Apparatus for production of filler packets for solid freeform fabrication
Inactive Publication Date: 2016-01-28
SIEMENS ENERGY INC
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Benefits of technology
The patent text describes a method for producing powdered metal packets for use in additive manufacturing and repair processes. These packets contain a precise amount of filler material that can be easily delivered to the point of processing, resulting in higher throughput and reduced waste. The use of powder packets simplifies the production process and allows for faster and more efficient implementation of this technology. The technical effects of this invention include improved efficiency and accuracy in the production of additive manufacturing components and repair parts.
Problems solved by technology
Superalloy materials are among the most difficult materials to fabricate and repair due to their susceptibility to melt solidification cracking and strain age cracking.
The disadvantages of preplacement include:only relatively horizontal surface can be processed; andpreplacement is somewhat labor intensive and generally slower than continuous processing.
Method used
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[0019]The present inventors have found that the use of powder packets during an additive manufacturing process is very desirable, but that the production of those packets can be very time consuming and labor intensive, particularly to form filler packets for gas turbine engine applications where manufacturing and repair tolerances may be very tight. Accordingly, the inventors have developed techniques and devices for producing filler powder packets that advance the art and that facilitate the commercial implementation of this technology.
[0020]The present inventors utilize packets of powdered filler material for laser deposition in solid freeform fabrication and repair of difficult to weld superalloy components. The packets contain metal and flux for preplacement on an article being repaired or fabricated. A laser beam melts the metal into a layer and fuses it to the article. The flux facilitates metal fusion and provides a slag blanket that shields the melt pool from air. It also tr...
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Abstract
A hopper (30) holds a metal and flux powder (24). A filler tube (28) conveys the powder from the hopper. Compressed gas (36) is injected into the powder to fluidize and convey the powder through the filler tube. The hopper may be vibrated (34) to prevent clumping. A gas permeable envelope (29) surrounds the filler tube and is filled with powder as it moves off the end of the filler tube. The gas escapes from the permeable envelope. Feed mechanisms (54, 56, 66, 74) may feed gas permeable sheets (55, 57) over opposite sides of the filler tube. A seaming device (58A-B, 78A-B) may seam the sheets along their edges to form the gas permeable envelope surrounding the filler tube. Closing (40) and cutting (42) machines close and cut the envelope, forming a packet (22) containing the powder.
Description
FIELD OF THE INVENTION[0001]This invention relates generally to the field of additive manufacturing, and more specifically to the production of packets of powdered metal or powdered metal and flux for preplacement of filler material for laser deposition in solid freeform fabrication and repair, and particularly for laser cladding on superalloy turbine components.BACKGROUND OF THE INVENTION[0002]Solid Freeform Fabrication (SFF) technologies produce functional metal parts by layer-wise accumulation and consolidation of feed material (e.g. powder or wire), allowing parts to be produced with a high geometric freedom directly from a CAD model. The feed material is called “filler” because it provides additive material that forms a bead or layer for repair or fabrication. A group of SFF technologies known as direct metal laser fabrication (DMLF) utilizes lasers to consolidate powder. Other groups use tungsten inert gas (TIG), metal inert gas (MIG), or electron beam technologies.[0003]In ad...
Claims
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Patent Timeline
Login to View More IPC IPC(8): B65B9/02B65B1/16B65B35/02B65B39/00B65B51/07B65B61/06
CPCB65B9/023B65B1/16B65B39/007B65B61/06B65B51/07B65B35/02B65B37/04B65B39/12B65B51/02B65B51/10
Inventor BRUCK, GERALD J.KAMEL, AHMED
Owner SIEMENS ENERGY INC