Method for Manufacturing a Component by Layer-by-Layer Construction

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This invention describes a method for manufacturing components from metal materials using a layer-by-layer additive process that forms single crystals (monocrystals) rather than polycrystalline structures. The method involves heating and melting the metal in a line-shaped region and moving this region to build new layers. By precisely controlling the thermal and mechanical conditions during layer formation, the orientation of the resulting single crystal can be finely adjusted, allowing for highly tailored material properties suited to demanding applications.

Use CasesContent extracted from patent full text and abstract with AI.

• Production of high-performance turbine blades for gas or jet engines with superior mechanical properties
• Manufacturing of components for power generation turbines (e.g., steam, water, or gas turbines) operating under high thermal and mechanical stress
• Fabrication of parts requiring precise material properties, such as those in aerospace or automotive industries
• Repair or restoration of single-crystal components, such as the tip of turbine blades
• Manufacturing of functional components using shape memory alloys (e.g., Nitinol) or highly conductive copper alloys for electrical/thermal applications

BenefitsContent extracted from patent full text and abstract with AI.

• Enables the creation of single-crystal components with precisely controlled crystal orientation, improving performance and lifespan
• Reduces material defects associated with grain boundaries, such as creep and fatigue, leading to higher reliability in critical environments
• Facilitates local and flexible adjustment of mechanical properties within a part by combining single-crystal and polycrystalline regions
• Allows adaptation of crystal orientation to local stress/strain directions, optimizing component durability
• Enables additive manufacturing (3D printing) of complex geometry parts from high-performance alloys, reducing production steps and allowing for on-demand, customizable manufacturing
• Allows for in-situ repair of single-crystal parts, extending component life and reducing replacement costs

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Inventors & Applicants

Patent Abstract

The invention relates to a method for manufacturing a component (1) by means of layered construction, by combining a plurality of crystallites of a metal material to form a single crystal. The single crystal is produced by means of thermomechanically activated successive anisotropic plastic deformation. The metal material is heated during the construction of a new layer so that the metal material is melted in a line-shaped region (2). The line-shaped region (2) is moved in order to construct the new layer.