SUPERALLOY SOLID FREEFORM FABRICATION AND REPAIR WITH PREFORMS OF METAL AND FLUX

摘要

A preform (22, 22A-U) containing metal (32, 34) and flux (33) for forming a metal layer to be added to a component being repaired or additively manufactured. The metal may be constrained in the preform in a distribution that forms a shape of a sectional layer or a surface repair of a component in response to an energy beam (58) that melts the preform. The preform is placed on a working surface (42), which may be a previously formed layer (42A-C) in additive manufacturing, or may be an existing component surface (122) for repair The preform is then melted by the energy beam (58) to form a new integrated layer (40A-F) on the component with an over-layer of slag (56) that shields and insulates the melt pool (54) and the solidifying layer The slag is removed, and a subsequent layer may be added.

主权项

1. A process comprising:
forming a preform comprising a metal and a flux, wherein the metal is distributed in the preform responsive to a desired shape of a metal layer of a metal component; placing the preform on a working surface, directing an energy beam onto the preform to melt the metal, forming the metal layer overlaid by a slag layer; and removing the slag layer