Directed energy deposition systems and methods for component repair

Abstract

A directed energy deposition (DED) system may include a nozzle that deposits metal powder onto a plurality of locations of a repair region. The first energy source is configured to output a first energy beam from a first output positionable by one or more actuators to direct the first energy beam onto the repair region at a first angle or a second angle relative to the cavity axis, thereby melting a deposit of metal powder at a first set of locations of the plurality of locations or a second set of locations of the plurality of locations.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority from European application No. 24425005.6, filed on March 1, 2024, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] These teachings relate generally to jet engines and, more particularly, to directed energy deposition systems and methods for repairing jet engine-related components. Background Art

[0004] Directed energy deposition (DED) systems use additive manufacturing to repair or construct metal parts. These systems deposit metal powder or similar material onto a substrate and apply a directed energy source (e.g., a laser) to the deposited material as it is deposited. The directed energy source melts and welds the material to the substrate and / or to previously laid-down layers of previously melted and now solidified metal powder. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Various needs are at least partially met by providing a directed energy deposition system and method for component repair as described in the following detailed description, particularly when studied in conjunction with the accompanying drawings. A complete and enabling disclosure of various aspects of the present description, including the best mode thereof, is set forth in the specification with reference to the accompanying drawings, wherein:

[0006] Figure 1 is a schematic diagram of a directed energy deposition (DED) system according to various embodiments;

[0007] Figure 2 According to various embodiments Figure 1 Schematic diagram of a DED system in which the nozzle and its energy source are positioned at different angles relative to the cavity axis;

[0008] Figure 3 According to various embodiments, Figure 1 and Figure 2 A perspective view of the first and second energy sources of the DED system;

[0009] Figure 4 is a method for Figure 1 and Figure 2 A perspective view of an induction heating element used with a DED system;

[0010] Figure 5 is a schematic diagram of a DED system for depositing metal powder onto a repair area in a spiral deposition pattern according to various embodiments;

[0011] Figure 6 and Figure 7 is a schematic diagram of a spiral deposition pattern according to various embodiments; and

[0012] Figure 8 is a schematic cross-sectional view of a repaired area of ​​a part after filling with multiple layers of melted and solidified metal powder according to various embodiments;

[0013] Figure 9 is a schematic diagram of a spiral deposition pattern according to various embodiments; and

[0014] Figure 10 is a flow chart of a method according to various embodiments.

[0015] The elements shown in the figures are shown for simplicity and clarity and are not necessarily drawn to scale. For example, the size and / or relative positioning of some elements in the figures may be exaggerated relative to other elements to help improve understanding of the various embodiments of the present teachings. In addition, in order to facilitate viewing these various embodiments of the present teachings with less obstruction, common but easy-to-understand elements that are useful or necessary in commercially viable embodiments are generally not depicted. Certain actions and / or steps may be described or depicted in a specific order of occurrence, and those skilled in the art will understand that such specificity about the order is not actually required. DETAILED DESCRIPTION

[0016] Unless otherwise specified herein, the terms and expressions used herein have the ordinary technical meanings ascribed to them by those skilled in the art. Unless expressly provided otherwise, the term "or" as used herein should be interpreted as having a disjunctive rather than a conjunctive structure. Unless otherwise specified herein, the terms "coupled," "fixed," "attached to," and the like refer to both direct coupling, fixing, or attachment and indirect coupling, fixing, or attachment via one or more intermediate components or features.

[0017] The singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0018] As used herein throughout the specification and claims, approximating language is used to modify any quantitative representation that can be permissibly varied without resulting in a change in the basic function to which it is related. Thus, values ​​modified by terms such as "about," "approximately," and "substantially" are not limited to the precise values ​​specified. In at least some instances, approximating language may correspond to the precision of an instrument used to measure the value, or the precision of a method or machine used to construct or manufacture a component and / or system. For example, approximating language may mean within a 10% margin.

[0019] Currently known directed energy deposition (DED) systems for part repair utilize a single energy source, such as a laser beam, to melt and bond a metal deposit to the repair area. The repair area is typically a flat surface area where successive layers of deposited and melted metal material are built up to rebuild or repair thin-walled areas of the part. Furthermore, these DED systems utilize only a secondary directed energy source for preheating purposes and employ simple linear or similar tool paths when depositing the metal material. These characteristics can pose problems for repairing more complex jet engine-related components, where the repair area includes a concave cutout with sloped sidewalls.

[0020] Generally speaking, various aspects of the present disclosure can be used with a laser energy deposition (DED) system having a nozzle for depositing metal powder (e.g., titanium aluminide powder or the like) at multiple locations on a repair region of a part according to a preconfigured deposition pattern. In some aspects, first and second energy sources are positioned and / or tilted at different locations relative to the repair region and activated throughout the preconfigured deposition pattern to melt the deposits of metal powder at different groups of locations within the preconfigured deposition pattern. Specifically, the DED systems and methods described herein can be used to perform buildup repairs in cavity-shaped geometries using laser metal deposition techniques to repair titanium aluminide components affected by internal defects (e.g., turbine blades for jet engines, etc.). The repair region can be characterized as a concave or partially U-shaped cavity with sloped sidewalls. Such a cavity can be achieved by removing internal defects from the titanium aluminide component using a drilling tool or similar tool. The DED system described herein can include a multi-jet laser metal deposition system comprising a primary laser beam source and a secondary laser beam source, the primary laser beam source being directed concentrically with the primary nozzle through which the metal powder is deposited and directed to the repair region. Both sources contribute to melting the titanium aluminide metal powder that is deposited onto the repair area through the primary nozzle. In some cases, an induction heating system is used to locally preheat the repair area to a target heating temperature to avoid crack formation in the fill cavity due to thermal gradients. Preconfigured deposition patterns can include a bidirectional spiral deposition strategy for filling the cavity. The bidirectional spiral deposition pattern is advantageous for filling repair area cavities that include sloping vertical walls. These types of cavities can be used to remove internal defects located within the part, rather than surface-level defects that can be cut and easily filled with less complex deposition strategies employed by current systems. In addition, the alternating bidirectional starting point nature of the spiral deposition pattern and the spiral nature of the pattern itself help provide a good thermal profile for the molten metal powder as it cools. This thermal profile helps ensure uniformity in the final solidified quality of the metal powder and adherence of that quality to the repair area.

[0021] The above and other benefits may become more apparent after a thorough review and study of the following detailed description. Figure 1 and Figure 2 , a DED system 100 compatible with many of these teachings will now be described. The DED system 100 includes a first energy source 102, a nozzle 104, and a second energy source 106. In some embodiments, the first energy source 102 and the second energy source 106 include laser energy sources, but other alternative directed energy sources known in the art may also be used.

[0022] The nozzle 104 is configured to deposit metal powder (e.g., titanium aluminide powder) onto a plurality of locations of a repair area 114 of a part 116 while moving according to a preconfigured deposition pattern. The part 116 may include a component of a turbine engine, such as a fan blade, a rotor blade, a stator blade, etc. In some embodiments, as described in more detail below, the repair area may include a cavity cut out from the surface of the part 116, wherein an internal or external defect is present in the repair area 114. The first energy source 102 is configured to output a first energy beam 108 from its first output end 103. The first energy source 102 and / or its output end may be positioned to direct a central axis B of the first energy beam 108 onto the repair area 114 at a first angle X relative to a cavity axis A of the repair area 114. The cavity axis A is located at a surface at the center of the repair area 114 and extends orthogonal to the surface. The first energy beam 108 positioned at the first angle X is used to melt the deposits of metal powder at a first group of locations among a plurality of locations. As Figure 2 As shown, the first energy source 102 and / or its output can be positioned to direct the central axis B of the first energy beam 108 at a second angle Z relative to the cavity axis A onto the repair area 114. The first energy beam 108 positioned at the second angle Z is used to melt the deposit of metal powder located at a second set of locations in the plurality of locations. The second angle Z is different from the first angle X. In some embodiments, the first angle X is in a range of about 0 degrees to about 5 degrees, while the second angle Z is in a range of about 5 degrees to about 20 degrees.

[0023] The second energy source 106 is configured to output a second energy beam 110 from its second output end 105. The second energy source 106 and / or its second output end 105 are positioned to direct a central axis C of the second energy beam 110 at a third angle Y relative to a central axis B of the first energy beam 108 onto a repair region 114 of the part 116. In some embodiments, the third angle Y is in a range of approximately 30 degrees to approximately 40 degrees. The second energy source 106 is activated along with the first energy source 102 and is used to melt the deposits of metal powder at a first set of locations in the plurality of locations and a second set of locations in the plurality of locations. Additionally, the first energy source 102 and / or the second energy source 106 may be activated to preheat the repair region 114 to a predetermined temperature before the nozzle 104 deposits material onto the repair region 114.

[0024] like Figure 1 and Figure 2 As shown, the first energy source 102 and the nozzle 104 can be juxtaposed within the housing 112. In some embodiments, the first energy source 102 and the nozzle 104 can be in a concentric relationship. However, in some embodiments, the first energy source 102 and the nozzle 104 are distinct components having separate respective housings that can be manipulated independently.

[0025] Furthermore, the DED system 100 may include a drilling tool 118 or similar machine tool configured to form the repair region 114. The drilling tool 118 may be a distinct component from the first energy source 102, the nozzle 104, and / or the second energy source 106. The drilling tool 118 may be configured to form the repair region 114 in the part as a symmetrical cavity. In some examples, the maximum depth of the cavity is in the range of approximately 4 mm to approximately 7 mm. The symmetrical cavity may also include walls disposed at an angle in the range of approximately 5 degrees to approximately 20 degrees relative to the cavity axis A. In other examples, the cavity may have different depths and / or walls disposed at different angles. The cavity dimensions described herein are particularly advantageous for minimizing the amount of material removed relative to internal porosity defects in the part 116. Specifically, the shape and dimensions of the cavity minimize the amount of buildup material deposited on the part 116 and, therefore, minimize the material / mechanical impact of the repair. Furthermore, these dimensions limit the preparation time for depositing material onto the repair region 114.

[0026] Furthermore, the DED system 100 includes at least one actuator 121 or similar precision movement device for moving the deposited material according to a preconfigured deposition pattern and at least Figure 1 and Figure 2 , and / or the second energy source 106 are positioned at the angles X and Z shown in FIG. The controller 122 is in electrical communication with the at least one actuator 121 and instructs the at least one actuator 121 to position the first energy source 102, the nozzle 104, and / or the second energy source 106 according to a preconfigured deposition pattern. The controller 122 can also be configured to activate the first energy source 102 and the second energy source 106 to emit the first energy beam 108 and the second energy beam 110, respectively. Similarly, the controller 122 can control the flow rate of the metal powder flowing out of the nozzle 104.

[0027] The controller 122 may include one or more processors, for example, one or more processors may include a microprocessor, a system on a chip, an application specific integrated circuit (ASIC), and / or a field programmable gate array (FPGA). The controller 122 may also include a memory, which may store program instructions related to a preconfigured deposition pattern and may include, for example, a charge-based storage medium such as an electrically erasable programmable read-only memory (EEPROM) or a random access memory (RAM), or other non-transitory computer-readable media such as an optical or magnetic storage device.

[0028] like Figure 3 As shown, the housing 112 containing the first energy source 102 and the nozzle 104 is fixed to the support structure 120 together with the second energy source 106. In this way, the central axis C ( Figure 1 and Figure 2 ) angle Y( Figure 1 and Figure 2 ) can be relative to the central axis B of the first energy beam 108 of the first energy source 102 ( Figure 1 and Figure 2 ) is fixed. In addition, the output terminals 103 and 105 ( Figure 1 and Figure 2 ) follows a preconfigured deposition pattern as described herein, which may be achieved by moving the support structure 120 using at least one actuator 121 as directed by a controller 122.

[0029] In some embodiments, the DED system 100 may include: Figure 4 The induction heating element 200 is configured to apply electromagnetic waves to the repair area 114 ( Figure 1 ), to the nozzle 104 ( Figure 1 ) depositing metal powder onto the repair area 114 ( Figure 1 ) before starting to repair area 114 ( Figure 1) to a target heating temperature. When activated by the controller 122, the induction heating element 200 generates an alternating electromagnetic field that induces eddy currents in the part 116, which heat the part 116 through the Joule effect. The induction heating element 200 is configured to take into account the shape of the part 116 and the repair area 116 being preheated, the physical constraints of the DED system 100 (for example, conflicts with other components of the DED system 100 and / or the part 116), to output desired power and frequency values ​​of the alternating electromagnetic field and generate a target temperature at the repair area 114. In some embodiments, the induction heating element 200 can continue to heat the repair area 114 while the metal powder is being deposited and melted according to a preconfigured deposition pattern. In some embodiments, the induction heating element includes a heating section 202 having a substantially uniform distribution of heat energy with respect to the repair area 114 ( Figure 1 ) of the repair area 114 ( Figure 1 ) inside and / or around the outside of the repair area 114 (e.g., from Figure 1 bottom of the part 116) so that electromagnetic waves are applied to the repair area 114.

[0030] Now refer to Figure 5 , it is shown that, in some embodiments, the preconfigured deposition pattern includes moving the nozzle 104 to deposit metal powder on the repair area 114 in a plurality of spiral pattern layers 300. Specifically, the nozzle 104 moves along the repair area 114 according to the preconfigured deposition pattern to deposit metal powder in tracks 302, which, when viewed together, are formed in the plurality of spiral pattern layers 300 (see Figure 6 and 7 ) in a spiral pattern moving between a starting point 304 and an end point 306 of each of the first and second energy sources 102 and 106. As the metal powder is deposited, both the first and second energy sources 102 and 106 are activated to melt the deposited powder, thereby forming a metal layer that is aligned with the repair area 114 itself or with a previously laid metal layer formed of melted and solidified metal powder (see, e.g., Figure 8 ) bonded metal layer.

[0031] like Figure 6 and Figure 7 As shown, the starting point 304 of each of the plurality of spiral pattern layers 300 may be located at a position as shown in FIG. Figure 6 The shown cavity axis A( Figure 1 ) aligned internal position and such Figure 7 The repair area 114 ( Figure 1). Furthermore, the end points 306 alternate in a manner opposite to the start points 304. The initial layer in the plurality of spiral pattern layers 300 can begin at either the inner or outer positions. Alternating the start points 304 and end points 306 in this manner can help evenly cool the molten metal powder layer and provide uniform heat distribution between and across the plurality of spiral pattern layers 300.

[0032] like Figure 8 As shown, after multiple spiral pattern layers 300 are laid down, melted by the first energy source 102 and the second energy source 106, and cooled to form a solid metal block that is bonded to the part 116, the repair area 114 of the part 116 is filled with each of these layers. In this example, the repair area 114 is filled with ten spiral pattern layers labeled 300a-300j. However, in other examples, the repair area 114 can be filled with more or fewer spiral pattern layers, which may depend on the depth of the repair area 114. Figure 8 As shown, with the repair area 114 ( Figure 1 ) is slowly filled with solidified layers of previously melted metal powder, with the total width and / or two-dimensional area of ​​each of the plurality of spiral pattern layers 300a-300j increasing upward from the initially laid layer 300a. This increase in width and / or two-dimensional area will track the increase in width and / or two-dimensional area of ​​the repair region 114 from its bottom to the top section aligned with the non-cut portion of the part 116 (see Figure 1 and Figure 8 ).

[0033] refer to Figure 5-8 In some embodiments, the preconfigured deposition pattern may include about 10 to about 20 spiral pattern layers 300. In addition, each of the tracks 302 in the plurality of spiral pattern layers 300 may have a width 307 that depends on the first energy source 102 ( Figure 1 )'s first power output, the second energy source 106 ( Figure 1 ), the rate at which the nozzle 104 deposits the metal powder, and / or the vertical distance 800 ( Figure 8 In some embodiments, the first power output of the first energy source 102 is in the range of about 50 watts to about 500 watts, and the second power output of the second energy source 106 is in the range of about 50 watts to about 500 watts. The first and second power outputs may be the same or different. The deposition rate of the metal powder from the nozzle 104 may be in the range of about 0.5 g / s to about 2 g / s. In addition, the vertical distance 800 ( Figure 8) can be in the range of about 0.3 mm to about 0.7 mm. These variables can result in a width of track 302 in the range of about 1 mm to about 3.5 mm. This combination of specific process parameters can result in a repaired version of part 116 that is free of deposition-induced internal defects (e.g., missing material, porosity, cracks, inclusions, etc.), has good adhesion between the deposited material and the original base metal of part 116 (e.g., has no fusion defects), and has a cavity that is completely filled with the deposited material.

[0034] In some embodiments, the nozzle 104 is moved by at least one actuator 121 and a controller 122 according to a preconfigured deposition pattern to deposit the metal powder in a plurality of spiral pattern layers 300, which can be configured such that there is at least some overlap in the width 307 of each of the tracks 302 in the plurality of spiral pattern layers 300, e.g. Figure 6 After the operation of the DED system 100 is completed, this overlap can help to repair the area 114 ( Figure 1 and Figure 8 ) creates a strong and cohesive metal mass within and joined to the repair area 114. In some embodiments, the overlap between the tracks 302 is in the range of about 1.0 mm to about 2.5 mm.

[0035] Now refer to Figure 1 、 2 and 9, in some embodiments, the first energy beam 108 is at a first angle X( Figure 1 ) includes a plurality of locations on a first set of spiral pattern layers in the plurality of spiral pattern layers and an inner portion 308 ( Figure 9 ). The first energy beam 108 is at a second angle Z ( Figure 2 ) includes an outer portion 310 ( Figure 9). A first group of spiral pattern layers in the plurality of spiral pattern layers 300 may include layer numbers 1 to 7, while a second group of spiral pattern layers in the plurality of spiral pattern layers 300 may include layer numbers 8 and above. For example, each of the plurality of spiral pattern layers 300 numbered 1-7 will be constructed by having an energy beam 108 positioned at a first angle X to melt the deposit of metal powder laid down by the nozzle 104 for the entire spiral pattern layer. In addition, for 8 layers and above, the inner portion 308 of each spiral pattern deployment is constructed by the energy beam 108 at the first angle X, such as layers 1-7, while the outer portion of 8 layers and above is constructed by the energy beam 108 positioned at the second angle Y. The angle of the first energy beam 108 is changed to accommodate the inclination in the wall of the repair area 114 and helps promote proper melting and adhesion of the metal powder to the repair area 114 and / or previously deposited layers having similar inclinations. It should be understood that the specific number of layers in the first and second groups may vary based on the specific dimensions of the cavity engraved to form the repair area 114. For example, a smaller cavity with more steeply sloping walls may have fewer layers in the first group than a larger cavity with more gradually sloping walls.

[0036] like Figure 9 As shown, the angle of the first energy beam 108 can be at a first angle X( Figure 1 ) and the second angle Z( Figure 2 ). In some embodiments, the outer portion 310 may correspond to a location near the inclined wall of the repair area 114. As described herein, the inclination of the wall may be relative to the cavity axis A ( Figure 1 and Figure 2 ) has an angle of about 5 degrees to about 20 degrees. In some embodiments, the second angle Z can match the angle of the tilt. The combination of the tilted walls and the tilt of the first energy beam 108 and / or the second energy beam 110 is beneficial for diluting the deposited material on the repair area 114 and obtaining a good quality deposit thereon. Ideal deposition is when the repair area is perpendicular to the tilt of the energy source, but this situation cannot be achieved for defects such as internal porosity. Therefore, the specific tilt of the cavity wall and the angles of the energy beams 108 and 110 are selected to achieve a compromise between minimizing the amount of material removed from the part 116 and obtaining a good quality deposit.

[0037] Furthermore, the transition point 312 may be positioned at a different point on each of the plurality of spiral pattern layers 300 in the second group and may correspond to a location where the repair area 114 or a previously deposited layer is displaced from the sloped wall and is relatively flat in comparison (e.g., having a slope of less than about 5 degrees). In some embodiments, the distance between the transition point 312 and the sloped wall of the repair area 114 may be in the range of about 1 mm to 3.5 mm. Changing the angle of the first energy beam 108 based on the slope of the wall of the repair area 114 helps promote adhesion of the molten metal powder to the repair area 114 and / or a previously deposited layer having a similar slope.

[0038] In some embodiments, the angle of the first energy beam 108 may be continuously varied throughout the trajectory 302 such that the central axis B of the first energy beam 108 remains substantially perpendicular to the immediate area of ​​the repair area 114 where the nozzle 104 is depositing metal powder. This continuous variation in the angle of the first energy beam 108 may be pre-programmed based on a known profile of the repair area 114 or may be dynamically determined using feedback from a sensor that determines the tilt angle of the immediate area of ​​the repair area 114 where the nozzle 104 is depositing metal powder.

[0039] refer to Figure 1 、 210, the DED system 100 described herein can also be used in conjunction with a method 1000 for repairing a part 116. The method includes forming a repair region 114 in the part 116, as shown in 1010. For example, the repair region 114 can be formed in the part 116 using a drilling tool 118 as described herein. The method 1000 then includes positioning and activating the nozzle 104 to deposit metal powder onto a plurality of locations of the repair region 114 according to a preconfigured deposition pattern, as shown in 1020. For example, the controller 122 can instruct at least one actuator 121 to move the nozzle 104 according to the preconfigured deposition pattern and / or control the flow rate of the metal powder deposited onto the repair region 114. The method 1000 also includes moving the first output 103 of the first energy source 102 to a first position to direct a central axis B of the first energy beam 108 at a first angle X relative to the cavity axis A onto the repair region 114 when the nozzle 104 is at a first set of the plurality of positions, as shown in 1030. Furthermore, method 1000 includes activating the first energy source 102 to melt deposits of metal powder at a first set of locations among the plurality of locations when the metal powder is deposited at those locations through the nozzle 104, as shown in 1040. Method 1000 also includes moving the first output end 103 of the first energy source 102 to a second position to direct the central axis B of the first energy beam 108 at a second angle Z relative to the cavity axis A of the repair area 114 onto the repair area 114 when the nozzle 104 is at the second set of locations among the plurality of locations, and activating the first energy source 102 to melt deposits of metal powder at the second set of locations when the metal powder is deposited at those locations through the nozzle 104, as shown in 1050 and 1060. Finally, method 1000 includes activating the second energy source 106 in conjunction with the first energy source 102 to output the second energy beam 110 from its second output end 105, as shown in 1070. As described herein, the second output end 105 of the second energy source 106 is positioned to direct the central axis C of the second energy beam 110 at a third angle Y relative to the central axis B of the first energy beam 108 onto the repair area 114 so as to melt the deposits of metal powder at the first set of locations in the plurality of locations and the second set of locations in the plurality of locations when the metal powder is deposited at those locations through the nozzle 104. In some embodiments, the method 1000 may further include activating the induction heating element 200 ( Figure 4 ) to apply electromagnetic waves to the repair area 114 so as to heat the repair area 114 to a target heating temperature before the nozzle 104 deposits metal powder onto multiple locations of the repair area 114.

[0040] The DED system 100 and method of operation 1000 provide improvements for repairing complex defects in parts such as jet engine-related components (e.g., fan blades, rotor blades, stator blades, etc.). Specifically, the use of spiral patterned layers and multiple energy sources to melt the metal deposit enables the DED system 100 and associated method 1000 to completely fill a concave cutout area having sloped sidewalls with a solid, cohesive mass of metal.

[0041] Further aspects of the present disclosure are provided by the subject matter of the following clauses:

[0042] A directed energy deposition (DED) system comprises: a nozzle configured to deposit metal powder onto a plurality of locations of a repair region of a part according to a preconfigured deposition pattern; a controller; a first energy source configured to output a first energy beam from a first output end thereof; and at least one actuator in electrical communication with the controller, the at least one actuator being configured, under the direction of the controller, to: move the nozzle according to the preconfigured deposition pattern; position the first output end of the first energy source at a first position, wherein a central axis of the first energy beam is directed onto the repair region at a first angle relative to a cavity axis of the repair region so as to melt deposits of the metal powder at a first set of locations among the plurality of locations; and position the first output end of the first energy source at a second position, wherein the central axis of the first energy beam is directed onto the repair region at a second angle relative to the cavity axis of the repair region so as to melt deposits of the metal powder at a second set of locations among the plurality of locations, wherein the second angle is different from the first angle.

[0043] The DED system according to any preceding clause, further comprising a second energy source configured to output a second energy beam from a second output end thereof, wherein the controller is configured to direct the at least one actuator to position the second output end of the second energy source so as to direct a central axis of the second energy beam onto the repair area of ​​the part at a third angle relative to the central axis of the first energy beam so as to melt the deposits of the metal powder located at the first group of positions among the plurality of positions and the second group of positions among the plurality of positions.

[0044] The DED system of any preceding clause, further comprising a housing containing the nozzle and the first energy source.

[0045] The DED system of any preceding clause, further comprising an induction heating element, wherein the controller is configured to activate the induction heating element to apply electromagnetic waves to the repair area to begin heating the repair area to a target heating temperature before the nozzle deposits the metal powder onto the plurality of locations on the repair area.

[0046] The DED system of any preceding clause, wherein the induction heating element comprises a heating section having a geometry that matches a geometry of the repair region.

[0047] The DED system of any preceding clause, further comprising a drilling tool configured to form the repair area in the part as a symmetrical cavity having a maximum depth in the range of 4 mm to 7 mm, the symmetrical cavity comprising walls disposed at an angle in the range of 5 degrees to 20 degrees relative to the cavity axis.

[0048] A DED system according to any preceding clause, wherein the preconfigured deposition pattern in which the actuator moves the nozzle to deposit the metal powder onto the repair area includes a plurality of spiral pattern layers, wherein the starting point of each of the plurality of spiral pattern layers alternates between an inner position aligned based on the cavity axis and an outer position aligned based on the periphery of the repair area present at each of the plurality of spiral pattern layers.

[0049] The DED system of any preceding clause, wherein the plurality of spiral pattern layers comprises 10 to 20 layers.

[0050] The DED system of any preceding clause, wherein a vertical distance between each of the plurality of spiral pattern layers is in the range of 0.3 mm to 0.7 mm.

[0051] The DED system of any preceding clause, wherein the individual trace of each of the plurality of spiral pattern layers has an overlap with a previously deposited trace of the same spiral pattern layer of the plurality of spiral pattern layers, the overlap being in the range of 1.0 mm to 2.5 mm.

[0052] A DED system according to any preceding clause, wherein the first group of positions in the plurality of positions includes all of the plurality of positions on the first group of spiral pattern layers in the plurality of spiral pattern layers and the inner portion of the second group of spiral pattern layers in the plurality of spiral pattern layers, and wherein the second group of positions in the plurality of positions includes the outer portion of the second group of spiral pattern layers in the plurality of spiral pattern layers.

[0053] The DED system of any preceding clause, wherein the first set of the plurality of spiral pattern layers comprises layer numbers 1 through 7, and wherein the second set of the plurality of spiral pattern layers comprises layer numbers 8 and above.

[0054] The DED system of any preceding clause, wherein the first angle is in the range of 0 degrees to 5 degrees.

[0055] The DED system of any preceding clause, wherein the second angle is in the range of 5 degrees to 20 degrees.

[0056] A DED system as in any preceding clause, wherein the first power output of the first energy source is in the range of 50 Watts to 500 Watts.

[0057] The DED system of any preceding clause, wherein the second power output of the second energy source is in the range of 50 watts to 500 watts.

[0058] The DED system of any preceding clause, wherein the controller directs the nozzle to deposit the metal powder onto a plurality of locations at a rate of 0.5 g / s to 2 g / s.

[0059] A method for repairing a part using a directed energy deposition (DED) system, the method comprising: forming a repair region in the part to be repaired; positioning and activating a nozzle according to a preconfigured deposition pattern to deposit metal powder onto a plurality of locations of the repair region; when the nozzle is located at a first set of positions among the plurality of positions, moving a first output end of a first energy source to a first position to direct a central axis of a first energy beam onto the repair region at a first angle relative to a cavity axis of the repair region; activating the first energy source to melt the deposits of the metal powder located at the first set of positions among the plurality of positions; when the nozzle is located at a second set of positions among the plurality of positions, moving the first output end of the first energy source to a second position to direct the central axis of the first energy beam onto the repair region at a second angle relative to the cavity axis of the repair region, wherein the second angle is different from the first angle; and activating the first energy source to melt the deposits of the metal powder located at the second set of positions among the plurality of positions.

[0060] The method of any preceding clause, further comprising: activating a second energy source together with the first energy source to output a second energy beam from a second output end thereof, the second output end being positioned to direct a central axis of the second energy beam onto the repair area of ​​the part at a third angle relative to the central axis of the first energy beam so as to melt the deposits of metal powder located at the first set of locations in the plurality of locations and the second set of locations in the plurality of locations.

[0061] The method of any preceding clause, further comprising activating an induction heating element to apply electromagnetic waves to the repair area to heat the repair area to a target heating temperature before the nozzle deposits the metal powder onto the plurality of locations on the repair area.

[0062] A method according to any preceding clause, wherein the preconfigured deposition pattern includes directing the nozzle to deposit the metal powder onto the repair area in the form of a plurality of spiral pattern layers, wherein the starting point of each of the plurality of spiral pattern layers alternates between an inner position aligned based on the axis of the cavity and an outer position aligned based on the periphery of the repair area present at each of the plurality of spiral pattern layers.

[0063] A method according to any preceding clause, wherein the first group of positions in the plurality of positions includes the plurality of positions on the first group of spiral pattern layers in the plurality of spiral pattern layers and all of the inner portions of the second group of spiral pattern layers in the plurality of spiral pattern layers, and wherein the second group of positions in the plurality of positions includes the outer portions of the second group of spiral pattern layers in the plurality of spiral pattern layers.

[0064] The method of any preceding clause, wherein the first set of the plurality of spiral pattern layers comprises layer numbers 1 through 7, and wherein the second set of the plurality of spiral pattern layers comprises layer numbers 8 and above.

[0065] A DED system or method as in any preceding clause, wherein the metal powder comprises titanium aluminide powder.

[0066] The DED system or method of any preceding clause, wherein the first energy source and / or the second energy source are activated to preheat the repair area to a preset temperature before the nozzle deposits material onto the repair area.

[0067] The DED system or method of any preceding clause, wherein the first energy source, the nozzle, and the second energy source are commonly coupled to a support structure, and wherein movement of the support structure facilitates movement of the nozzle, the first output end, and the second output end.

[0068] A DED system or method as in any preceding clause, wherein the induction heating element continues to heat the repair area while the metal powder is being deposited.

[0069] A DED system or method as in any preceding clause, wherein an initial layer in said plurality of spiral pattern layers begins at said interior location.

[0070] A DED system or method as in any preceding clause, wherein an initial layer in said plurality of spiral patterned layers begins at said outer location.

[0071] A DED system or method as in any preceding clause, wherein the total width and / or two-dimensional area of ​​each of the plurality of spiral pattern layers increases upwardly from an initially laid layer.

[0072] A DED system or method according to any of the preceding clauses, wherein the position of the first output end emitting the first energy beam continuously varies throughout the trajectory of the plurality of spiral pattern layers so that the central axis of the first energy beam generally remains perpendicular to the direct area of ​​the repair area 114 where the nozzle is depositing the metal powder.

Claims

1. A directed energy deposition (DED) system, characterized in that: include: a nozzle configured to deposit metal powder onto a plurality of locations of a repair area of ​​the part according to a preconfigured deposition pattern; Controller; a first energy source configured to output a first energy beam from a first output end thereof; as well as at least one actuator in electrical communication with the controller, the at least one actuator being configured, under the direction of the controller, to: moving the nozzle according to the preconfigured deposition pattern; positioning the first output end of the first energy source at a first position, wherein a central axis of the first energy beam is directed onto the repair area at a first angle relative to a cavity axis of the repair area to melt deposits of the metal powder at a first set of locations among the plurality of locations; Positioning the first output end of the first energy source at a second position, wherein the central axis of the first energy beam is directed onto the repair area at a second angle relative to the cavity axis of the repair area to melt the deposits of metal powder located at a second group of positions among the plurality of positions, wherein the second angle is different from the first angle.

2. The DED system according to claim 1, wherein: Further comprising a second energy source configured to output a second energy beam from a second output end thereof, wherein the controller is configured to direct the at least one actuator to position the second output end of the second energy source so as to direct a central axis of the second energy beam onto the repair area of ​​the part at a third angle relative to the central axis of the first energy beam so as to melt the deposits of the metal powder located at the first group of positions among the plurality of positions and the second group of positions among the plurality of positions.

3. The DED system according to claim 1, wherein: Further comprising an induction heating element, wherein the controller is configured to activate the induction heating element to apply electromagnetic waves to the repair area, thereby starting to heat the repair area to a target heating temperature before the nozzle deposits the metal powder on the plurality of locations of the repair area.

4. The DED system according to claim 3, wherein: The induction heating element includes a heating section having a geometry that matches the geometry of the repair area.

5. The DED system according to claim 1, wherein: Further included is a drilling tool configured to form the repair area in the part into a symmetrical cavity having a maximum depth in the range of 4 mm to 7 mm, the symmetrical cavity including walls disposed at an angle in the range of 5 degrees to 20 degrees relative to the cavity axis.

6. The DED system according to claim 1, wherein: The preconfigured deposition pattern in which the actuator moves the nozzle to deposit the metal powder onto the repair area includes a plurality of spiral pattern layers, wherein a starting point of each of the plurality of spiral pattern layers alternates between an inner position aligned based on the cavity axis and an outer position aligned based on the periphery of the repair area present at each of the plurality of spiral pattern layers.

7. The DED system according to claim 6, wherein: Wherein a vertical distance between each of the plurality of spiral pattern layers is in a range of 0.3 mm to 0.7 mm.

8. The DED system according to claim 6, wherein: The individual traces of each of the plurality of spiral pattern layers have an overlap with a previously deposited trace of the same spiral pattern layer of the plurality of spiral pattern layers, the overlap being in the range of 1.0 mm to 2.5 mm.

9. The DED system according to claim 6, wherein: wherein the first group of positions among the plurality of positions includes the plurality of positions on the first group of spiral pattern layers among the plurality of spiral pattern layers and all of the inner portions of the second group of spiral pattern layers among the plurality of spiral pattern layers, and wherein the second group of positions among the plurality of positions includes the outer portions of the second group of spiral pattern layers among the plurality of spiral pattern layers.

10. The DED system according to claim 9, wherein: The first set of spiral pattern layers in the plurality of spiral pattern layers includes layer numbers 1 to 7, and the second set of spiral pattern layers in the plurality of spiral pattern layers includes layer numbers 8 and above.

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