Object production

Abstract

Methods and apparatus for producing an object, the method comprising: performing an Additive Manufacturing process to produce an intermediate object from provided metal or alloy, whereby the intermediate object comprises regions having a contaminant concentration level above a threshold level; based upon one or more parameters, determining a temperature and a duration; and performing, on the intermediate object, a contaminant dispersion process by, for a duration that is greater than or equal to the determined duration, heating the intermediate object to a temperature that is greater than or equal to the determined temperature and less than the melting point of the metal or alloy, the contaminant dispersion process being performed so as to disperse, within the intermediate object, a contaminant from regions of high contaminant concentration to regions of low contaminant concentration until the intermediate object comprises no regions having a contaminant concentration level above the threshold level.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]This application is the National Stage of International Application No. PCT / GB2013 / 050410, filed 20 Feb. 2013, which claims the benefit of and priority to GB 1203359.3, filed 24 Feb. 2012, and GB1301173.9, filed 23 Jan. 2013, the contents of all of which are incorporated by reference as if fully set forth herein.FIELD OF THE INVENTION[0002]The present invention relates to the production of objects.BACKGROUND[0003]Additive Manufacturing (AM) (also known as Additive Layer Manufacturing (ALM), 3D printing, etc.) refers to processes that may be used to produce functional, complex objects, layer by layer, without moulds or dies. Typically, AM processes include providing material (e.g. metal, ceramic or plastic) in the form of a powder or a wire, and, using a powerful heat source (such as a laser beam, electron beam or an electric, or plasma welding arc), an amount of that material is melted and deposited upon a base work piece. Subsequent layer...

AI Technical Summary

Benefits of technology

This patent describes a method for making an object by forming multiple open cavities in an intermediate object and then sealing them to create a closed cavity. This reduces the size of the object and improves its strength. The technical effect is the creation of an object with a hollow interior that is sealed and consolidated, resulting in a stronger, more durable object.

Problems solved by technology

However, objects produced using AM processes, particularly those made using powder material, may comprise one or more contaminated regions, i.e. regions in which the material that forms the object has been contaminated by a contaminant (e.g. oxygen).

The presence of such contaminated regions and other imperfections tend to adversely affect the fatigue performance of an object, especially in high-cycle fatigue situations.

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