Rolls-royce Corporation

Jacque Sue Bader

Quinlan Yee Shuck

Sean E Landwehr

Scott Nelson

Kong Ma

Raymond Ruiwen Xu

Brandon David Ribic

Robert F Proctor

Pavlo Earle

Brian Drier

Amanda Dawn Graham

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

The disclosure describes techniques for joining a first part including a ceramic or a CMC and a second part including a ceramic or a CMC using brazing. A technique may include positioning a filler material in a joint region between the first and second parts and a metal or alloy on a bulk surface of the filler material. The metal or alloy may be locally heated to melt the metal or alloy, which may infiltrate the filler material. A constituent of the molten metal or alloy may react with a constituent of the filler material to join the first and second parts. Another technique may include depositing a powder that includes the filler material and the metal or alloy in the joint region. Substantially simultaneously with depositing the powder, the powder may be locally heated. A constituent of the molten metal or alloy may react with a constituent of the filler material to join the first and second parts.

Braze for ceramic and ceramic matrix composite components

Example systems may include an energy source, a material delivery device, and a computing device. The computing device, based on a target height of a layer deposited on a component by directed energy deposition, may control an energy source directed at a component and may control a material delivery device. Controlling the energy source may include advancing an energy beam along a first path to form an advancing molten pool on the component. Controlling the material delivery device may include delivering a material to the advancing molten pool. The material may combine with the advancing molten pool to form a first raised track having an actual height. The layer may include the first raised track. A deposited region of the component may include the layer. The actual height may affect a resultant microstructure within the deposited region.

Directed energy deposition for processing gas turbine engine components

A material deposition system and method for cooling a component after material deposition. The method of deposition and cooling comprising a platform, a deposition head, and a cooling mechanism. The platform adapted to support a component for the addition of material. The deposition head including a material depositor configured to deposit material on a surface of a component supported on the platform an and an energy source configured to energize material deposited onto a surface of a component supported on the platform to bond the material to the component. The cooling system including bristles.

Directed energy deposition with cooling mechanism

In some examples, a technique includes delivering, using a material delivery device, material adjacent to a repair surface of a component and delivering, using a gas delivery device, a gas adjacent to the repair surface. The technique also may include delivering, from an energy source, energy to the material adjacent the repair surface to fuse the material to the repair surface; and receiving, by a computing device, at least one parameter indicative of at least one of a temperature or a geometry of the component. The technique may further include, responsive to the at least one parameter indicative of the at least one of the temperature or the geometry of the component, controlling, by the computing device, at least one processing parameter to control the temperature of the component.

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Martinsville, IN, United States of America

Jacque Sue Bader