General Electric Company

Ansaldo Energia IP UK Limited

General Electric Technology Gmbh

Alstom Technology Limited

Thomas Etter

Matthias Hoebel

Felix Martin Gerhard Roerig

Julius Andreas Schurb

Brendon James Leary

Robert John Filkins

Michael Evans Graham

Subhrajit Roychowdhury

Maxim Konter

Prabhjot Singh

Alexander Stankowski

Hanspeter Zinn

Hartmut Haehnle

Roman Engeli

Fabian Geiger

Andreas Kuenzler

Lang Yuan

Mikhail Pavlov

Robert Baumann

Jan Vladimir Schwerdtfeger

Andreas Künzler

Guenter Ambrosy

Sabrina Michelle Puidokas

Daniel Beckel

Giuseppe Bandiera

Julius Schurb

Thomas Opderbecke

Roland Mücke

Felix Roerig

Simone Hoevel

Lukas Emanuel Rickenbacher

Hossein Meidani

A Ni-based superalloy composition to be used for powder-based additive manufacturing (AM) technology, such as selective laser melting (SLM) or electron beam melting (EBM). The cracking susceptibility during an AM process is considerably reduced by controlling the amount of elements, especially Hf, that form low-melting eutectics.

Ni-base superalloy composition and method for SLM processing such Ni-base superalloy composition

A manufactured article is comprised of an additively manufactured component having sequentially joined layers of metallic powder. A braze material is disposed on at least a portion of an outer surface of the component. The braze material is located in expected crack locations in the outer surface. At least one crack formed in the outer surface, during a heat treatment, is filled with the braze material. The additively manufactured component comprises a metallic material from a precipitation hardened nickel-based superalloy, which forms a &#x3b3;' phase.

Manufactured article and method

A Ni-base superalloy composition to be used for powder-based additive manufacturing (AM) technology, such as selective laser melting (SLM) or electron beam melting (EBM). The cracking susceptibility during an AM process is considerably reduced by controlling the amount of elements, especially Hf, that form low-melting eutectics.

An additive manufacturing system includes a laser device, a build plate, and a scanning device. The laser device is configured to generate a laser beam with a variable intensity. The build plate is configured to support a powdered build material. The scanning device is configured to selectively direct the laser beam across the powdered build material to generate a melt pool on the build plate. The scanning device is configured to oscillate a spatial position of the laser beam while the laser device is configured to simultaneously modulate the intensity of the laser beam to thermally control the melt pool.

Systems and methods for dynamic shaping of laser beam profiles for control of micro-structures in additively manufactured metals

Controlling microstructure in an object created by metal powder additive manufacturing is disclosed. During additive manufacturing of one or more objects using an irradiation beam source system, for each respective layer in a selected range of layers including a cross-sectional area of the one or more objects including the selected object, a duration controller controls actuation of each irradiation device to maintain constant a sum of: an irradiation device melting time, an irradiation device idle time, and a recoating time expended applying a new powder material layer, while otherwise maintaining all other operation parameters of each irradiation device constant.

Controlling microstructure of selected range of layers of object during additive manufacture

In some cases, an additive manufacturing (AM) system includes: a process chamber for additively manufacturing a component, the process chamber having: a build platform; at least one melting beam scanner configured to emit a melting beam for melting powder on the build platform; an applicator for applying layers of powder to the build platform; and a reservoir for storing powder; and a control system coupled with the set of melting beam scanners, the control system configured to: apply the melting beam to a layer of powder on the build platform along a primary melting path; and apply the melting beam to the layer of powder on the build platform along a re-melting path after applying the melting beam along the primary melting path, the re-melting path overlapping a portion of the primary melting path and applied only in an area proximate a perimeter of the component.

Melting beam surface processing in additive manufacturing

A method for manufacturing a mechanical component by additive manufacturing which includes at least one layering sequence of depositing a powder material and locally melting and resolidifying the powder material. In each layering sequence, a solid layer of solidified material is formed, wherein the solid layers jointly form a solid body. An annealing sequence subsequent to at least one layering sequence includes, locally heating at least a region of the solid body in effecting a local heat input to the immediately beforehand manufactured solid layer which was formed by the immediately precedent layering sequence, with temperature being is maintained below a melting temperature of the material.

Method for manufacturing a mechanical component

Additive manufactured components including sacrificial caps, and methods of forming components including sacrificial caps are disclosed. The additive manufactured components may include a body portion including a first surface, and a feature formed in the body portion. The feature may include an aperture formed through the first surface of the body portion. Additionally, the components may include a sacrificial cap formed integral with at least a portion of the first surface of the body portion. The sacrificial cap may include a conduit in fluid communication with the feature. The sacrificial cap including the conduit may be removed from the body portion to expose the first surface and the aperture of the feature, respectively, after performing one or more post-build processes, such as shot peening, on the component and the sacrificial cap.

Additive manufactured components including sacrifical caps and methods of forming same

Methods include converting a residual surface stress in a component made by a metal powder additive manufacturing process. The component includes a body having an external surface and an internal opening passing at least partially through the body, the internal opening including an unused metal powder from the additive manufacturing process therein. Residual surface stress is converted in at least a portion of a body about the internal opening by applying a pressure in the internal opening using a non-compressible fluid and the unused metal powder. The method is advantageous for use with gamma primed hardened superalloys. An additively manufactured component including the stress-converted internal opening is also disclosed.

Converting residual surface stress in internal opening of additively manufactured component

The invention refers to a method for manufacturing a hybrid component including the following steps of manufacturing a preform as a first part of the hybrid component, then successively building up on that preform a second part of the component from a metallic powder material by means of an additive manufacturing process by scanning with an energy beam, thereby establishing a controlled grain orientation in primary and in secondary direction of at least a part of the second part of the component. The controlled secondary grain orientation is realized by applying a specific scanning pattern of the energy beam, which is aligned to the cross section profile of the component or to the local load conditions for the component.

Method for manufacturing a hybrid component

A method for post-weld heat treatment of a without a filler material welded high strength component made of a gamma prime (&#x3b3;') strengthened superalloy can include providing the welded component, heating the welded component by applying a rapid heating-up rate in the range of 20&#xb0; C./min to 40&#xb0; C./min during the entire temperature range from room temperature (RT) up to a temperature Tof at least 1000&#xb0; C., holding the welded component at Tand then heating the component by applying a slow heating-up rate of about 5&#xb0; C./min to a final temperature T, then holding the welded component at Tfor a time tsufficient for at least partially dissolving the gamma prime phase in a weld of the welded component and also in a base material surrounding the weld, and cooling the component with a cooling rate that is greater than or equal to about 20&#xb0; C./min.

Method for post-weld heat treatment of welded components made of gamma prime strengthened superalloys

The invention relates to a method for manufacturing a component, especially of a gas turbine, made of a single crystal (SX) or directionally solidified (DS) nickelbase superalloy, including a heat treatment and a machining and/or mechanical treatment step. The ductility of the component is improved by doing the machining and/or mechanical treatment step prior to said heat treatment and a solution heat treatment of the component is done prior to the machining/mechanical treatment step.

Method for manufacturing components made of single crystal (SX) or directionally solidified (DS) nickelbase superalloys

The invention relates to a method of post-built up heat treatment of an additively manufactured high strength component made of a gamma-prime strengthened superalloy based on Ni or Co or Fe or combinations thereof. An application of a rapid heating-up rate of 25 to 60&#xb0; C./min in a specific temperature range during the first post-built heat treatment after additive manufacturing avoids or at least minimizes the gamma-prime precipitation in the component during heat-up. This results in crack-free components/articles compared to significant cracking present in conventionally heat treated components.

Method for post-built heat treatment of additively manufactured components made of gamma-prime strengthened superalloys

A method for forming an oxygen resistant aluminum oxide layer on an outer surface of a thermocouple sheath composed of a nickel alloy containing between 1% to 7% aluminum comprises removing a pre-formed oxide layer from the outer surface so as to create a prepared sheath; performing a controlled oxidation by subjecting the prepared sheath to atmospheric conditions at a temperature between 1000&#xb0; C. and 1250&#xb0; C. so as to form the oxygen resistant layer on the thermocouple sheath and to thus form an oxidized sheath; and cooling the oxidized sheath so as to prepare the oxidized sheath for service.

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Muhen, Switzerland

Thomas Etter