Granted Patent B2

US 12,617,018 · App. 18/117,200 · Granted May 5, 2026

Inventors: Donald B. Bell (Wichita Falls, TX); Charles Trent Daulton (Burkburnett, TX); Kevin M. Tracy (Wichita Falls, TX)

Assignee: PRATT & WHITNEY CANADA CORP.

B22F10/85B22F10/66B22F12/44B22F12/58B22F12/82B33Y10/00B33Y30/00B33Y40/20B33Y50/02B33Y80/00

Abstract

Claims (30)

1 . A method of overhaul of a component, comprising:

a) scanning a component using structured light to provide first scanned data;

b) comparing the first scanned data to reference data to provide additive manufacturing data;

c) depositing material on the component using an additive manufacturing device based upon the additive manufacturing data to provide a first object, the depositing of material includes initially depositing a first material having a relatively high melting point, and then depositing a second material which has a melting point lower than the relatively high melting point of the first material, with the depositing step further including heating the first and second materials with a laser to sinter the materials to the component, then putting the component into a furnace for a heat cycle, and such that the second material moves around the first material, as they both melt;

d) determining predicted characteristics of the first object;

e) comparing the predicted characteristics of the first object to the reference data to provide machining data;

f) machining the first object using the machining data;

wherein the second material fills a void in the component; and

wherein the first material forms a cladding over a substrate of the component.

2 . The method as set forth in claim 1 , wherein step d) includes scanning the component again utilizing structured light to provide second scan data.

3 . The method as set forth in claim 1 , wherein the structured light comprises structured white light.

4 . The method as set forth in claim 1 , wherein the structured light comprises structured blue light.

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

6 . The method as set forth in claim 1 , further comprising removing a residual coating from the component to expose a surface prior to step c).

7 . The method as set forth in claim 1 , wherein the machining of step f) removes some of the material deposited during step c).

8 . The method as set forth in claim 1 , further comprising coating a surface of a second object, wherein the second object is formed by the machining of the first object in step f).

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

10 . A method of overhaul of a component, comprising:

a) scanning a component using structured light to provide first scanned data;

b) comparing the first scanned data to reference data to provide additive manufacturing data;

c) depositing material on the component using an additive manufacturing device based upon the additive manufacturing data to provide a first object, the depositing of material includes initially depositing a first material having a relatively high melting point, and then depositing a second material which has a melting point lower than the relatively high melting point of the first material, with the depositing step further including heating the first and second materials with a laser to sinter the materials to the component, then putting the component into a furnace for a heat cycle, and such that the second material moves around the first material, as they both melt;

d) determining predicted characteristics of the first object wherein step d) includes scanning the first object utilizing structured light to provide second scan data;

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

wherein the machining of step f) removes some of the material deposited during step c);

wherein the second material fills a void in the component; and

wherein the first material forms a cladding over a worn surface on the component.

11 . The method as set forth in claim 10 , wherein the first material forms a cladding over a worn surface on the component.

12 . The method as set forth in claim 10 , wherein the structured light comprises structured white light.

13 . The method as set forth in claim 10 , wherein the structured light comprises structured blue light.

Assignments (1)

Continuity (1)

References Cited (66)