Rolls-royce Corporation

European Space Agency

Wayne Eric Voice

Junfa Mei

Stephen John Tuppen

David John Jarvis

Nicholas John Elsworth Adkins

Xinhua Wu

Colin J Small

Steven J Hessell

Allister W James

Sarah A Blackham

Michael R Winstone

Michael Loretto

Thomas P Jarvis

Daniel Clark

Dragos Aurelian Axinte

Robert Charles Tonks

Ming Chu Kong

Richard C Dewes

Martin R Bache

George Thorne

Hong G Lee

Hany Salamam Sayed Ali Hassanin

David K Aspinwall

Nicholas Wain

Dawei Hu

Martin Ronald Bache

Richard Charles Dewes

David Keith Aspinwall

Stephen Tuppen

Hong Guan Lee

Carol Kong

Thomas Peter Jarvis

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

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.

Multi-wire feeder method and system for alloy sample formation and additive manufacturing

This invention relates to a mould assembly for a hot isostatic pressing, HIP, process for fabricating a component, comprising: a first part which includes a shaped surface for forming a first surface of the component, the shaped surface having at least one recess; a second part arranged to move relative to the first part during the HIP process so as to compress a powder in-fill held therebetween, wherein the second part includes a formation configured to focus pressure toward the recess so as to aid consolidation of the powder in-fill at a distal end thereof.

Mould assembly for a hot isostatic pressing process

The present method creates a relatively thin in situ brazing alloy layer upon first and second component edges which are brought together in order to create a component joint. This in situ brazing alloy layer is created by deposition of brazing elements, such as copper or nickel, from an electrical discharge cutting process electrode depletion utilized in order to cut the component edges, and then a subsequent brazing technique creates through interstitial migration between that brazing alloy layer and the underlying material substrate of the components a robust component joint wherein the in situ brazing alloy layer penetrates the respective component cut edge surface to only a limited depth such that the geometric effect is similarly limited, and the properties of the underlying component material structure are maintained.

Brazed joining with electrical deposition

A method of forming a component () by isostatic pressing, the method comprising: providing a canister () suitable for isostatic pressing, the canister comprising first and second membranes () which, in use, are disposed within the canister (); the first and second membranes () defining a component cavity () disposed between the first and second membranes (), a first tool cavity () disposed between the first membrane () and an adjacent wall () of the canister (), and a second tool cavity () disposed between the second membrane () and another adjacent wall () of the canister (); filling the component cavity () with the component powder for forming the component (); filling the first and second tool cavities () with a second tool powder; and isostatically pressing the canister () to form the component ().

Method and assembly for forming a component by isostatic pressing

A method of forming a fully consolidated joint between first and second components comprising the steps of forming a slot in the first component; inserting at least part of the second component into the slot; inserting a powder material into the slot; heating the powder material to form a pressure tight skin; and applying hot isostatic pressure to the pressure tight skin to form a fully consolidated joint. Also a method of repairing a component.

Joining and a repair method

A component is manufactured from a powdered material such as a titanium alloy, by performing a first hot isostatic pressing HIP operation on the powdered materialwhile the powdered material is in contact with a molding surfaceof a rigid, usable molding tool. The first HIP operation creates a non-porous shaped surfaceon a partially consolidated component, but avoids bonding or reaction between the partially consolidated componentand the molding tool. After separation of the partially consolidated componentfrom the molding tool, the partially consolidated componentis subjected to a second HIP operation in which the powdered material is fully consolidated.

Method of manufacturing a component

A pocket () is machined into the surface of a component () by pressurising a fluid () and directing a jet () of the pressurized fluid () at the surface to be machined. Continuous relative movement is provided between the component () and the pressurized jet () of fluid () during machining. Material is removed from the component () in a series of layers, whereby the path of the fluid jet () in one of the layers is perpendicular to the path of the fluid jet () in the subsequent layer. The fluid jet () operates continuously until the required amount of material has been removed from the component ().

Method of fluid jet machining

A method of manufacturing a metal component from metal powder comprises preparing () a metal powder, providing () gallium on at least part of the surface of at least some of the metal powder particles, encapsulating () the metal powder in a container, evacuating () the container to remove air and/or gas from the container, sealing () the container, hot isostatically pressing () the container to consolidate the metal powder particles to produce the metal component and removing () the container from the metal component. The process is used to produce gas turbine engine metal components, for example turbine discs with improved fatigue properties.

Method of manufacturing a metal component from metal powder

A method of manufacturing an article by diffusion bonding, the method comprising the steps of assembling first and second component parts having a joint therebetween; sealing the joint against infiltration by solid particulate material, without causing phase change of the component parts; and applying heat and isostatic pressure via a solid particulate material to form a consolidated joint by diffusion bonding.

Joining method and resultant article

A method of correcting the shape of a brittle cast component such as a low pressure turbine blade. The method includes steps of placing the component against a creep mold having a surface defining the desired profile of the component and HIP treating it to creep deform the component to the desired shape whilst consolidating it and removing gas and shrinkage porosity.

Shape correcting components

A surface treatment device for applying a surface treatment medium to an article is provided with the surface treatment device having an application member for applying the surface treatment medium to the article and an electrode, which applies an electrical potential between the application member and the article. The device provides localized treatment to the article and can remove oxide layers or the like from metallic materials without removing or damaging the underlying metallic material.

Method and apparatus for treating a component of a gas turbine engine

A method of manufacturing a blisk comprising a disc joined to an aerofoil, wherein a union piece of partially sintered powder and having an alignment feature is provided. The union piece is connected between the disc and the aerofoil, which is aligned relative to the disc by the alignment feature of the union piece. Heat and pressure is subsequently applied to consolidate the first workpiece, union piece and second workpiece.

Method of manufacturing a component by consolidating powder material

A manufacturing process that comprises placing an article within a particulate medium (), the article being provided with a molded body () of small ceramic particles. On application of heat and pressure the small ceramic particles are pushed between the particulate medium () to permit localized deformation of the article ().

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Nottingham, United Kingdom

Wayne Eric Voice