IPC分类号：
B22F5/04 | B22F7/08 | B22F10/25 | B22F10/66 | B22F10/85 | B23K26/342 | B33Y10/00 | B33Y50/02 | F01D5/00 | G01N23/046 | B23P6/00 | B22F7/06 | B22F12/90 | B33Y40/20 | B23K26/00 | B23K26/03 | B22F10/80 | B33Y50/00 | B33Y30/00
国民经济行业分类号：
C3516 | C3252 | C3251 | C3393
当前申请(专利权)人：
PRATT & WHITNEY CANADA CORP.
原始申请(专利权)人：
PRATT & WHITNEY CANADA CORP.
当前申请(专利权)人地址：
1000 Marie Victorin, (01BE5),Longueuil, Québec J4G 1A1,CA
发明人：
TRACY, KEVIN M. | DAULTON, CHARLES TRENT
摘要：
A method of manufacturing a component (20) 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 (40A, 40B) using an additive manufacturing device (24) based upon the additive manufacturing data to provide a first object, the additive manufacturing device (24) melting the powder (40). 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 (99) for manufacturing a component (20) is also disclosed.
技术问题语段：
The patent text describes a method for manufacturing or repairing components using a CT scan to develop an additive manufacturing toolpath, which is then used to determine a machining toolpath for the component.
技术功效语段：
The technical efficacy of the patent scheme is that it provides a method for manufacturing a component using additive manufacturing. The method involves scanning the component using computed tomography, developing additive manufacturing data 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, determining predicted characteristics of the first object based upon the additive manufacturing data, comparing the predicted characteristics of the first object to the reference data to provide machining data, and machining the first object using the machining data.
权利要求：
1. A method of manufacturing a component, comprising: a) scanning a component (20) using computed tomography to provide scanned data; b) developing an additive manufacturing data using the scanned data compared to reference data; c) depositing powder (40A, 40B) using an additive manufacturing device (24) based upon the additive manufacturing data to provide a first object, the additive manufacturing device (24) melting the powder (40A, 40B); 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; and f) machining the first object using the machining data.
2. The method as set forth in claim 1, wherein the depositing of a material in step c) repairs the component (20).
3. The method as set forth in claim 1, wherein the depositing of a material in step c) forms a new component.
4. The method as set forth in claim 1, 2 or 3, wherein the component (20) is a gas turbine engine component.
5. A method of repairing of a component, comprising: a) scanning a component (20) using computed tomography to provide scanned data; b) comparing the scanned data to reference data to provide additive manufacturing data; c) depositing powder (40A, 40B) on the component (20) using an additive manufacturing device (24) based upon the additive manufacturing data to provide a first object, the additive manufacturing device (24) melting the powder (40A, 40B); 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; and f) machining the first object using the machining data.
6. The method as set forth in any preceding claim, wherein the reference data comprises data from a design specification for the component (20).
7. The method as set forth in any preceding claim, wherein the depositing of a material in step c) fills a void (22) in the component (20).
8. The method as set forth in claim 7, wherein the depositing of the material in step c) also forms a cladding (123) over a substrate (42) of the component (20).
9. The method as set forth in claim 8, wherein a first material is utilized to fill the void (22), and a second different material is utilized to form the cladding (123).
10. The method as set forth in any preceding claim, wherein the depositing of a or the material forms a or the cladding (123) over a worn surface (124) on the component (20).
11. The method as set forth in any preceding claim, wherein the machining of step f) removes some of the material deposited during step c).
12. The method as set forth in any preceding claim, wherein the component (20) is from a gas turbine engine.
13. A system (99) for manufacturing a component (20) comprising: 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 (20); an additive manufacturing device (24) configured to deposit powder (40A, 40B) on the component (20) to provide a first object, with the additive manufacturing device (24) controlled by additive manufacturing data and having a laser (34) to melt the deposited powder (40A, 40B); a machining device (102) configured to remove material from the first object based upon machining data; and a controller (100) programmed to compare the scanned data with reference data to provide the additive manufacturing data, and the controller (100) further programmed to compare the scanned data along with the additive manufacturing data to develop the machining data.
14. The system (99) as set forth in claim 13, wherein the deposited powder (40A, 40B) is alloy powder.
15. The system (99) as set forth in claim 14, wherein there are two different alloy powders.