Abstract:
An airfoil includes an airfoil body that defines a longitudinal axis. The airfoil body includes a leading edge and a trailing edge and a first side wall and a second side wall that is spaced apart from the first side wall. The first side wall and the second side wall join the leading edge and the trailing edge and at least partially define a cavity in the airfoil body. A lattice network connects the first side and the second side. The lattice network includes at least one enlarged node spaced apart from the first side wall and the second side wall and ribs that extend from the at least one enlarged node. Each of the ribs connects to one of the first side wall and the second side wall.
Abstract:
A multi-dimensional component building system (18) comprising a first chamber (10) adjacent to and in fluid communication with at least one second chamber (12) through at least one door, wherein the first chamber (10) is fluidly sealed from the at least one second chamber (12) if the at least one door is in a closed position, the at least one second chamber (12) configured to provide a base to a first platform in the first chamber (10) if at least one door is open and fluid parameters of the first chamber (10) and the at least one second chamber (12) are substantially equal, wherein the first chamber (10) includes the first platform moveable by a first piston adjacent a second platform moveable by a second piston, wherein the first platform is configured to receive at least one base, wherein a dispenser in communication with build-up material disposed on the second platform is configured to move a portion of the build-up material from the second platform onto the at least one base on the first platform, the first chamber (10) including a beam source to form a component on the at least one base from the build-up material by melting or sintering.
Abstract:
A multi-dimensional component building system (18) comprising a first chamber (10) adjacent to and in fluid communication with at least one second chamber (12) through at least one door, wherein the first chamber (10) is fluidly sealed from the at least one second chamber (12) if the at least one door is in a closed position, the at least one second chamber (12) configured to provide a base to a first platform in the first chamber (10) if at least one door is open and fluid parameters of the first chamber (10) and the at least one second chamber (12) are substantially equal, wherein the first chamber (10) includes the first platform moveable by a first piston adjacent a second platform moveable by a second piston, wherein the first platform is configured to receive at least one base, wherein a dispenser in communication with build-up material disposed on the second platform is configured to move a portion of the build-up material from the second platform onto the at least one base on the first platform, the first chamber (10) including a beam source to form a component on the at least one base from the build-up material by melting or sintering.
Abstract:
A system is provided for additively manufacturing a part. This additive manufacturing system includes a base, a solidification device and a detection device. The base is adapted to support material; e.g., powder material. The solidification device is adapted to solidify at least a portion of the supported material to form at least a portion of the part. The detection device is adapted to detect emissions produced by the solidification of at least a portion of the material.
Abstract:
A powder bed deposition apparatus comprises a movable build plate, a powder delivery system, an energy beam apparatus capable of selectively steering at least one focused energy beam over successive quantities of metal powder, a non-metallic barrier layer, and an anchor removably secured to the build plate. The non-metallic barrier layer is disposed over a metal upper surface of the build plate. The anchor has a metal bonding surface flush with the non-metallic barrier layer, the non-metallic barrier layer and the anchor defining a removable build assembly with a powder bed working surface.
Abstract:
A gas turbine airfoil having internal cooling passages is formed by additive manufacturing. Layers of superalloy powder are fused by an energy beam using a two-dimensional pattern providing unmelted areas forming passageways therein. Layers of the powder are added and fused using sufficient two-dimensional patterns to form the entire airfoil with the desired pattern of internal cooling passages. After completion of the formation of the airfoil, it may be hot isostatic pressed, directionally recrystallized, bond coated, and covered with a thermal barrier layer.
Abstract:
An airfoil includes an airfoil body that defines a longitudinal axis. The airfoil body includes a leading edge and a trailing edge and a first side wall and a second side wall that is spaced apart from the first side wall. The first side wall and the second side wall join the leading edge and the trailing edge and at least partially define a cavity in the airfoil body. A lattice network connects the first side and the second side. The lattice network includes at least one enlarged node spaced apart from the first side wall and the second side wall and ribs that extend from the at least one enlarged node. Each of the ribs connects to one of the first side wall and the second side wall.
Abstract:
A method of forming an object includes installing multiple foil drums within a processing chamber of an ultrasonic consolidation system. The multiple foil drums each include different materials than the other foil drums. The multiple foil drums are positioned so that one of the foils is selected to be placed on top of the build platform. The selected foil is welded onto the build platform or onto a previously processed layer. A portion of the welded foil is then cut. The multiple foil drums are retracted away from the build platform. The portion of the welded foil that was just cut is then consolidated to the object. The build platform is incrementally lowered before the process is repeated to form the next layer of the object.