Siemens Energy, Inc.

Siemens Energy Global Gmbh & Co. Kg

Siemens Aktiengesellschaft

Siemens Power Generation, Inc.

Mikro Systems, Inc.

Ahmed Kamel

Gerald Joseph Bruck

Kazim Ozbaysal

Anand A Kulkarni

Dhafer Jouini

Bernd Burbaum

Gary Brian Merrill

Allister William James

Daniel J Ryan

David G Maire

Brandon W Shinn

Zafir A M Abdo

Henning Hanebuth

Ivan F Oliver Vargas

Atul L Navale

Kyle I Stoodt

Ramesh Subramanian

Clifford Hatcher

Christian X Campbell

Jay Edgar Lane

Michael Ott

Michael P Appleby

John R Paulus

Cora Schillig

Daniel M Eshak

Stefan Lampenscherf

Dustin C Boudin

Jill Klinger

Jonathan E Shipper

Ovidiu Timotin

Ingo Reinkensmeier

Arindam Dasgupta

Thomas Lorenz

Shankar P Srinivasan

Zafir A Abdo

Luiz F Guimaraes

Andreas Rucki

Phillip Behling

Ritwik Biswas

Iain Alasdair Fraser

Christian Xavier Campbell

Gabriel Victor Orsinger

Clifford Hatcher Jr

Daniel Ellgass

Zafir AM Abdo

A method is provided that facilitates additive manufacturing a superalloy component using a liquid assisted additive manufacturing process. The method includes successively depositing and fusing together layers of a superalloy powder mixture comprising a high melt superalloy powder and a low melt superalloy powder to build up an additive portion of the superalloy component. The method may further include heat treating the additive portion to form a homogenized base alloy of which the additive portion is comprised, which base alloy has a chemistry defined by the superalloy powder mixture. Each of the high melt superalloy powder, the low melt superalloy powder, and the superalloy powder mixture may have a nickel content by weight greater than 40% and have an aluminum content by weight of greater than 1.5%. The low melt superalloy powder may include at least 5% by weight of tantalum, and the high melt superalloy powder may include less than half the content by weight percent of tantalum compared to the content by weight percent of tantalum in the low melt superalloy powder.

Liquid assisted additive manufacturing of a superalloy component

Systems () and methods () for additively manufacturing or repairing a component from a base material (). The system may include a laser metal deposition (LMD) system () operably connected to a means for cooling () the base material during laser processing of additive materials deposited in a melt pool on the base material. The LMD system includes a laser energy source () configured to direct laser energy towards the base material to form the melt pool thereon and to processes the deposited additive materials to form layers on the base material upon solidification. The means for cooling may be configured to cool the base material to within a cooling temperature range during the LMD process, which results in, e.g., a cooling/freezing effect. This cooling effect shortens the solidification period during laser processing and allows for weld heat to be released from the base material.

Laser metal deposition of high gamma prime superalloys with cooling effect

A replacement assembly for replacing a damaged portion of a component includes a replacement piece including a first plurality of layers with each layer of the first plurality of layers formed on top of a prior formed layer of the first plurality of layers, the first plurality of layers arranged to define a curved leading-edge portion and a first interface surface, the first interface surface defined by a first continuous curve. An attachment piece includes a second plurality of layers with each layer of the second plurality of layers formed on top of a prior formed layer of the second plurality of layers, the attachment piece arranged to fit between the first interface surface and the component to fixedly attach the replacement piece to the component to replace the damaged portion of a component.

System and method for repairing high-temperature gas turbine components

A system for manufacturing of a sintered wire and in-situ feeding to a laser wire welding system is presented. The system includes a pressure vessel connected to a powder feed system for delivering at least two powders to a powder mixing zone of the pressure vessel. The at least two powders are mixed via a rotating cone in the pressure vessel. After mixing, a heating device contained within the pressure vessel heats the mixture so that liquid phase sintering occurs and a sintered rod is created. The sintered wire is continuously fed to a laser metal deposition system for depositing a layer of additive material on a base material. A method of additively manufacturing or repairing a superalloy component is also presented.

Method and system for additive manufacturing or repair with in-situ manufacturing and feeding of a sintered wire

A method of forming a component includes mixing a powdered base material and a binder to define a mixture, forming the mixture into a desired shape without melting the base material, removing the binder from the desired shape to define a skeleton, the volume of the skeleton being between 80 percent and 95 percent base material, and infiltrating the skeleton with a melting point depressant material to define a finished component, the finished component having less than one percent porosity by volume.

A blade for a gas turbine includes a removed portion space, and further includes an airfoil portion defining the removed portion space, the airfoil portion formed from a base material, and a replacement component formed to fill the removed portion space. The replacement component is formed from a material that includes 50%-80% base material, 0%-30% braze material, and 0%-8% aluminum. A braze joint is formed between the airfoil portion and the replacement component to attach the replacement component to the airfoil portion and fill the removed portion space.

System and method for repairing high-temperature gas turbine blades

Systems and methods for additively manufacturing or repairing a component from a base material. The system may include an inoculation source to direct inoculation materials and a laser metal deposition (LMD) system to direct laser energy during laser processing of additive materials deposited in a melt pool on the base material. The LMD system includes a laser energy source configured to direct laser energy towards the base material and inoculation materials to form the melt pool thereon and to process the deposited additive materials and inoculation materials to form layers on the base material upon solidification.

Laser metal deposition with inoculation

A method of repairing a component includes removing a damaged portion from the component to leave a first interface surface that is defined by a continuous curve, mixing a powdered base material and a binder to define a mixture, and printing the mixture into a desired shape without melting the base material. The method also includes removing the binder from the desired shape, solid-state sintering the desired shape to form a replacement piece having a second interface surface that is defined by the continuous curve, and attaching the second interface surface to the first interface surface to replace the damaged portion of the component.

A low melt superalloy powder mixture is provided for use with additive manufacturing or welding metal components or portions thereof. The low melt superalloy powder may include by weight about 9.5% to about 10.5% chromium, about 2.9% to about 3.4% cobalt, about 8.0% to about 9.0% aluminum, about 3.8% to about 4.3% tungsten, about 0.8% to about 1.2% molybdenum, about 10% to about 20% tantalum, about 3% to about 12% hafnium, and at least 40% nickel.

Low melt superalloy powder for liquid assisted additive manufacturing of a superalloy component

A method of additively manufacturing is provided. The method may include successively depositing and fusing together layers of a superalloy powder mixture comprised of a base material powder and a eutectic powder, to build up an additive portion, which eutectic powder has a solidus temperature lower than the solidus temperature of the base material powder. The method may also include heat treating the additive portion at a temperature greater than 1200&#xb0; C. to heal cracks and/or fill pores and to homogenize the alloy of which the additive portion is comprised. The additive portion alloy has a chemistry defined by the superalloy powder mixture. The base material powder may be formed of a nickel-base superalloy with an aluminum content by weight of at least 1.5%. The eutectic powder may be a nickel-base alloy including by weight about 6% to about 11% chromium, about 5% to about 9% titanium, and about 9% to about 13% zirconium, with balance nickel as its primary components.

Crack healing additive manufacturing of a superalloy component

A high melt superalloy powder mixture is provided for use with additive manufacturing or welding metal components or portions thereof. The high melt superalloy powder may include by weight about 7.7% to about 18% chromium, about 10.6% to about 11% cobalt, about 4.5% to about 6.5% aluminum, about 10.6% to about 11% tungsten, about 0.3% to about 0.55% molybdenum, about 0.05% to about 0.08% carbon, and at least 40% nickel.

High melt superalloy powder for liquid assisted additive manufacturing of a superalloy component

A method of manufacturing a hard-to-weld material by a beam-assisted additive manufacturing process is presented. The method includes depositing a first layer for the material onto the substrate, the first layer including a major fraction of a base material for the component and a minor fraction of a solder, depositing a second layer of the base material for the component and a thermal treatment of the layer arrangement. The thermal treatment includes a first thermal cycle at a first temperature above 1200&#xb0; C. for a duration of more than 3 hours, a subsequent second thermal cycle at a second temperature above 1000&#xb0; C. for more than 2 hours, and a subsequent third thermal cycle and a third temperature above 700&#xb0; C. for more than 12 hours. A manufactured component is also presented.

Manufacturing method for hard-to-weld materials

A composition of a nickel based alloy mixture which can be used for welding via especially liquid metal deposition or as a powder bed of an additive manufacturing method. A metallic powder mixture includes (in wt %): a cobalt (Co) or nickel (Ni) based super alloy with a content of 20% to 60%, a NiCoCrAlY-composition with a content of 70% to 30% and a metallic braze material with a content between 10% to 5%. The melting point of the braze material is at least 10K lower than the melting point of the nickel or cobalt based superalloy.

Composition for material for liquid metal deposition or additive manufacturing, method and product

A process of welding a superalloy is provided. The process includes applying a first amount of energy to a substrate comprised of the superalloy to form a melt pool along a length of the substrate and in a weld direction. The process also comprises advancing the melt pool in the weld direction along the length via the first amount of energy, the melt pool having a width transverse to the weld direction. Further, the process includes applying a second amount of energy to the substrate that extends outside the width of the melt pool at a trailing edge of the melt pool, which second amount of energy causes, relative to a process without application of the second amount of energy: broadening of the width of the melt pool at the trailing edge of the melt pool as the melt pool advances in the weld direction; and reducing segregation of artifacts and stress concentration along a centerline of the width.

Optimization of melt pool shape in a joining process

A method of additive manufacturing a component. The method includes selecting powder characterization, depositing powder materials, inspecting the powder materials, selecting process and laser parameters for laser processing, laser processing the powder materials, performing layer cleanup, determining stress state and relieving, additionally inspecting the laser processed powder materials, and repeating steps until a buildup of the component is complete.

Method of additive manufacturing of components

Growing community of inventors

Orlando, FL, United States of America

Ahmed Kamel