General Electric Company

Huan Qi

Prabhjot Singh

Magdi Naim Azer

Marshall Gordon Jones

Bhupendra Kumar Gupta

Mark Douglas Gledhill

Sudhir Kumar Tewari

Joseph Giancarlo Sabato

A laser net shape manufactured BLISK, compressor blade, turbine blade or turbine component including a plurality of overlapping predetermined variable bead widths of a material defining a first material layer, a plurality of overlapping predetermined variable bead widths of a material deposited on top of the first material layer, forming a second material layer; and additional material layers deposited on top of the first material layer and the second material layer. The variable bead width of the deposited material is controlled to maintain the approximately constant percent of bead width overlap. A first 2 to 100 deposited powder layers are deposited by a first laser power and the remaining powder layers are deposited by a laser power that is ramped down over the course of depositing the remaining powder layers. In addition, disclosed is A BLISK, compressor blade, turbine blade or turbine component formed by a method.

Laser net shape manufactured component using an adaptive toolpath deposition method

A method is described, for treating a superalloy substrate which includes at least one cavity containing adherent metal oxide material on its surface. A short-pulsed, high repetition rate laser beam is directed against the cavity surface for a period of time sufficient to remove substantially all of the adherent metal oxide material. The laser beam is characterized by a peak power density in the range of about 10 megawatts/cmto about 10 gigawatts/cm. In another embodiment, a high-power, short-pulsed, high repetition rate laser beam is directed to a region on the substrate which includes the cavity, under laser operational conditions which are capable of cutting into the superalloy material; so that a boundary region is formed within the substrate, which encloses the cavity. The cavity can be a crack in a turbine blade, and the crack can be repaired after treatment, by welding, or by another suitable technique.

Methods for treating superalloy articles, and related repair processes

A method is disclosed for laser cladding a substrate, comprising providing the substrate; depositing a first determined variable bead width of a material along a toolpath upon the substrate; depositing a second adjacent determined variable bead width of a material along the toolpath which overlaps the first determined variable bead width of deposited material; continuing to deposit a plurality of overlapping predetermined adjacent variable bead widths of a material until a first material layer is complete; forming a second material layer by depositing a plurality of overlapping predetermined variable bead widths of a material on top of the first material layer; and continuing to deposit material layers on top of deposited material layers until the cladding is complete; wherein the variable bead width of the deposited material is controlled by a computer having a plurality of input parameters to maintain an approximately constant percent of bead width overlap.

Laser net shape manufacturing using an adaptive toolpath deposition method

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Niskayuna, NY, United States of America

Huan Qi