an irradiation surface which is to be at least partially covered with a layer of powder to enable welding by passing a laser beam over the layer of powder, the laser beam passing over the irradiation surface of the first protective element during welding and then the irradiation surface of the second protective element, the second protective element having a shape capable of containing a layer of powder having a height that is greater at the end, in the direction of propagation of the laser beam during welding, of the second protective element than at the start of the second protective element.
    Type: Application
    Filed: December 21, 2012
    Publication date: April 16, 2015
    Inventors: Philippe Fabrice Jean-Yves Roussarie, Frédérique Laurence Machi, Nicolas Haettel, Thibaut Florent Wenger
  • Publication number: 20150093287
    Abstract: A a titanium alloy can be applied on a substrate by one of melting, welding, and depositing said titanium alloy on said substrate and solidifying said deposited or molten titanium alloy. Further, 0.01-0.4 weight % Boron can be added to said titanium alloy before or during said melting, welding or depositing said titanium alloy on said substrate.
    Type: Application
    Filed: May 16, 2012
    Publication date: April 2, 2015
    Applicant: GKN Aerospace Sweden AB
    Inventors: Robert Pederson, Frank Skystedt
  • Publication number: 20150090074
    Abstract: The invention refers to a method for manufacturing a three-dimensional metallic article/component made of a Ni-, Co-, Fe-based superalloy or combinations thereof, entirely or partly, by a powder based additive manufacturing process. During the step of performing powder melting by scanning a dual laser setup is used, where two laser beams of different beam properties are combined in the same machine and by adjusted beam profiling and integration of a suitable beam switch in a controlled manner a switching between two different laser beam diameters is performed. In each layer the laser beam with the smaller diameter scans the whole area and in every kth layer, with k>1, the laser beam with the larger diameter scans the area where a coarse grain size is needed thereby remelting the area with fine grain sizes. With such a manufacturing method higher lifetime and operation performances of metallic parts and prototypes can be reached.
    Type: Application
    Filed: September 25, 2014
    Publication date: April 2, 2015
    Inventors: Thomas ETTER, Matthias HOEBEL, Julius SCHURB, Felix ROERIG
  • Publication number: 20150093283
    Abstract: Improved devices and methods for additive manufacturing of implant components are disclosed, including improvements relating to utilizing support structures, aligning implant designs within the manufacturing apparatus, and making patient-adapted implants.
    Type: Application
    Filed: April 13, 2013
    Publication date: April 2, 2015
    Inventors: Bob Miller, David P. Hesketh
  • Publication number: 20150093719
    Abstract: A method of manufacturing an article including taking an article in an initial state formed using an additive manufacturing process, the article including at least one set of mounting features; performing a second manufacturing process to transform the article into a second state, which includes mounting, via the at least one set of mounting features, the article in a holding device of a machine for operating on the article, wherein the position and orientation of the article in three linear and three rotational degrees of freedom within the machine operating volume is known and defined by virtue of the interaction of the mounting features with the holding device, and processing at least one feature on the article. The at least one mounting feature includes kinematic mount features which engage with corresponding kinematic mount features on the holding device of the machine.
    Type: Application
    Filed: May 10, 2013
    Publication date: April 2, 2015
    Inventor: David Beeby
  • Publication number: 20150083692
    Abstract: Laser cladding filler material is introduced in a pattern on a on a substrate by a filler distribution apparatus having a linear or polygonal array of dispensing apertures for uniform distribution in advance of or during a laser beam transferring optical energy to the substrate. The distribution apparatus includes a housing (or assembly of coupled housings) that defines the distribution aperture array and an internal chamber in communication with the apertures that is adapted for retention of filler material. A mechanical feed mechanism, such as an auger, is adapted for feeding filler material from the internal chamber through the distribution apertures. A feed mechanism drive system is coupled to the mechanical feed mechanism, adapted for selectively varying filler material feed rate. The distribution aperture array may be selectively reconfigured to vary selectively the filler material distribution pattern.
    Type: Application
    Filed: September 12, 2012
    Publication date: March 26, 2015
    Inventor: Gerald J. Bruck
  • Publication number: 20150069668
    Abstract: An example multi-dimensional component building system includes a first chamber having at least one base disposed therein, a second chamber adjacent to and in fluid communication with the first chamber through a first door, and a third chamber adjacent to and in fluid communication with the second chamber through a second door. The second chamber is fluidly sealed from the first chamber if the first door is in a closed position. The second chamber is configured to receive the at least one base via a first transfer mechanism if the fluid parameters of the first chamber are approximately equal to the fluid parameters of the second chamber. The second chamber includes a directed heat source and a build-up material configured to form a component on the at least one base by melting or sintering. The third chamber is fluidly sealed from the second chamber if the first door is in a closed position.
    Type: Application
    Filed: November 14, 2014
    Publication date: March 12, 2015
    Inventors: Sergey Mironets, Agnes Klucha, Wendell V. Twelves, JR., Benjamin T. Fisk
  • Publication number: 20150068629
    Abstract: A three-dimensional printing process, a swirling device, and a thermal management process are disclosed. The three-dimensional printing process includes distributing a material to a selected region, selectively laser melting the material, and forming a swirling device from the material. The swirling device is printed by selective laser melting. The thermal management process includes providing an article having a swirling device printed by selective laser melting, and cooling a portion of the article by transporting air through the swirling device.
    Type: Application
    Filed: September 9, 2013
    Publication date: March 12, 2015
    Applicant: General Electric Company
    Inventors: Srikanth Chandrudu KOTTILINGAM, Victor John MORGAN, Benjamin Paul LACY, John Wesley HARRIS, Jr., David Edward SCHICK
  • Publication number: 20150071809
    Abstract: The present invention relates to a method for forming a three-dimensional article through successive fusion of parts of at least one layer of a powder bed provided on a work table. Said method comprising the steps of: providing at least a first and second powder tank, providing a first type of powder in said first powder tank having a first particle size distribution, providing a second type of powder in said second powder tank having a second particle size distribution, providing a first sub-layer of said first type of powder on said work table, providing a second sub-layer of said second type of powder on top of said first layer of said first type of powder, fusing said first and second sub-layers simultaneously with a high energy beam from a high energy beam source for forming a first cross section of said three-dimensional article.
    Type: Application
    Filed: April 15, 2014
    Publication date: March 12, 2015
    Applicant: Arcam AB
    Inventors: Johan Nordkvist, Ulf Ackelid, Anders Snis
  • Publication number: 20150055909
    Abstract: A method of refurbishing a bearing is disclosed. The method includes providing a bearing having a tube structure and inner and outer surfaces. The bearing is mounted onto a mounting unit and a cladding head of a laser cladding unit is positioned within a bore of the bearing. The cladding head forms laser cladding layers disposed on the inner surface of the bearing. The cladding layers increase a thickness of the bearing and reduce an internal diameter of the bearing.
    Type: Application
    Filed: August 21, 2014
    Publication date: February 26, 2015
    Inventor: David Weng Seng LOKE
  • Publication number: 20150050463
    Abstract: A powder rapid prototyping method includes steps of forming a thin layer 35a of a powder material, irradiating a heating energy beam to a specific region of the thin layer 35a of the powder material to thereby form a preliminary heating layer 35c whose temperature is elevated, and irradiating the heating energy beam to an inside region of the preliminary heating layer 35c whose temperature is elevated to melt and then solidify the thin layer 35a of the powder material to thereby form a solidified layer, wherein the respective steps are repeatedly implemented to fabricate a rapid prototyping model 51, 52.
    Type: Application
    Filed: April 30, 2014
    Publication date: February 19, 2015
    Applicant: Aspect Inc.
    Inventors: Shizuka NAKANO, Toru SHIMIZU, Masashi HAGIWARA, Masahiro SASSA
  • Publication number: 20150048058
    Abstract: Superalloy components, such as service-degraded turbine blades and vanes, are clad by laser beam welding. The welding/cladding path, including cladding application profile, is determined by prior, preferably real time, non-contact 3D dimensional scanning of the component and comparison of the acquired dimensional scan data with specification dimensional data for the component. A welding path for cladding the scanned component to conform its dimensions to the specification dimensional data is determined The laser welding apparatus, preferably in cooperation with a cladding filler material distribution apparatus, executes the welding path to apply the desired cladding profile. In some embodiments a post-weld non-contact 3D dimensional scan of the welded component is performed and the post-weld scan dimensional data are compared with the specification dimensional data.
    Type: Application
    Filed: July 8, 2013
    Publication date: February 19, 2015
    Inventors: Gerald J. Bruck, Ahmed Kamel
  • Publication number: 20150048059
    Abstract: The laser welding apparatus includes a welding head and a welding head scanning apparatus. A collimate lens installed on a head body of the welding head is arranged opposite to an end face of optical fibers. The welding head includes only the collimate lens as a lens and the length is shortened. A laser generated by a laser oscillator is introduced into the optical fiber, enters the collimate lens, and then is converted to a parallel beam by the collimate lens. The laser of a parallel beam is irradiated on a surface a welding portion of the welding object through a laser path and the surface of the welding portion is melted. Metallic powder is jetted from powder feed paths formed in a head body to the melted portion and build-up welding is performed on the surface of the welding portion.
    Type: Application
    Filed: August 4, 2014
    Publication date: February 19, 2015
    Inventors: Koichi KUROSAWA, Shinya OHMORI, Ren MORINAKA, Kazuhiro NITTA, Yoichi MAHARA, Keigo UCHIYAMA
  • Publication number: 20150041442
    Abstract: The invention relates to a method of forming a coating or of three-dimensional structural elements on substrate surfaces which is/are formed by TiAl, Said coating/Said three-dimensional structural elements is/are manufactured by laser build-up welding. The procedure is followed in the method in accordance with the invention that titanium and aluminum are supplied into the region of influence of at least one laser beam in wire and/or band form in a pure or alloyed form in each case as a single wire or a single band. They are melted by the thermal input and in this respect the materials are mixed with one another. The coating or three-dimensional structural elements are thereby formed with TiAl on the substrate surface.
    Type: Application
    Filed: March 25, 2013
    Publication date: February 12, 2015
    Inventors: Sebastian Thieme, Christoph Leyens, Steffen Nowotny
  • Publication number: 20150045903
    Abstract: A method of manufacturing an orthopedic implant is provided. The method includes creating a 3D model of an orthopedic implant having a solid portion and a porous portion and selectively adjusting a physical property of at least one of porosity of the porous portion, lattice thickness of the porous portion, beam profile of the porous portion, and topography of the 3D model. The entire implant is then additively manufactured based on the 3D model.
    Type: Application
    Filed: August 8, 2014
    Publication date: February 12, 2015
    Inventor: David J. Neal