General Electric Company

Bechtel Bwxt Idaho, Lcc

James William Sears

William Thomas Carter

Marshall Gordon Jones

Michael Evans Graham

Harry Kirk Mathews, Jr

Kevin George Harding

Jason Harris Karp

Thomas Charles Adcock

Justin John Gambone, Jr

Bernard Patrick Bewlay

Victor Petrovich Ostroverkhov

Farshad Ghasripoor

Vasile Bogdan Neculaes

Guanghua Wang

Brian Magann Rush

Subhrajit Roychowdhury

Mark Alan Frontera

David Charles Bogdan, Jr

Steven Charles Woods

Nirm Velumylum Nirmalan

Jinjie Shi

Naveenan Thiagarajan

Yanzhe Yang

Kenneth Lee Fisher

George Hanna Ghanime

Pinghai Yang

Lang Yuan

Peter Andras Zavodszky

Jason Edward Dees

James DeLancey

Mohamed Sakami

Jessica Godin Karp

John E Flinn

Hongqing Sun

John Madelone

Joseph V Burch

Jeffrey Jay Porubcan

Vijay Shilpiekandula

Jr Harry Kirk Mathews

David Charles Bogdan Jr

Justin John Gambone Jr

A powder melting device for an additive manufacturing system including a laser device configured to emit an energy beam and a beam modulator. The beam modulator is configured to selectively induce an angular deflection in the energy beam for a predetermined time period such that the energy beam generates a plurality of melt pools in a powder bed.

Systems and methods for fabricating a component with a simulated laser array

According to some embodiments, system and methods are provided comprising generating a nominal computer-aided design (CAD) image of a component; producing a physical representation of the component from the nominal CAD image using an additive manufacturing (AM) process; measuring the physical component to obtain measurement data; determining a deviation between geometry associated with the nominal CAD image and the obtained measurement data; determining a compensation field for the deviation, if the deviation is outside of a tolerance threshold; modifying the nominal CAD image by the compensation field; and producing a physical representation of the component from the modified nominal CAD image. Numerous other aspects are provided.

System and method for distortion mitigation and compensation in additive manufacturing processes through B-spline hyperpatch field

A method of forming a build in a powder bed includes emitting a plurality of laser beams from selected fibers of a diode laser fiber array onto the powder bed, the selected fibers of the array corresponding to a pattern of a layer of the build; and simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build. An apparatus for forming a build in a powder bed includes a diode laser fiber array including a plurality of diode lasers and a plurality of optical fibers corresponding to the plurality of diode lasers, each optical fiber configured to receive a laser beam from a respective diode laser and configured to emitting the laser beam; a support configured to support a powder bed or a component configured to support the powder bed at a distance from ends of the optical fibers; and a controller configured to control the diode laser fiber array to emit a plurality of laser beams from selected fibers of the diode laser fiber array onto the powder bed, the selected fibers of the array corresponding to a pattern of a layer of the build and simultaneously melt the powder in the powder bed corresponding to the pattern of the layer of the build.

Diode laser fiber array for powder bed fabrication or repair

Adaptively forming a three-dimensional component may include providing a plurality of electron beam sources, and simultaneously controlling the plurality of electron beam sources to direct a plurality of electron beams onto a plurality of deposited layers of metallic powder to sequentially consolidate patterned portions of the plurality of deposited metallic powder layers to adaptively form the three-dimensional component.

Additive manufacturing employing a plurality of electron beam sources

An imaging device for an additive manufacturing system is provided. The additive manufacturing system includes a material. The imaging device includes a high resolution imaging bar including at least one detector array, and an imaging element positioned between the at least one detector array and the material. The high resolution imaging bar is displaced from the material along a first direction and extends along a second direction. The high resolution imaging bar is configured to generate an image of a build layer within the material.

Imaging devices for use with additive manufacturing systems and methods of imaging a build layer

A component is fabricated in a powder bed by moving a laser array across the powder bed. The laser array includes a plurality of laser devices. The power output of each laser device of the plurality of laser devices is independently controlled. The laser array emits a plurality of energy beams from a plurality of selected laser devices of the plurality of laser devices to generate a melt pool in the powder bed. A non-uniform energy intensity profile is generated by the plurality of selected laser devices. The non-uniform energy intensity profile facilitates generating a melt pool that has a predetermined characteristic.

System and methods for fabricating a component with laser array

An imaging system includes a sight tube extending along a longitudinal axis of the imaging system and configured to extend through an access port. The sight tube includes a wall extending about the longitudinal axis and defining a cavity. The imaging system also includes a plurality of cooling channels extending through the sight tube. The plurality of cooling channels are configured to direct cooling fluid through the sight tube for cooling the imaging system. The plurality of cooling channels are formed in the sight tube such that at least one cooling channel of the plurality of cooling channels extends in a direction oblique to the longitudinal axis.

Imaging system for inspecting components of turbomachines and method of assembly thereof

A method includes applying thermal and/or strain modeling to the CAD representation of an object. In addition, scan path data is generated based at least in part on a result of the thermal and/or strain modeling. A build file comprising the scan path data is generated. The build file comprises instructions that configure an additive manufacturing tool to generate the object according to the scan path data.

Methods and apparatus for generating additive manufacturing scan paths using thermal and strain modeling

In accordance with one aspect of the invention, a thermal management system for electronics includes a vapor chamber that at least partially envelops the electronics, a working fluid contained within the vapor chamber and used to dissipate heat from a part of a heated portion of the electronics and a precision sintered 3D wick structure independently created on some of the interior of the vapor chamber. The precision sintered 3D wick structure transports the working fluid by capillary action from at least one working fluid receptacle to a part of the heated portion of the electronics. In one embodiment of the invention, the 3D vapor chamber may be formed by the additive manufacturing processes. A further example includes precision sintered 3D support structures integrated into the closed 3D vapor chamber. The support structures mainly facilitate to support the 3D closed vapor chamber envelope from collapsing during operation, and add overall structural strength and additionally facilitate transfer of liquids and gas through their internal 3D porous zones.

System and method for thermal management using vapor chamber

Embodiments of a bearing are provided herein. In one embodiment a bearing may include a bearing assembly having an inner race and an outer race; a plurality of rolling elements disposed between the inner race and the outer race, wherein at least one of the inner race, the outer race, and the plurality of rolling elements is at least partially fabricated from an AlMgBcontaining ceramic matrix composite.

Bearing having components fabricated from a ceramic matrix composite

A metal alloy is melted in a crucible and ejected from the bottom of the crucible as a descending stream of molten metal. The descending stream is impacted with a plurality of primary inert gas jets surrounding the molten metal stream to produce a plume of atomized molten metal droplets. An inert gas is blown onto a lower portion of the plume with a plurality of auxiliary inert gas jets to deflect the plume into a more restricted pattern of high droplet density, thereby substantially eliminating unwanted overspray and resulting wasted material. The plume is projected onto a moving substrate to form a monolithic metallic product having generally parallel sides.

Spray casting of metallic preforms

Growing community of inventors

Niskayuna, NY, United States of America

James William Sears