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Patent · US10328685B2 · B2 · US

Diode laser fiber array for powder bed fabrication or repair

(11) Publication number
US10328685B2
(21) Application number
14/106,970
(22) Filing date
2013-12-16
(30) Priority date
2013-12-16
(43) Publication date
2019-06-25
(45) Date of grant
2019-06-25
(51) IPC
B29C 67/00; B23K 26/06; B23K 26/34; B28B 1/00; B29C 73/00; B22F 3/105; B22F 5/00; B23K 26/073; B29C 64/153; B29C 64/20; B29C 73/34; B33Y 10/00; B33Y 30/00; G02B 6/42
(52) CPC
  • B33Y Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering: 30/00, 10/00
  • B22F Working metallic powder; manufacture of articles from metallic powder; making metallic powder; apparatus or devices specially adapted for metallic powder: 10/00, 10/28, 10/36, 10/362, 12/41, 12/45, 2003/1056, 3/1055, 5/009
  • B23K Soldering or unsoldering; welding; cladding or plating by soldering or welding; cutting by applying heat locally, e.g. flame cutting; working by laser beam: 2101/001, 26/0608, 26/0626, 26/073, 26/34
  • B23P Metal-working not otherwise provided for; combined operations; universal machine tools: 6/007
  • B28B Shaping clay or other ceramic compositions; shaping slag; shaping mixtures containing cementitious material, e.g. plaster: 1/001
  • B29C Shaping or joining of plastics; shaping of material in a plastic state, not otherwise provided for; after-treatment of the shaped products, e.g. repairing: 64/153, 64/20, 64/268, 64/277, 64/282, 73/00, 73/34
  • B29K Indexing scheme associated with subclasses B29B, B29C or B29D, relating to moulding materials or to materials for {moulds, } reinforcements, fillers or preformed parts, e.g. inserts: 2105/251
  • B29L Indexing scheme associated with subclass B29C, relating to particular articles: 2031/08
  • F05D Indexing scheme for aspects relating to non-positive-displacement machines or engines, gas-turbines or jet-propulsion plants: 2230/31
  • G02B Optical elements, systems or apparatus: 6/4206, 6/425
  • H01S Devices using the process of light amplification by stimulated emission of radiation [laser] to amplify or generate light; devices using stimulated emission of electromagnetic radiation in wave ranges other than optical: 3/23
  • Y02P Climate change mitigation technologies in the production or processing of goods: 10/25, 10/295
(73) Assignee
General Electric Co
(72) Inventors
Marshall Gordon Jones; William Thomas Carter; James William Sears
(54) Title
Diode laser fiber array for powder bed fabrication or repair
(57) Abstract

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.

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Claims (37)

  1. A method of forming a build in a powder bed, comprising: turning on selected diode lasers of a diode laser fiber array, the selected lasers of the diode laser fiber array corresponding to a desired pattern of a layer of the build; emitting a plurality of laser beams from fibers coupled to the selected diode lasers onto the powder bed; simultaneously melting powder in the powder bed corresponding to the desired pattern of the layer of the build; and turning off the selected diode lasers.
  2. A method according to claim 1, further comprising: controlling at least one of a duration of each laser beam, a pulse energy of each diode laser, a pulse width of each diode laser, an average output power of each diode laser, an energy distribution of each laser beam, power density of each laser beam, a rate of reduction of the power of each laser beam, and/or a distance of ends of the fibers from the powder bed.
  3. A method according to claim 2, wherein the average output power of each diode laser is up to about 60 W.
  4. A method according to claim 2, wherein the average output power of each diode laser is between about 2 W to about 60 W.
  5. A method according to claim 2, wherein the power density of each laser beam is about 1,000,000 W/cm 2.
  6. A method according to claim 2, wherein the distance of ends of the fibers from the powder bed is between about 5 mm to about 150 mm.
  7. A method according to claim 2, wherein the energy distribution of each laser beam is Gaussian or a top hat.
  8. A method according to claim 1, wherein the powder is metal, ceramic, glass or plastic.
  9. A method according to claim 1, further comprising: emitting laser beams from fibers coupled to diode lasers of the diode laser fiber array that are adjacent to the desired pattern of the layer; and heating the powder adjacent to the powder of the layer of the build to control a cooling rate of the melted powder.
  10. A method according to claim 9, wherein heating the powder adjacent to the powder of the layer comprises heating the powder at least one of prior to and/or during and/or after simultaneous melting of the powder of the desired pattern of the layer.
  11. A method according to claim 9, wherein a power density of the laser beams heating the powder adjacent the desired pattern is in a range of from about 100 W/cm 2 to about 100,000 W/cm 2.
  12. A method according to claim 1, wherein a thickness of each layer is between about 1 μm to about 1 mm.
  13. A method according to claim 12, wherein a thickness of each layer is about 100 μm.
  14. A method according to claim 1, wherein the build is a repair of a component.
  15. A method according to claim 14, wherein the component is a turbine component.
  16. A method according to claim 15, wherein the turbine component is an airfoil.
  17. A method according to claim 1, wherein the build is a component of a turbine.
  18. A method according to claim 17, wherein the component is an airfoil.
  19. A method according to claim 1, further comprising: repeating the emitting and simultaneous melting to form a plurality of layers of the build.
  20. A method according to claim 1, further comprising: allowing the melted powder to cool and solidify.
  21. A method according to claim 1, further comprising: moving the selected diode lasers and the powder bed relative to each other; and simultaneously controlling the selected diode lasers of the diode laser fiber array during relative movement.
  22. A method of forming a build in a powder bed, comprising: turning on selected diode lasers of a diode laser fiber array, the selected lasers of the diode laser fiber array corresponding to a desired pattern of a layer of the build; emitting a plurality of laser beams from fibers coupled to the selected diode lasers onto the powder bed, wherein the average output power of each diode laser is between about 2 W to about 60 W, the power density of each laser beam is about 1,000,000 W/cm 2, the distance of ends of the fibers from the powder bed is between about 5 mm to about 150 mm, the energy distribution of each laser beam is Gaussian or a top hat; simultaneously melting powder in the powder bed corresponding to the desired pattern of the layer of the build, wherein the powder is metal, ceramic, glass or plastic; controlling at least one of a duration of each laser beam, a pulse energy of each diode laser, a pulse width of each diode laser, an average output power of each diode laser, an energy distribution of each laser beam, power density of each laser beam, a rate of reduction of the power of each laser beam, and/or a distance of ends of the fibers from the powder bed, wherein a thickness of each layer is between about 1 μm to about 1 mm; moving the selected selected diode lasers and the powder bed relative to each other; and simultaneously controlling the selected diode lasers during relative movement; turning off the selected diode lasers; and allowing the melted powder to cool and solidify.
  23. A method according to claim 22, further comprising: emitting laser beams from fibers coupled to diode lasers at least adjacent to the desired pattern of the layer; and heating the powder adjacent to the powder of the desired pattern of the layer of the build to control a cooling rate of the melted powder, wherein a power density of the laser beams heating the powder adjacent the pattern is in a range of from about 100 W/cm 2 to about 100,000 W/cm 2.
  24. A method according to claim 23, wherein heating the powder adjacent to the powder of the desired pattern of the layer comprises heating the adjacent powder at least one of prior to and/or during and/or after simultaneous melting of the powder of the pattern of the layer.
  25. A method according to claim 22, wherein a thickness of each layer is about 100 μm.
  26. A method according to claim 22, wherein the build is a repair of a component.
  27. A method according to claim 26, wherein the component is a turbine component.
  28. A method according to claim 27, wherein the turbine component is an airfoil.
  29. A method according to claim 22, wherein the build is a component of a turbine.
  30. A method according to claim 29, wherein the component is an airfoil.
  31. A method according to claim 22, further comprising: repeating the emitting and simultaneous melting to form a plurality of layers of the build.
  32. A method according to claim 1, further comprising: controlling each of a duration of each laser beam, a pulse energy of each diode laser, a pulse width of each diode laser, an average output power of each diode laser, an energy distribution of each laser beam, a power density of each laser beam, a rate of reduction of the power of each laser beam, and a distance of ends of the fibers from the powder bed.
  33. A method according to claim 1, wherein emitting the plurality of laser beams from the selected diode lasers of the diode laser fiber array onto the powder bed comprises emitting the plurality of laser beams for 5 to 15 milliseconds.
  34. A method according to claim 1, wherein simultaneously melting powder in the powder bed corresponding to the desired pattern of the layer of the build comprises superheating the powder bed to control a viscosity of the melted region.
  35. A method according to claim 9, further comprising: controlling each of a duration of each laser beam, a pulse energy of each diode laser, a pulse width of each diode laser, an average output power of each diode laser, an energy distribution of each laser beam, a power density of each laser beam, a rate of reduction of the power of each laser beam, and a distance of ends of the fibers from the powder bed.
  36. A method according to claim 9, wherein emitting the plurality of laser beams from the selected diode lasers of the diode laser fiber array onto the powder bed comprises emitting the plurality of laser beams for 5 to 15 milliseconds.
  37. A method according to claim 9, wherein simultaneously melting powder in the powder bed corresponding to the desired pattern of the layer of the build comprises superheating the powder bed to control a viscosity of the melted region.

Description

The present technology relates generally to the use of a diode laser fiber array for Direct Metal Laser Melting (DMLM) for use in the fabrication or repair of components, more particularly components of a gas turbine engine.

Additive manufacturing is a known technology that enables the “3D-printing” of components of various materials including metals, ceramics and plastics. In additive manufacturing, a part is built in a layer-by-layer manner by leveling metal powder and selectively fusing the powder using a high-power laser or electron beam. After each layer, more powder is added and the laser forms the next layer, simultaneously fusing it to the prior layers to fabricate a complete component buried in a powder bed. Additive manufacturing systems and processes are used to fabricate precision three-dimensional components from a digital model.

In making a build in current powder bed systems, the laser beam or electron beam is used to scan a layer of powder to sinter and melt the desired shape in the layers of the powder bed. The typical scanning time for such systems per layer is in the range of 70-100 seconds. For some applications, the build can require days of processing time. One application of DMLM is in the fabrication and repair of airfoils for gas turbine engines for aircraft. The geometries of the airfoils are difficult to form using conventional casting technologies, thus fabrication of the airfoils using a DMLM process or an electron-beam melting process has been proposed.

Citations (25)

  • US5672464A
  • US5508489A
  • EP0740976A1
  • US6292251B1
  • US6180050B1
  • DE19905300A1
  • US6423935B1
  • US20020090313A1
  • US20020149137A1
  • US6980321B2
  • US6717106B2
  • US7550251B2
  • US6894712B2
  • US20030214571A1
  • CN1593817A
  • US7444046B2
  • US20070283786A1
  • GB2453945A
  • US8509933B2
  • US20130136868A1
  • WO2013128416A2
  • US20150233345A1
  • US20160008922A1
  • WO2015109102A1
  • WO2016201309A1
Record as JSON 
{
  "publication_number": "US10328685B2",
  "country": "US",
  "kind": "B2",
  "title": "Diode laser fiber array for powder bed fabrication or repair",
  "abstract": "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.",
  "claims": [
    "1. A method of forming a build in a powder bed, comprising: turning on selected diode lasers of a diode laser fiber array, the selected lasers of the diode laser fiber array corresponding to a desired pattern of a layer of the build; emitting a plurality of laser beams from fibers coupled to the selected diode lasers onto the powder bed; simultaneously melting powder in the powder bed corresponding to the desired pattern of the layer of the build; and turning off the selected diode lasers.",
    "2. A method according to claim 1, further comprising: controlling at least one of a duration of each laser beam, a pulse energy of each diode laser, a pulse width of each diode laser, an average output power of each diode laser, an energy distribution of each laser beam, power density of each laser beam, a rate of reduction of the power of each laser beam, and/or a distance of ends of the fibers from the powder bed.",
    "3. A method according to claim 2, wherein the average output power of each diode laser is up to about 60 W.",
    "4. A method according to claim 2, wherein the average output power of each diode laser is between about 2 W to about 60 W.",
    "5. A method according to claim 2, wherein the power density of each laser beam is about 1,000,000 W/cm 2.",
    "6. A method according to claim 2, wherein the distance of ends of the fibers from the powder bed is between about 5 mm to about 150 mm.",
    "7. A method according to claim 2, wherein the energy distribution of each laser beam is Gaussian or a top hat.",
    "8. A method according to claim 1, wherein the powder is metal, ceramic, glass or plastic.",
    "9. A method according to claim 1, further comprising: emitting laser beams from fibers coupled to diode lasers of the diode laser fiber array that are adjacent to the desired pattern of the layer; and heating the powder adjacent to the powder of the layer of the build to control a cooling rate of the melted powder.",
    "10. A method according to claim 9, wherein heating the powder adjacent to the powder of the layer comprises heating the powder at least one of prior to and/or during and/or after simultaneous melting of the powder of the desired pattern of the layer.",
    "11. A method according to claim 9, wherein a power density of the laser beams heating the powder adjacent the desired pattern is in a range of from about 100 W/cm 2 to about 100,000 W/cm 2.",
    "12. A method according to claim 1, wherein a thickness of each layer is between about 1 μm to about 1 mm.",
    "13. A method according to claim 12, wherein a thickness of each layer is about 100 μm.",
    "14. A method according to claim 1, wherein the build is a repair of a component.",
    "15. A method according to claim 14, wherein the component is a turbine component.",
    "16. A method according to claim 15, wherein the turbine component is an airfoil.",
    "17. A method according to claim 1, wherein the build is a component of a turbine.",
    "18. A method according to claim 17, wherein the component is an airfoil.",
    "19. A method according to claim 1, further comprising: repeating the emitting and simultaneous melting to form a plurality of layers of the build.",
    "20. A method according to claim 1, further comprising: allowing the melted powder to cool and solidify.",
    "21. A method according to claim 1, further comprising: moving the selected diode lasers and the powder bed relative to each other; and simultaneously controlling the selected diode lasers of the diode laser fiber array during relative movement.",
    "22. A method of forming a build in a powder bed, comprising: turning on selected diode lasers of a diode laser fiber array, the selected lasers of the diode laser fiber array corresponding to a desired pattern of a layer of the build; emitting a plurality of laser beams from fibers coupled to the selected diode lasers onto the powder bed, wherein the average output power of each diode laser is between about 2 W to about 60 W, the power density of each laser beam is about 1,000,000 W/cm 2, the distance of ends of the fibers from the powder bed is between about 5 mm to about 150 mm, the energy distribution of each laser beam is Gaussian or a top hat; simultaneously melting powder in the powder bed corresponding to the desired pattern of the layer of the build, wherein the powder is metal, ceramic, glass or plastic; controlling at least one of a duration of each laser beam, a pulse energy of each diode laser, a pulse width of each diode laser, an average output power of each diode laser, an energy distribution of each laser beam, power density of each laser beam, a rate of reduction of the power of each laser beam, and/or a distance of ends of the fibers from the powder bed, wherein a thickness of each layer is between about 1 μm to about 1 mm; moving the selected selected diode lasers and the powder bed relative to each other; and simultaneously controlling the selected diode lasers during relative movement; turning off the selected diode lasers; and allowing the melted powder to cool and solidify.",
    "23. A method according to claim 22, further comprising: emitting laser beams from fibers coupled to diode lasers at least adjacent to the desired pattern of the layer; and heating the powder adjacent to the powder of the desired pattern of the layer of the build to control a cooling rate of the melted powder, wherein a power density of the laser beams heating the powder adjacent the pattern is in a range of from about 100 W/cm 2 to about 100,000 W/cm 2.",
    "24. A method according to claim 23, wherein heating the powder adjacent to the powder of the desired pattern of the layer comprises heating the adjacent powder at least one of prior to and/or during and/or after simultaneous melting of the powder of the pattern of the layer.",
    "25. A method according to claim 22, wherein a thickness of each layer is about 100 μm.",
    "26. A method according to claim 22, wherein the build is a repair of a component.",
    "27. A method according to claim 26, wherein the component is a turbine component.",
    "28. A method according to claim 27, wherein the turbine component is an airfoil.",
    "29. A method according to claim 22, wherein the build is a component of a turbine.",
    "30. A method according to claim 29, wherein the component is an airfoil.",
    "31. A method according to claim 22, further comprising: repeating the emitting and simultaneous melting to form a plurality of layers of the build.",
    "32. A method according to claim 1, further comprising: controlling each of a duration of each laser beam, a pulse energy of each diode laser, a pulse width of each diode laser, an average output power of each diode laser, an energy distribution of each laser beam, a power density of each laser beam, a rate of reduction of the power of each laser beam, and a distance of ends of the fibers from the powder bed.",
    "33. A method according to claim 1, wherein emitting the plurality of laser beams from the selected diode lasers of the diode laser fiber array onto the powder bed comprises emitting the plurality of laser beams for 5 to 15 milliseconds.",
    "34. A method according to claim 1, wherein simultaneously melting powder in the powder bed corresponding to the desired pattern of the layer of the build comprises superheating the powder bed to control a viscosity of the melted region.",
    "35. A method according to claim 9, further comprising: controlling each of a duration of each laser beam, a pulse energy of each diode laser, a pulse width of each diode laser, an average output power of each diode laser, an energy distribution of each laser beam, a power density of each laser beam, a rate of reduction of the power of each laser beam, and a distance of ends of the fibers from the powder bed.",
    "36. A method according to claim 9, wherein emitting the plurality of laser beams from the selected diode lasers of the diode laser fiber array onto the powder bed comprises emitting the plurality of laser beams for 5 to 15 milliseconds.",
    "37. A method according to claim 9, wherein simultaneously melting powder in the powder bed corresponding to the desired pattern of the layer of the build comprises superheating the powder bed to control a viscosity of the melted region."
  ],
  "description_excerpt": "The present technology relates generally to the use of a diode laser fiber array for Direct Metal Laser Melting (DMLM) for use in the fabrication or repair of components, more particularly components of a gas turbine engine.\n\nAdditive manufacturing is a known technology that enables the “3D-printing” of components of various materials including metals, ceramics and plastics. In additive manufacturing, a part is built in a layer-by-layer manner by leveling metal powder and selectively fusing the powder using a high-power laser or electron beam. After each layer, more powder is added and the laser forms the next layer, simultaneously fusing it to the prior layers to fabricate a complete component buried in a powder bed. Additive manufacturing systems and processes are used to fabricate precision three-dimensional components from a digital model.\n\nIn making a build in current powder bed systems, the laser beam or electron beam is used to scan a layer of powder to sinter and melt the desired shape in the layers of the powder bed. The typical scanning time for such systems per layer is in the range of 70-100 seconds. For some applications, the build can require days of processing time. One application of DMLM is in the fabrication and repair of airfoils for gas turbine engines for aircraft. The geometries of the airfoils are difficult to form using conventional casting technologies, thus fabrication of the airfoils using a DMLM process or an electron-beam melting process has been proposed.",
  "cpc": [
    "B33Y 30/00",
    "B22F 10/00",
    "B22F 10/28",
    "B22F 10/36",
    "B22F 10/362",
    "B22F 12/41",
    "B22F 12/45",
    "B22F 2003/1056",
    "B22F 3/1055",
    "B22F 5/009",
    "B23K 2101/001",
    "B23K 26/0608",
    "B23K 26/0626",
    "B23K 26/073",
    "B23K 26/34",
    "B23P 6/007",
    "B28B 1/001",
    "B29C 64/153",
    "B29C 64/20",
    "B29C 64/268",
    "B29C 64/277",
    "B29C 64/282",
    "B29C 73/00",
    "B29C 73/34",
    "B29K 2105/251",
    "B29L 2031/08",
    "B33Y 10/00",
    "F05D 2230/31",
    "G02B 6/4206",
    "G02B 6/425",
    "H01S 3/23",
    "Y02P 10/25",
    "Y02P 10/295"
  ],
  "ipc": [
    "B29C 67/00",
    "B23K 26/06",
    "B23K 26/34",
    "B28B 1/00",
    "B29C 73/00",
    "B22F 3/105",
    "B22F 5/00",
    "B23K 26/073",
    "B29C 64/153",
    "B29C 64/20",
    "B29C 73/34",
    "B33Y 10/00",
    "B33Y 30/00",
    "G02B 6/42"
  ],
  "assignees": [
    "General Electric Co"
  ],
  "inventors": [
    "Marshall Gordon Jones",
    "William Thomas Carter",
    "James William Sears"
  ],
  "filing_date": "2013-12-16",
  "publication_date": "2019-06-25",
  "grant_date": "2019-06-25",
  "priority_date": "2013-12-16",
  "application_number": "US-201314106970-A",
  "family_id": "53367280",
  "cited_by_count": 21,
  "citations": [
    "US5672464A",
    "US5508489A",
    "EP0740976A1",
    "US6292251B1",
    "US6180050B1",
    "DE19905300A1",
    "US6423935B1",
    "US20020090313A1",
    "US20020149137A1",
    "US6980321B2",
    "US6717106B2",
    "US7550251B2",
    "US6894712B2",
    "US20030214571A1",
    "CN1593817A",
    "US7444046B2",
    "US20070283786A1",
    "GB2453945A",
    "US8509933B2",
    "US20130136868A1",
    "WO2013128416A2",
    "US20150233345A1",
    "US20160008922A1",
    "WO2015109102A1",
    "WO2016201309A1"
  ]
}

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