U.S. patent application number 15/178438 was filed with the patent office on 2017-12-14 for powder deposition for additive manufacturing.
The applicant listed for this patent is Hamilton Sundstrand Corporation. Invention is credited to Eric Karlen.
Application Number | 20170355018 15/178438 |
Document ID | / |
Family ID | 60572180 |
Filed Date | 2017-12-14 |
United States Patent
Application |
20170355018 |
Kind Code |
A1 |
Karlen; Eric |
December 14, 2017 |
POWDER DEPOSITION FOR ADDITIVE MANUFACTURING
Abstract
An additive manufacturing method includes cold spraying a powder
onto a build area to create a densified powder layer. The method
can include high speed machining the densified powder layer after
cold spraying to create a smooth layer.
Inventors: |
Karlen; Eric; (Rockford,
IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hamilton Sundstrand Corporation |
Charlotte |
NC |
US |
|
|
Family ID: |
60572180 |
Appl. No.: |
15/178438 |
Filed: |
June 9, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B22F 2003/1056 20130101;
B33Y 30/00 20141201; B22F 3/1055 20130101; B22F 3/16 20130101; Y02P
10/295 20151101; B33Y 10/00 20141201 |
International
Class: |
B22F 3/105 20060101
B22F003/105; B22F 3/24 20060101 B22F003/24; B22F 3/10 20060101
B22F003/10; B33Y 50/02 20060101 B33Y050/02; B33Y 10/00 20060101
B33Y010/00; B33Y 30/00 20060101 B33Y030/00 |
Claims
1. An additive manufacturing method, comprising cold spraying a
powder onto a build area to create a densified powder layer.
2. The method of claim 1, further comprising high speed machining
the densified powder layer after cold spraying to create a smooth
layer.
3. The method of claim 2, further comprising inspecting the smooth
powder layer after machining to determine if a defect is
present.
4. The method of claim 3, wherein inspecting includes a visual
and/or interferometric inspection.
5. The method of claim 3, further comprising removing the smooth
layer via high speed machining if a defect is determined to be
present.
6. The method of claim 3, further comprising applying energy to a
portion of the powder layer after high speed machining if no defect
is determined to be present.
7. The method of claim 6, wherein applying energy includes lasing
the portion of the powder layer to fuse the portion of the powder
layer.
8. The method of claim 1, wherein cold spraying includes cold
spraying the powder on only a part area of the build area where the
part is grown.
9. The method of claim 1, wherein the build area includes a surface
of an existing part.
10. An additive manufacturing system, comprising: a build area; a
cold spray powder deposition system configured to cold spray powder
onto the build area to create successive densified powder layers;
and an energy applicator configured to fuse a portion of each
densified powder layer to additively manufacture a product.
11. The system of claim 10, wherein the cold spray powder
deposition system includes a pressure supply, a powder feeder, and
a nozzle.
12. The system of claim 11, wherein the nozzle is a supersonic
nozzle.
13. The system of claim 10, wherein the energy applicator includes
a laser.
14. The system of claim 10, wherein the build area is movable
between a cold spray station and an energy application station to
interleave cold spraying and energy application.
15. The system of claim 10, wherein the build area includes at
least one of a build platform or an existing part.
16. The system of claim 10, further comprising a high speed
machining system configured to machine each densified powder
layer.
17. The system of claim 10, further including an imaging system
configured to determine if any defects are present in each layer
after cold spraying and/or machining.
18. The system of claim 17, wherein the imaging system includes an
interferometric system and/or visual system.
Description
BACKGROUND
1. Field
[0001] The present disclosure relates to additive manufacturing,
more specifically to powder deposition for additive
manufacturing.
2. Description of Related Art
[0002] Current commercial powder bed laser fusion systems can
create consolidated parts or structures through metallurgical
bonding of powder feed stock. However, the processes are slow due
to the time spent spreading or rolling a new layer of powder after
each layer is joined through laser welding.
[0003] Such conventional methods and systems have generally been
considered satisfactory for their intended purpose. However, there
is still a need in the art for powder deposition for additive
manufacturing. The present disclosure provides a solution for this
need.
SUMMARY
[0004] An additive manufacturing method includes cold spraying a
powder onto a build area to create a densified powder layer. The
method can include high speed machining the densified powder layer
after cold spraying to create a smooth layer.
[0005] The method can include inspecting the smooth powder layer
after machining to determine if a defect is present. Inspecting can
include a visual and/or interferometric inspection.
[0006] The method can include removing the smooth layer via high
speed machining if a defect is determined to be present. The method
can include applying energy to a portion of the powder layer after
high speed machining if no defect is determined to be present.
[0007] In certain embodiments, applying energy includes lasing the
portion of the powder layer to fuse the portion of the powder
layer. Any other suitable form of energy application is
contemplated herein.
[0008] Cold spraying can include cold spraying the powder on only a
part area of the build area where the part is grown. In certain
embodiments, the build area includes a surface of an existing
part.
[0009] An additive manufacturing system can include a build area, a
cold spray powder deposition system configured to cold spray powder
onto the build area to create successive densified powder layer,
and an energy applicator configured to fuse a portion of each
densified powder layer to additively manufacture a product.
[0010] The cold spray powder deposition system can include a
pressure supply, a powder feeder, and a nozzle. In certain
embodiments, the nozzle is a supersonic nozzle. Any other suitable
components for a cold spray powder deposition system are
contemplated herein.
[0011] In certain embodiments, the energy applicator can include a
laser. The build area can be movable between a cold spray station
and an energy application station to interleave cold spraying and
energy application. The build area can include at least one of a
build platform or an existing part.
[0012] The system can include a high speed machining system
configured to machine each densified powder layer. The system can
include an imaging system configured to determine if any defects
are present in each layer after cold spraying and/or machining. The
imaging system can include an interferometric system and/or visual
system.
[0013] These and other features of the systems and methods of the
subject disclosure will become more readily apparent to those
skilled in the art from the following detailed description taken in
conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] So that those skilled in the art to which the subject
disclosure appertains will readily understand how to make and use
the devices and methods of the subject disclosure without undue
experimentation, embodiments thereof will be described in detail
herein below with reference to certain figures, wherein:
[0015] FIG. 1 is a schematic view of an embodiment of a system in
accordance with this disclosure, showing the build area in two
stages; and
[0016] FIG. 2 is a flow chart of an embodiment of method in
accordance with this disclosure.
DETAILED DESCRIPTION
[0017] Reference will now be made to the drawings wherein like
reference numerals identify similar structural features or aspects
of the subject disclosure. For purposes of explanation and
illustration, and not limitation, an illustrative view of an
embodiment of a system in accordance with the disclosure is shown
in FIG. 1 and is designated generally by reference character
100.
[0018] Other embodiments and/or aspects of this disclosure are
shown in FIG. 2. The systems and methods described herein can be
used to improve build quality and reduce time consumed in additive
manufacturing.
[0019] Referring to FIG. 1, an additive manufacturing system 100
can include a build area 101 and a cold spray powder deposition
system 103 configured to cold spray powder onto the build area 101
to create successive densified powder layer. While the build area
101 is shown as a moveable build platform (e.g., similar to those
used in a roller bed system), any suitable build area is
contemplated herein (e.g., a flat surface, a non-flat surface, a
stationary surface, an existing part surface). The cold spray
powder deposition system 103 can include a pressure supply 103a, a
powder feeder 103b, and a nozzle 103c. In certain embodiments, the
nozzle is a supersonic nozzle. Any other suitable components for a
cold spray powder deposition system 103 (e.g., an electric heater)
are contemplated herein.
[0020] The system 100 also includes an energy applicator 105
configured to fuse a portion of each densified powder layer to
additively manufacture a product. In certain embodiments, the
energy applicator 105 can include a laser. Any other suitable type
of energy applicator 105 is contemplated herein.
[0021] As shown, the build area 101 can be movable between a cold
spray station (shown on the right of FIG. 1) and an energy
application station (shown on the left of FIG. 1) to interleave
cold spraying and energy application. Any other suitable
arrangement (e.g., a single stage with moving systems 103, 105)
that allows both cold spraying and energy application is
contemplated herein.
[0022] The system 100 can further include an associated high speed
machining system 108 to machine each layer to a predetermined
smoothness. The high speed machining system 108 can be moveable
relative to the build area 101 to apply any suitable subtractive
machining to the spray deposited and/or sintered powder. Any
suitable high speed machining equipment is contemplated herein.
[0023] The system 100 can include an imaging system 110 (e.g., an
interferometric and/or visual system) to determine if any defects
are present in each layer after deposition and/or machining. The
imaging system 110 can include any suitable imaging device(s) and
can be stationary or movable relative to the build area 101.
[0024] While the high speed machining system 108 and the imaging
system 110 are shown positioned with the cold spray
station/position, it is contemplated that one or more of the
systems 108, 110 can be positioned and/or moveable for use with
either or both of the energy application station and/or the cold
spray station. Moreover, one or more of the cold spray powder
deposition system 103, the energy applicator 105, and/or a high
speed machining system 108 can be operatively connected to and/or
controlled by the imaging system 110 to automatically spray,
machine, and/or apply energy to the surface based on readings from
the imaging system 110 (e.g., interferometric readings).
[0025] In accordance with at least one aspect of this disclosure,
referring to FIG. 2, an additive manufacturing method 200 can
include cold spraying a powder (e.g., at block 201) onto a build
area 101 to create a densified powder layer. Cold spraying can be
done to any suitable portion of the build area (e.g., a size just
large enough for the build part/layer thereof, or the entire build
area for example). The cold spray size can change for different
layers, for example, as the layers of the part change. The method
200 can include high speed machining (e.g., at block 203) the
densified powder layer after cold spraying to create a smooth
layer.
[0026] The method 200 can include inspecting (e.g., at block 205)
the smooth powder layer after machining to determine (e.g., at
block 207) if a defect is present. Inspecting can include a visual
and/or interferometric inspection.
[0027] The method 200 can include removing (e.g., at block 209) the
smooth layer, e.g., via high speed machining if a defect is
determined to be present. The method can include applying (e.g., at
block 211) energy to a portion of the powder layer after high speed
machining if no defect is determined to be present.
[0028] In certain embodiments, applying energy includes lasing the
portion of the powder layer to fuse the portion of the powder
layer. Any other suitable form of energy application is
contemplated herein.
[0029] As described above, cold spray deposition technology can be
utilized to deposit a uniform layer of powder material on a
substrate or surface. The powder is compacted by cold spraying to
increase density but not fully metallurgically bonded at the
appropriate spraying parameters. Process parameters (e.g.,
pressure, nozzle location) can be adjusted such that the level of
densification and metallurgical bonding can be tailored such that
particles are only loosely joined, for example. An interferometry
and/or visual inspection system can inspect the deposited material
for layer quality. High speed machining/rework can be performed to
ensure the layer quality is uniform. Laser welding or other
suitable energy application can be used to melt and form a
metallurgical homogeneous material, layer by layer. The process is
repeated until the entire part is completely formed. Multiple parts
can be in process to further improve throughput.
[0030] Interferometry, for example, is capable of evaluating small
surface features. This technique can be employed to measure the
as-deposited surface for thickness and irregularities before laser
welding is performed to create a metallurgically homogeneous
structure. A closed loop inspection process would allow the
deposited surface to be re-worked before laser welding should an
excessive amount of voids or other defects be present that would
affect the integrity of the component.
[0031] Embodiments as described above can achieve a faster rate of
manufacture as there is no need to wait to spread a new layer of
powder across an entire build area. Non-spherical powder can be
used to create rough form which can reduce powder costs. Also,
density of cold spray deposits can be changed to provide better
mechanical support during powder fusion process. Further, the
result of embodiments that utilize localized deposition can be a
quicker process, require less powder, and open up the possibility
to build off a flat substrate (for a new part) or a surface from an
existing part, for example.
[0032] The methods and systems of the present disclosure, as
described above and shown in the drawings, provide for additive
manufacturing systems with superior properties as described above.
While the apparatus and methods of the subject disclosure have been
shown and described with reference to embodiments, those skilled in
the art will readily appreciate that changes and/or modifications
may be made thereto without departing from the spirit and scope of
the subject disclosure.
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