ADAPTIVE MANUFACTURING USING A CT SCAN AND AN ADAPTIVE MANUFACTURING TOOLPATH

Abstract

A method of manufacturing a component includes scanning a component using computed tomography to provide scanned data. Additive manufacturing data is developed using the scanned data compared to reference data. Depositing powder using an additive manufacturing device based upon the additive manufacturing data to provide a first object the additive manufacturing device melting the powder. Determining predicted characteristics of the first object based upon the additive manufacturing data. The predicted characteristics of the first object are compared to the reference data to provide machining data. Machining the first object using the machining data then occurs. A system for manufacturing a component is also disclosed.

Description

BACKGROUND

This application relates generally to manufacturing a component utilizing a CT scan of the component to develop an additive manufacturing toolpath, then using the toolpath and the scan to determine a machining toolpath. In one other embodiment the toolpath alone is utilized to determine the machining toolpath.

Modern systems are including more and more complex components. As the components become more complex they become more expensive. There is thus need to repair the components rather than simply replace them.

Defects in a component may be repaired using weld filler. Various processes are known in the art for applying such material to a component. While these known processes have various advantages, there is still room in the art for improvement.

One type of components which are frequently subject to repair are components in a gas turbine engine.

Also, the components are being manufactured by additive manufacturing.

SUMMARY

A method of manufacturing a component includes scanning a component using computed tomography to provide scanned data. Additive manufacturing data is developed using the scanned data compared to reference data. Depositing powder using an additive manufacturing device based upon the additive manufacturing data to provide a first object the additive manufacturing device melting the powder. Determining predicted characteristics of the first object based upon the additive manufacturing data. The predicted characteristics of the first object are compared to the reference data to provide machining data. Machining the first object using the machining data then occurs.

These and other features will be best understood from the following drawings and specification, the following is a brief description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows a gas turbine engine component.

FIG. 1B shows a gas turbine engine component to be repaired.

FIG. 1C shows a detail of the FIG. 1B component.

FIG. 2A shows an additive manufacturing device.

FIG. 2B shows a combined system for forming a component.

FIG. 3A is a flowchart of a method according to this disclosure.

FIG. 3B is a flowchart of an alternative method.

FIG. 4 shows a component needing repair.

FIG. 5 shows a first step in the repair process.

FIG. 6 shows a subsequent step in the repair process.

FIG. 7A shows a subsequent step.

FIG. 7B shows a calculation of what the part is expected to be after the FIG. 7A step.

FIG. 8 shows subsequent machining of the FIG. 7A component.

FIG. 9 shows a final optional manufacturing step.

FIG. 10 shows a newly manufactured component.

DETAILED DESCRIPTION

A component 20 is illustrated in FIG. 1A as a turbine section static guide vane for a gas turbine engine. It should be understood that the teaching of this disclosure would extend to any number of other components for a gas turbine engine. As examples, vanes, combustor liners, compressor section components and any number of housing components may all benefit from the teachings of this disclosure. In fact, the teachings of this disclosure extend to manufacturing or repairing components for applications other than gas turbine engines.

The component 20 is illustrated in FIG. 1B has two areas that indicate some needed repair. It should be understood that components in a gas turbine engine are subject to extreme conditions. Thus, a defect 22, such as a crack, a divot, a pitted area, etc. may form. Collectively these are referred to here as a void. Further, it is possible for an area of wear 124 to form.

As shown in FIG. 1C, the component 20 has a coating 27 which has been partially removed both in the area of the void 22, and in the wear area 124.

FIGS. 2A and 2B disclose a system which might be utilized to manufacture or repair the FIG. 1A/1B component.

Referring to FIG. 2A, the additive manufacturing device 24 may be configured as a laser material deposition device, and may be called a direct energy deposition laser cladding machine. A component support 28 supports a component 20 to be repaired. A pair of material reservoirs 30A and 30B are provided, as is a nozzle 32, a laser 34 and a material regulation device 36, all within an internal build chamber 38. The first material reservoir 30A stores a quantity of first powder 40A, and second material reservoir 30B stores a quantity of second powder 40B, to be supplied to the nozzle 32 through the material regulation device 36 during select additive manufacturing device operations.

A control 100 is programmed to control material regulation device 36 to selectively direct the first powder 40A during a first mode, and selectively direct the second powder 40B during a second mode. The material regulation device 36 may also be controlled to selectively direct one or more combinations of the first powder 40A and the second powder 40B to the nozzle 32 during a third mode.

The nozzle 32 is controlled to deliver a (e.g., annular, conical) stream 44 of the powder toward a substrate of component 20. A tubular inner sidewall 48 and a tubular outer sidewall 50 define passage 52 (e.g., an annulus) fluidly coupled (shown schematically) to material flow regulator 36, and extends to a nozzle orifice 54. A distal end portion of the nozzle 32 and its inner sidewall 48 and its outer sidewall 50 may radially taper inwards as the nozzle 32 extends axially toward nozzle orifice 54. The nozzle 32 may focus the powder 40 to, around or about a target point 56 on, slightly above or slightly below the substrate surface 42. Of course nozzle 32 may be configured to deliver the powder 40 through an internal bore rather than an annulus.

Control 100 is programmed to control laser 34 to generate a laser beam 58 for melting the powder 40 delivered by the nozzle 32 to the substrate 42. For example, a powder laser welding process is used where powder is melted to a liquid state (e.g., in a melt pool) by the laser beam and then solidified as a solid mass.

Laser 34 is controlled to direct the laser beam 58 to or about the target point 56 and heats the powder 40 for melting. The laser beam 58 directed through an internal bore 60 of the nozzle 32 formed by the inner sidewall 48. Of course, the laser 34 may be configured to direct the laser beam 58 outside of the nozzle 32 or along another path through the nozzle 32.

The first powder 40A, for example, may be deposited on the component 20 to repair a first type of substrate defect such as, but not limited to, the void 22. The second powder 40B, by contrast, may be deposited with the component 20 to repair a second type of substrate defect such as, but not limited to, the wear region 124 of FIG. 1A and FIG. 1B. More particularly, the first powder 40A may be provided (e.g., selected, formulated, etc.) for increased wettability, flowability and/or capillary penetration. The first powder may thereby be particularly suited for entering and filling voids. The second powder 40B, on the other hand, may be provided (e.g., selected, formulated, etc.) for improved dimensional repair of the surface due to lower wettability and flowability. The second powder may thereby be particularly suited for forming claddings. Of course, it is contemplated the first powder 40A and the second powder 40B may be mixed together in some proportion to provide a combined powder with intermediate properties.

Although the above description relates to repairing a component, the teachings of this disclosure would also extend to forming a new component 20 such as shown in FIG. 1A utilizing the tool 24 and the processes described above. Such a new component may be formed of a single material. For that matter only one material 40A or 40B may also be utilized for a repair process.

The first powder 40A may include a mixture of metal alloy powder (e.g., substrate powder). The metal alloy powder may be selected to have a relatively high melting point and common or similar material properties as the substrate of component 20, e.g., an aluminum (Al) superalloy, a nickel (Ni) superalloy, a titanium (Ti) superalloy, etc.

During the powder deposition, the additive manufacturing device 24 of FIG. 2A may dispose the respective powder 40 onto the substrate 42 at or about the target point 56. The laser 34 may concurrently melt this powder 40 at the target point 56 together and/or to the underlying substrate 42.

As shown, the additive manufacturing device 24 may selectively deposit the first powder and/or the second powder over the substrate such that areas which need repair, and optionally areas adjacent and/or surrounding those areas, are filled with the first material 62A and/or coated with the second material 62B. In other embodiments, the first powder and/or the second powder may be deposited over an entirety of the substrate 42 and excess material may later be removed. The powders may be deposited as one or more layers.

Following the melting deposition first filler material 62A, may partially or completely fill the void 66. The second filler material 62B may provide a cladding over the substrate 42 to restore a dimensional parameter of and/or reinforce the wear region 124 and/or other regions.

FIG. 2C shows an overall system 99 having a controller 100 controlling the additive manufacturing device 24, and a machining device 102, as will be explained below. The component 20 may be scanned by scanning device 103, which may be a computed tomography (CT) scan. As known, a CT scan takes a series of x-ray images taken from different angles around the component 20. Thus, an x-ray machine 104 is shown schematically with a guide 105 for allowing the x-ray machine to move to different angles relative to the component 20. Processing device 72 may operate as known to build the images. A memory 74 may be associated with historic manufacturing device for the component 20.

The component may alternatively move relative to the x-ray machine. The scanning device may be a flat-panel volumetric CT or conventional multidetector CT scanner. The flat-panel detector has wide z-axis coverage that enables imagine of entire object in one axial acquisition.

Controller 100 may be implemented with a combination of hardware and software. The hardware may include at least the processing device 72 and the memory 74. The processing device 72 may include single-core and/or multi-core processors. The memory 74 is configured to store software or execution by the processing device. The software execution may control and/or facilitate performance of the several operations described in this application. The memory 74 may be a non-transitory computer readable medium. As an example, the memory 74 can be configured to include a volatile memory and/or a non-volatile memory.

The scanning device, in combination with a controller 100, is thus able to identify a surface geometry of the component, and to map spatial coordinates for at least a portion (or the entirety) of the component 20. Such mapping would identify dimensions and location of features such as the void 22, and the wear area 124.

The scanned data may be in the form of a computer aided design model file, such as a stereolithography model file. Controller 100 may compare the mapped substrate characteristics from the scanned data with respective characteristics from reference data. The reference data may be data input from an OEM design specification for the component 20. In other words, the controller 100 may compare the mapped characteristics from the scan of the current component 20 being worked on to corresponding characteristics of the design specification.

The controller 100 may generate a solid model of the scan data to compare to a solid model of a design space component. The controller 100 thereby evaluates the current state and condition of the component 20 and determines what additive operations need to be performed. Among the determined operations could be the amount of additive manufacturing materials to be deposited, which type, where to deposit the additive manufacturing materials, paths to follow for depositing of the additive manufacturing materials, all to put the component back to being closer to the design space.

When a new component is being manufactured the scan would likely be eliminated.

A flowchart of a method according to this disclosure is illustrated in FIG. 3A. The flowchart should be studied in combination with FIGS. 4, 5, 6, 7A, 7B, 8 and 9.

As shown in FIG. 4, the component 20 to be repaired is as shown in FIG. 1B. There is a void 22 and a worn area 124. There is residual coating 27. At step 402 this component is provided for repair.

At step 404 the component is then prepared for additive manufacturing repair. Any number of steps may be performed as known to prepare the component. One such step is shown in FIG. 4 with a tool 101 removing the residual coating 27. Other known preparation steps may also be taken.

Then, at step 406, the component 20 is scanned. The scanning device 103 is shown with x-ray machine 104 movable about the surface of the component and the image capture devices 104A and 104B capturing images. The scanning device 103 shown schematically with the x-ray machine 104 movable in a guide 105. As mentioned above, the component may alternatively move relative to the scanning device.

The scanned data may be aligned with reference data such as a design specification of the component or an OEM model. Because the vane may have shifted during an engine heat cycle, the individual surface of the model vanes are broken apart and aligned to create a substrate model from the scan. This creates a unique geometry to correct the performance of the part without returning the part to the original casting. This unique geometry represents a desired component file. Steps may further include importing pre-deposition data, reverse engineered surfacing and subsequent toolpath generation. The substrate model is essentially what the part to be repaired is now.

As step 408, the data from the scan is provided to the controller 100, and the additive manufacturing toolpath is determined based upon the scan.

As shown in FIG. 6, the additive manufacturing tool 24 now applies the first material 62A to the void 22.

In the FIG. 7A, the additive manufacturing tool is shown supplying a second material 62B to the worn area 124. In addition, as can be appreciated, there is additional material 125 which has been deposited which is not desired on the final repaired component. Thus, there is material 123 which is desirably left and additional material 125 which is desirably removed.

The additive manufacturing machine applies material with an over application percentage to allow the following subtractive process to be successful. As an example, if a surface needs to have 0.02 inch added, the additive system may add an extra 50 percent. This results in 0.03 inch of buildup. After diffusion, the material may only have 0.025 inch remaining. Leaving 0.005 inch for the subtractive machining process to achieve the correct result.

Thus, as shown in FIG. 7B, the scanned data 106 and a estimate 108 of the additive material having been added are utilized in the controller 100 to determine the amount of material which is to be subtracted or removed from the intermediate component.

Next, at step 412 a toolpath is determined for removing the material 125 such that repaired component will approach its original state. Machining data will be developed in the controller 100 based upon the step 412 data. The desired component file is what is essentially compared to the substrate model.

Essentially, at step 412 the AM data is aligned to the substrate model. The result is then compared to reference data (e.g. the desired component file) and the subtractive machining toolpath is determined.

Then, at step 416 and as shown in FIG. 8, a tool 102 may remove the additional material as shown. Finally, at step 418 and FIG. 9, an outer coating 73 could be added to the repaired component 20.

FIG. 3B shows an alternative flow chart for forming a new component such as component 200 shown in FIG. 10. A plurality of layers of material 202, 204 and 206 are laid down. However, additional material 208 is also laid down. The amount of additional material 208 is determined relying upon the additive manufacturing toolpath such as described above with regard to FIG. 7B. Since no scan is used the additive manufacturing toolpath is determined based upon a desired final component shape and dimensions. A cutting tool 210 then cuts the added material away. Thus, as shown in FIG. 3B, at step 502 additive manufacturing toolpath is provided to an additive manufacturing system using desired data for the new component at step 502. A machining toolpath is then generated from the known additive path at step 504. Machining data is provided to a machining tool based upon step 504 data at step 506. The new component is then machined using the machining data at step 508. By utilizing the additive manufacturing toolpath to provide extra material for removal, a very accurate machining tool will be utilized to machine the component such that the desired dimensions may be more accurately reached.

Examples of the machining tools 101, 102 and 210 may be any number of known material removable tools controlled to be movable about any number of axes.

The reference data used to develop the AM path and the machining path may be the same file or could include two distinct files. While specific reference data sets are mentioned, other reference data sets can be used.

In a featured embodiment, a method of manufacturing a component 20 includes scanning a component using computed tomography 103 to provide scanned data. Additive manufacturing data is developed 408 using the scanned data compared to reference data. Depositing powder 410 using an additive manufacturing device 201 based upon the additive manufacturing data to provide a first object the additive manufacturing device melting the powder. Determining predicted characteristics of the first object based upon the additive manufacturing data. The predicted characteristics of the first object are compared 412 to the reference data to provide machining data. Machining 416 the first object using the machining data then occurs.

In another embodiment according to the previous embodiment, the reference data includes data from a design specification for the component.

In another embodiment according to any of the previous embodiments, the depositing of the material in step c) repairs the component.

In another embodiment according to any of the previous embodiments, the depositing of a material in step c) forms a new component.

In another embodiment according to any of the previous embodiments, the component is a gas turbine engine component.

In another featured embodiment, a method of repairing of a component including a) scanning a component 103/406 using computed tomography to provide scanned data, b) comparing the scanned data to reference data to provide additive manufacturing data, c) depositing powder 410 on the component using an additive manufacturing device 24 based upon the additive manufacturing data to provide a first object, the additive manufacturing device melting the powder, d) determining predicted characteristics of the first object based upon the additive manufacturing data developed in step b) and the scanned data of step a), e) comparing the predicted characteristics 412 of the first object to the reference data to provide machining data 414 and f) machining 416 the first object using the machining data.

In another embodiment according to any of the previous embodiments, the reference data includes data from a design specification for the component.

In another embodiment according to any of the previous embodiments, the depositing of the material in step c) fills a void 22 in the component.

In another embodiment according to any of the previous embodiments, the depositing of a material in step c) also forms a cladding 123 over a substrate of the component.

In another embodiment according to any of the previous embodiments, a first material is utilized to fill the void, and a second different material is utilized to form the cladding.

In another embodiment according to any of the previous embodiments, the depositing of the material in step c) fills a void in the component.

In another embodiment according to any of the previous embodiments, the depositing of a material in step c) also forms a cladding over a substrate of the component.

In another embodiment according to any of the previous embodiments, a first material is utilized to fill the void, and a second different material is utilized to form the cladding.

In another embodiment according to any of the previous embodiments, the machining of step f) removes some of the material 125 deposited during step c).

In another embodiment according to any of the previous embodiments, the depositing of the material forms a cladding 123 over a worn surface 124 on the component.

In another embodiment according to any of the previous embodiments, the machining of step f) removes some of the material 125 deposited during step c).

In another embodiment according to any of the previous embodiments, the component is from a gas turbine engine.

In another featured embodiment, a system 99 for manufacturing a component 20 includes a scanning device 103 configured to scan a component using computed tomography and provide scanned data indicative of one or more characteristics of the component. An additive manufacturing device 24 is configured to deposit powder on the component to provide a first object, with the additive manufacturing device controlled by additive manufacturing data and having a laser 32 to melt the deposited powder. A machining device 102 is configured to remove material from the first object based upon machining data. A controller 100 is programmed to compare the scanned data with reference data to provide the additive manufacturing data. The controller is further programmed to compare the scanned data along with the additive manufacturing data to develop the machining data.

In another embodiment according to any of the previous embodiments, the deposited powder is alloy powder.

In another embodiment according to any of the previous embodiments, there are two different alloy powders.

Although embodiments have been disclosed, a worker of skill in this art would recognize that modifications would come within the scope of this disclosure. For that reason, the following claims should be studied to determine the true scope and content.

Claims

1. A method of manufacturing a component, comprising: a) scanning a component using computed tomography to provide scanned data;b) developing an additive manufacturing data using the scanned data compared to reference data;c) depositing powder using an additive manufacturing device based upon the additive manufacturing data to provide a first object, the additive manufacturing device melting the powder;d) determining predicted characteristics of the first object based upon the additive manufacturing data developed in step b);e) comparing the predicted characteristics of the first object to the reference data to provide machining data; andf) machining the first object using the machining data.

2. The method as set forth in claim 1, wherein the reference data comprises data from a design specification for the component.

3. The method as set forth in claim 1, wherein the depositing of the material in step c) repairs the component.

4. The method as set forth in claim 1, wherein the depositing of a material in step c) forms a new component.

5. The method as set forth in claim 1, wherein the component is a gas turbine engine component.

6. A method of repairing of a component, comprising: a) scanning a component using computed tomography to provide scanned data;b) comparing the scanned data to reference data to provide additive manufacturing data;c) depositing powder on the component using an additive manufacturing device based upon the additive manufacturing data to provide a first object, the additive manufacturing device melting the powder;d) determining predicted characteristics of the first object based upon the additive manufacturing data developed in step b) and the scanned data of step a);e) comparing the predicted characteristics of the first object to the reference data to provide machining data; andf) machining the first object using the machining data.

7. The method as set forth in claim 6, wherein the reference data comprises data from a design specification for the component.

8. The method as set forth in claim 7, wherein the depositing of the material in step c) fills a void in the component.

9. The method as set forth in claim 8, wherein the depositing of a material in step c) also forms a cladding over a substrate of the component.

10. The method as set forth in claim 9, a first material is utilized to fill the void, and a second different material is utilized to form the cladding.

11. The method as set forth in claim 6, wherein the depositing of the material in step c) fills a void in the component.

12. The method as set forth in claim 11, wherein the depositing of a material in step c) also forms a cladding over a substrate of the component.

13. The method as set forth in claim 12, a first material is utilized to fill the void, and a second different material is utilized to form the cladding.

14. The method as set forth in claim 13, wherein the machining of step f) removes some of the material deposited during step c).

15. The method as set forth in claim 6, wherein the depositing of the material forms a cladding over a worn surface on the component.

16. The method as set forth in claim 6, wherein the machining of step f) removes some of the material deposited during step c).

17. The method as set forth in claim 6, wherein the component is from a gas turbine engine.

18. A system for manufacturing a component comprising: a scanning device configured to scan a component using computed tomography and provide scanned data indicative of one or more characteristics of the component;an additive manufacturing device configured to deposit powder on the component to provide a first object, with the additive manufacturing device controlled by additive manufacturing data and having a laser to melt the deposited powder;a machining device configured to remove material from the first object based upon machining data; anda controller programmed to compare the scanned data with reference data to provide the additive manufacturing data, and the controller further programmed to compare the scanned data along with the additive manufacturing data to develop the machining data.

19. The system as set forth in claim 19, wherein the deposited powder is alloy powder.

20. The system as set forth in claim 19, wherein there are two different alloy powders.