European Space Agency

David John Jarvis

Wayne Eric Voice

Nicholas John Elsworth Adkins

Christian Lehnert

Koulis Pericleous

Valdis Bojarevics

Hany Salamam Sayed Ali Hassanin

The present invention relates to a method of manufacturing a componentby additive manufacturing. The method comprises providing a work surfaceon which the componentis to be manufactured, and providing at least one deposition materialfrom which the componentis to be composed. The deposition material, typically in the form of wire, is advanced to a localized deposition areawhere it is added to the componentbeing manufactured. The method further comprises focusing at least one light beamof incoherent light emitted from at least one heating sourcein the deposition areaso that the deposition materialis deposited for building up the component. At least one light focusing mirrorand/or lensis used to focus the incoherent light in the deposition area. The invention further relates to the use of such a method in space, such as on a space station, on a space craft or on parabolic flights for testing.

Additive manufacturing method using focused light heating source

The present invention relates to a method of manufacturing a ceramic article () from a metal or metal matrix composite preform () provided by 3D-printing or by 3D-weaving. The preform () is placed in a heating chamber (), and a predetermined time-temperature profile is applied in order to controllably react the preform () with a gas introduced into the heating chamber (). The metal, the gas and the time-temperature profile are chosen so as to induce a metal-gas reaction resulting in at least a part of the preform () transforming into a ceramic. Preferred embodiments of the invention comprises a first oxidation stage involving a metal-gas reaction in order to form a supporting oxide layer () at the surface of the metal, followed by a second stage in which the heating chamber () is heated to a temperature above the melting point of the metal to increase the kinetics of the chemical reaction. The invention also relates to a number of advantageous uses of a ceramic article manufactured as described.

Manufacturing of a ceramic article from a metal preform or metal matrix composite preform provided by 3D-printing or 3D-weaving

The present invention relates to a system for contactless induction of high-frequency vibrations in a volume of molten metal during the manufacturing of a metal component or a metal matrix composite component. The system includes a moveably arranged electromagnetic primary coil, adjustment means for adjusting the position of the primary coil, and a control unit for controlling the position of the primary coil to a predefined distance above, but not in contact with, an upper free surface of the molten metal. The molten metal may be contained in a foundry crucible during manufacturing. The system can be used as an additive manufacturing system, with the primary coil arranged above the melt pool. A secondary low-frequency electromagnetic coil may be arranged around and at a distance from the molten metal to induce flow and/or vibrations in the molten metal.

Manufacturing of a metal component or a metal matrix composite component involving contactless induction of high-frequency vibrations

Systems and methods, comprising a directed heat source coupled to a multi-wire feed-head configured to feed one or more wires having diverse compositions into a heat affected region, are provided for the synthesis of alloy samples having defined compositions, combinatorial alloy sample series and libraries, and shaped alloy components.

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Voorschoten, Netherlands

David John Jarvis