Raytheon Technologies Corporation

Rtx Corporation

Hamilton Sundstrand Corporation

Brian A Fisher

David W Morganson

Matthew E Lynch

Malcolm P MacDonald

Ranadip Acharya

Masoud Anahid

A process for uncertainty quantification for a predictive defect model for multi-laser additive manufacturing of a part including executing computational fluid dynamics modeling of a gas flow in an additive manufacturing machine manufacturing chamber; assigning a spatter particle size, velocity and direction relative to a melt pool on a powder bed disposed on a build plate within the manufacturing chamber; executing computational fluid dynamics post processing for spatter particle tracking; predicting a spatter particle landing pattern; feeding the spatter particle landing pattern prediction into a defect model; producing a layer thickness map, the layer thickness map configured to demonstrate a location of locally thicker layers on the part; and predicting defect location and density to accumulate lack-of-fusion risk as a function of part placement, orientation, and scan strategy.

Uncertainty quantification or predictive defect model for multi-laser powder bed fusion additive manufacturing

Disclosed herein is a laser beam measurement system that includes a beam measurement device, a positioning apparatus, and a control system. The beam measurement device can include an imager and a plurality of optical elements configured to form an optical path to the imager within the beam measurement device. The positioning apparatus is configured to adjust a position of the beam measurement device relative to a build plate of a laser powder bed fusion system. The control system is configured to determine an intended measurement position to observe a laser beam profile of the laser powder bed fusion system, determine a target position of a beam measurement device to align with the intended measurement position, and command an adjustment of one or more aspects of the beam measurement device to achieve alignment of the target with the intended measurement position.

Off-axis laser beam measurement for laser powder bed fusion

A gas knife system for an additive manufacturing system can include one or more gas delivery members configured to move relative to a build area of the additive manufacturing system, and an inlet conduit configured to supply gas to the one or more gas delivery members while the one or more gas delivery members are moved relative to the build area. The system can also include one or more gas collection members configured to move relative to the build area of the additive manufacturing system, and an outlet conduit configured collect gas from the one or more gas collection members while the one or more gas collection members move relative to the build area.

Air knife systems

A cutting system for removing an excess material along a length of a channel constructed using an additive manufacturing process is disclosed. In various embodiments, the cutting system includes a cutter head; a cutter blade attached to the cutter head; a drive cable configured to rotate the cutter head; and a cutter base attached to the cutter head and having a cutter base outer surface configured to contact an internal surface within the channel to guide the cutter blade against the excess material.

Apparatus and methods for improvement of surface geometries of internal channels of additively manufactured components

A cutting system for removing an excess material along a length of a channel constructed using an additive manufacturing process is disclosed. In various embodiments, the cutting system includes a cutting component having an abrasive surface configured to remove the excess material along a down-facing surface of the channel and a smooth surface configured for sliding contact with an up-facing surface of the channel; and a motive component configured to urge the cutting component through the channel.

Growing community of inventors

West Hartford, CT, United States of America

Brian A Fisher