Rolls-royce Corporation

Brian Drier

Robert Anthony Ress, Jr

Quinlan Yee Shuck

Robert F Proctor

Jacque Sue Bader

Mark E Bartolomeo

Gangshu Shen

Eugene Sun

Amanda Dawn Graham

Stephanie M Janicek

Robert Ress Iii

Stephanie Janicek

A method of forming a ferrous metal case-hardened layer using additive manufacturing. The method includes delivering, by a material delivery device, a filler material to a surface of a substrate. The substrate includes a first ferrous metal. The filler material includes a second ferrous metal and a carbon-based material. The method also includes directing, by an energy delivery device, an energy toward a volume of the filler material to join at least some of the filler material to the substrate to form a component.

Additive manufactured ferrous components

An example system may include a computing device including a finite element analysis module solving for a finite element model representing a component including a metal or an alloy and including a plurality of respective elements. The finite element analysis module may solve a respective stress Sand a respective temperature Tat each respective element during the predetermined cooling operating. The finite element analysis module may determine a respective impact energy Ebased on the temperature Tand cooling rate, using a predetermined cooling rate-dependent energy relationship that relates a temperature of the metal or the alloy to an impact energy, determine a respective weakness index W=[A&#xd7;E/S](A being a predetermined constant, n being a predetermined real number greater than or equal to 1), and identify a respective element having a minimum weakness index less than a predetermined weakness index threshold as a cracking-prone element.

Predicting cracking in cooled metal or alloy components

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Indianapolis, IN, United States of America

Brian Drier