Patent US2181829A successfully refreshed from Google Patents.
US5038014A
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US
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Fabrication of components by layered deposition
Assignee: General Electric Co
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Filing: 1989-12-01
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Granted: 1991-08-06
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Expires: 2009-12-01
Abstract
Abstract A component is fabricated by depositing a succession of overlying beads of a material, the pattern and position of the beads being assigned the proper characteristics of the corresponding section of the desired component. Shape definition is accomplished by characterizing the component as a series of sections or slices having the thickness of the bead, and programming a computer-controlled deposition head to deposit a succession of beads with the respective patterns and positions. Deposition is preferably by precision laser welding. Complex shapes having properties comparable to properties of forged or cast material are readily prepared. The material used in successive beads may be varied, producing a component of graded composition to achieve particular properties in various regions.
Inventors
- 👤 Vanon D. Pratt
- 👤 Wilbur D. Scheidt
- 👤 Eric J. Whitney
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-24 19:30
CPC Classifications
F; F01; F01D; F01D5/00; F01D5/005; B; B22; B22F; B22F10/00; B22F10/20; B22F10/25; B22F10/30; B22F10/38; B22F10/385; B23; B23K; B23K26/00; B23K26/14; B23K26/144; B23K26/34; B23K26/342; B23K35/00; B23K35/02; B23K35/0222; B23K35/0244; B23K35/0255; B23K35/0261; B23K35/0272; B23K35/22; B23K35/24; B23K35/30; B23K35/3033; B23K35/3046; B23K35/3053; B23K35/32; B23K35/325; B23K35/38; B23K35/383; B23P; B23P15/00; B23P15/006; B23P6/00; B23P6/002; B23P6/007; B29; B29C; B29C64/00; B29C64/10; B29C64/106; B29C64/124; B22F12/00; B22F12/50; B22F12/53; G; G05; G05B; G05B2219/00; G05B2219/30; G05B2219/45; G05B2219/45164; G05B2219/45238; G05B2219/50; G05B2219/50214; Y; Y02; Y02P; Y02P10/00; Y02P10/25; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49316; Y10T29/49336; Y10T29/49337; Y10T29/4998; Y10T29/49982
Claims Analysis
Total Claims: 27
Claim 1
Independent Claim
251 words
A process for fabricating an article using laser welding, the article having a preselected shape and characterized as a plurality of parallel cross sections, each cross section having a preselected pattern and thickness, comprising the steps of: melting a powder material with a laser beam and depositing the molten material to form a first layer in the pattern of a first cross section of the article, the thickness of the first deposited layer corresponding to the thickness of the first cross section; melting a powder material with a laser beam and depositing the molten material to form a second layer in the pattern of a second cross section of the article and at least partially overlying the first layer of deposited material, the thickness of the second deposited layer corresponding to the thickness of the second cross section; and melting a powder material with a laser beam and depositing the molten material to form successive layers in patterns of corresponding cross sections of the article, at least one of the successive cross sections partially overlying the underlying cross section and partially offset from the underlying cross section, so that a layer deposited in at least one of the cross sections is partially unsupported by the previously deposited material so as to form an overhang, and further, the thickness of each deposited layer and the thickness of the corresponding cross section in which the layer is deposited being about equal, the layers deposited in successive cross sections until the article is complete.
Claim 2
Dependent Claim
251 words
A process for fabricating an article using laser welding, the article having a preselected shape and characterized as a plurality of parallel cross sections, each cross section having a preselected pattern and thickness, comprising the steps of: melting a powder material with a laser beam and depositing the molten material to form a first layer in the pattern of a first cross section of the article, the thickness of the first deposited layer corresponding to the thickness of the first cross section; melting a powder material with a laser beam and depositing the molten material to form a second layer in the pattern of a second cross section of the article and at least partially overlying the first layer of deposited material, the thickness of the second deposited layer corresponding to the thickness of the second cross section; and melting a powder material with a laser beam and depositing the molten material to form successive layers in patterns of corresponding cross sections of the article, at least one of the successive cross sections partially overlying the underlying cross section and partially offset from the underlying cross section, so that a layer deposited in at least one of the cross sections is partially unsupported by the previously deposited material so as to form an overhang, and further, the thickness of each deposited layer and the thickness of the corresponding cross section in which the layer is deposited being about equal, the layers deposited in successive cross sections until the article is complete.
Claim 3
Dependent Claim
10 words
The process of claim 1, wherein the article is curved.
Claim 4
Dependent Claim
44 words
The process of claim 1, wherein in the step of melting a powder material with a laser beam and depositing the molten material to form successive layers, the deposited material of a successive layer is different from the material of the previously deposited layer.
Claim 5
Dependent Claim
22 words
The process of claim 1, wherein the article is selected from the group consisting of compressor blades, turbine blades and fan blades.
Claim 6
Dependent Claim
42 words
The process of claim 1, wherein in the step of melting a powder material with a laser beam and depositing the molten material to form successive layers, a portion of the previously deposited material is melted forming a welded bond between layers.
Claim 7
Dependent Claim
36 words
The process of claim 1, wherein a material used in the layers is selected from the group consisting of a titanium alloy, a nickel alloy, a cobalt alloy, an iron alloy, a ceramic, and a plastic.
Claim 8
Dependent Claim
44 words
The process of claim 1 wherein in the step of melting a powder material with a laser beam and depositing the molten material to form a second layer, a portion of the first layer is melted, forming a welded bond between the two layers.
Claim 9
Dependent Claim
201 words
A process for fabricating an article using laser welding, the article having a preselected complex curved shape and characterized as a plurality of parallel cross sections, each cross section having a preselected pattern and thickness, comprising the steps of: melting a powder material with a laser beam and depositing the molten material on a substrate to form a first bead of material in the pattern of a first cross section of the article, the thickness of the first deposited bead corresponding to the thickness of the first cross section; and melting a powder material with a laser beam and depositing the molten material as successive beads of material in successive deposition steps, each successive bead deposited in a pattern of a corresponding cross section of the article, each cross section partially overlying the underlying cross section and partially offset from the underlying cross section, and further, so that each deposited bead after the first deposited bead is partially unsupported by the underlying material, the thickness of the deposited material and the thickness of the corresponding cross section in which the material is deposited being about equal, the successive beads deposited in successive cross sections until the complex, curved article is complete.
Claim 10
Dependent Claim
201 words
A process for fabricating an article using laser welding, the article having a preselected complex curved shape and characterized as a plurality of parallel cross sections, each cross section having a preselected pattern and thickness, comprising the steps of: melting a powder material with a laser beam and depositing the molten material on a substrate to form a first bead of material in the pattern of a first cross section of the article, the thickness of the first deposited bead corresponding to the thickness of the first cross section; and melting a powder material with a laser beam and depositing the molten material as successive beads of material in successive deposition steps, each successive bead deposited in a pattern of a corresponding cross section of the article, each cross section partially overlying the underlying cross section and partially offset from the underlying cross section, and further, so that each deposited bead after the first deposited bead is partially unsupported by the underlying material, the thickness of the deposited material and the thickness of the corresponding cross section in which the material is deposited being about equal, the successive beads deposited in successive cross sections until the complex, curved article is complete.
Claim 11
Dependent Claim
44 words
The process of claim 8 wherein the steps of melting the powder material and depositing the molten material in patterns of corresponding cross sections of the article is controlled by a computer, and the pattern of parallel cross sections is stored in the computer.
Claim 12
Dependent Claim
11 words
The process of claim 8, wherein the article is doubly curved.
Claim 13
Dependent Claim
37 words
The process of claim 8, wherein in at least one instance in the step of melting and depositing successive beads of material overlying each other, the succeeding bead is a different material than the previously deposited bead.
Claim 14
Dependent Claim
18 words
The process of claim 8, wherein the article is a compressor blade integrally joined to a compressor disk.
Claim 15
Dependent Claim
49 words
The process of claim 8, wherein in the step of melting and depositing successive beads of material overlying each other, during the deposition of the overlying bead, a portion of the previously deposited bead is melted, forming a welded bond between the previously deposited bead and the overlying bead.
Claim 16
Dependent Claim
32 words
The process of claim 8, wherein a material used in the beads is selected from the group consisting of a titanium alloy, a nickel alloy, a cobalt alloy, and an iron alloy.
Claim 17
Dependent Claim
220 words
A process for fabricating a compressor blade that is integral with a compressor disk using laser welding, the compressor blade having a preselected complex curved shape and characterized as a plurality of parallel cross sections, each cross section having a preselected pattern and thickness, comprising the steps of: furnishing a compressor disk having a substrate surface at its periphery; melting a powder material with a laser beam and depositing the molten material onto the substrate surface to form a first bead of material in the pattern of a first cross section of the blade, the thickness of the first deposited bead corresponding to the thickness of the first cross section; and melting a powder material with a laser beam and depositing the molten material as successive beads of material in successive deposition steps, each successive bead deposited in a pattern of a corresponding cross section of the blade, each cross section partially overlying the underlying cross section and partially offset from the underlying cross section so that each deposited bead after the first deposited bead is partially unsupported by the previously deposited material, the thickness of the deposited bead and the thickness of the corresponding cross section in which the material is deposited being about equal, the successive beads deposited in successive cross sections until the compressor blade is complete.
Claim 18
Dependent Claim
220 words
A process for fabricating a compressor blade that is integral with a compressor disk using laser welding, the compressor blade having a preselected complex curved shape and characterized as a plurality of parallel cross sections, each cross section having a preselected pattern and thickness, comprising the steps of: furnishing a compressor disk having a substrate surface at its periphery; melting a powder material with a laser beam and depositing the molten material onto the substrate surface to form a first bead of material in the pattern of a first cross section of the blade, the thickness of the first deposited bead corresponding to the thickness of the first cross section; and melting a powder material with a laser beam and depositing the molten material as successive beads of material in successive deposition steps, each successive bead deposited in a pattern of a corresponding cross section of the blade, each cross section partially overlying the underlying cross section and partially offset from the underlying cross section so that each deposited bead after the first deposited bead is partially unsupported by the previously deposited material, the thickness of the deposited bead and the thickness of the corresponding cross section in which the material is deposited being about equal, the successive beads deposited in successive cross sections until the compressor blade is complete.
Claim 19
Dependent Claim
32 words
The process of claim 15, wherein a material used in the beads is selected from the group consisting of a titanium alloy, a nickel alloy, a cobalt alloy, and an iron alloy.
Claim 20
Dependent Claim
45 words
The process of claim 15, wherein in the step of melting a powder material and depositing the molten material as successive beads, during the deposition of each successive bead, a portion of the previously deposited bead is melted forming a welded bond between the beads.
Claim 21
Dependent Claim
40 words
The process of claim 15, wherein during the step of depositing the first bead of material onto the substrate surface, a portion of the substrate surface is melted, forming a welded bond between the substrate surface and the first bead.
Claim 22
Dependent Claim
35 words
The process of claim 8 wherein in at least one bead, different compositions of powder material are melted and deposited within the same bead. furnishing a turbine disk having a substrate surface at its periphery.
Claim 23
Dependent Claim
24 words
The process of claim 8 wherein in at least one bead, different and continuously variable compositions of material are deposited within the same bead.
Claim 24
Dependent Claim
272 words
A process for fabricating a turbine blade that is integral with a turbine disk using laser welding, the turbine blade having a preselected complex curved shape and characterized as a plurality of parallel cross sections, each cross section having a preselected pattern and thickness, comprising the steps of: furnishing a turbine disk having a substrate surface at its periphery; melting a powder material with a laser beam and depositing the molten material onto the substrate surface to form a first bead of material in the pattern of a first cross section of the blade, the thickness of the first deposited bead corresponding to the thickness of the first cross section; and melting a powder material with a laser beam and depositing the molten material onto the substrate surface to form a first bead of material in the pattern of a first cross section of the blade, the thickness of the first deposited bead corresponding to the thickness of the first cross section; and melting a powder material with a laser beam and depositing the molten material as successive beads of material in successive deposition steps, each successive bead deposited in a pattern of a corresponding cross section of the blade, each cross section partially overlying the underlying cross section and partially offset from the underlying cross section so that each deposited bead after the first deposited bead is partially unsupported by the previously deposited material, the thickness of the deposited bead and the thickness of the corresponding cross section in which the material is deposited being about equal, the successive beads deposited in successive cross sections until the turbine blade is complete.
Claim 25
Dependent Claim
272 words
A process for fabricating a turbine blade that is integral with a turbine disk using laser welding, the turbine blade having a preselected complex curved shape and characterized as a plurality of parallel cross sections, each cross section having a preselected pattern and thickness, comprising the steps of: furnishing a turbine disk having a substrate surface at its periphery; melting a powder material with a laser beam and depositing the molten material onto the substrate surface to form a first bead of material in the pattern of a first cross section of the blade, the thickness of the first deposited bead corresponding to the thickness of the first cross section; and melting a powder material with a laser beam and depositing the molten material onto the substrate surface to form a first bead of material in the pattern of a first cross section of the blade, the thickness of the first deposited bead corresponding to the thickness of the first cross section; and melting a powder material with a laser beam and depositing the molten material as successive beads of material in successive deposition steps, each successive bead deposited in a pattern of a corresponding cross section of the blade, each cross section partially overlying the underlying cross section and partially offset from the underlying cross section so that each deposited bead after the first deposited bead is partially unsupported by the previously deposited material, the thickness of the deposited bead and the thickness of the corresponding cross section in which the material is deposited being about equal, the successive beads deposited in successive cross sections until the turbine blade is complete.
Claim 26
Dependent Claim
220 words
A process for fabricating a fan blade that is integral with a fan disk using laser welding, the fan blade having a preselected complex curved shape and characterized as a plurality of parallel cross sections, each cross section having a preselected pattern and thickness, comprising the steps of: furnishing a fan disk having a substrate surface at its periphery; melting a powder material with a laser beam and depositing the molten material onto the substrate surface to form a first bead of material in the pattern of a first cross section of the blade, the thickness of the first deposited bead corresponding to the thickness of the first cross section; and melting a powder material with a laser beam and depositing the molten material as successive beads of material in successive deposition steps, each successive bead deposited in a pattern of a corresponding cross section of the blade, each cross section partially overlying the underlying cross section and partially offset from the underlying cross section so that each deposited bead after the first deposited bead is partially unsupported by the previously deposited material, the thickness of the deposited bead and the thickness of the corresponding cross section in which the material is deposited being about equal, the successive beads deposited in successive cross sections until the fan blade is complete.
Claim 27
Dependent Claim
220 words
A process for fabricating a fan blade that is integral with a fan disk using laser welding, the fan blade having a preselected complex curved shape and characterized as a plurality of parallel cross sections, each cross section having a preselected pattern and thickness, comprising the steps of: furnishing a fan disk having a substrate surface at its periphery; melting a powder material with a laser beam and depositing the molten material onto the substrate surface to form a first bead of material in the pattern of a first cross section of the blade, the thickness of the first deposited bead corresponding to the thickness of the first cross section; and melting a powder material with a laser beam and depositing the molten material as successive beads of material in successive deposition steps, each successive bead deposited in a pattern of a corresponding cross section of the blade, each cross section partially overlying the underlying cross section and partially offset from the underlying cross section so that each deposited bead after the first deposited bead is partially unsupported by the previously deposited material, the thickness of the deposited bead and the thickness of the corresponding cross section in which the material is deposited being about equal, the successive beads deposited in successive cross sections until the fan blade is complete.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1994-08-05 | 1995-02-04 | 1995-08-06 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-08-05 | 1999-02-04 | 1999-08-06 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-08-05 | 2003-02-04 | 2003-08-06 | $7700.00 | Window Closed / Lapsed |