Systems and methods for adding material to castings

Abstract

A system includes a controller, a pretreating machine, and an additive manufacturing machine. The pretreating machine is coupled to the controller. The pretreating machine includes a pretreater structured to form an interface layer on a component. The additive manufacturing machine is coupled to the controller. The additive manufacturing machine includes a material feed and a forming beam. The material feed is configured to selectively provide a first amount of material on the interface layer. The forming beam is configured to substantially melt the first amount of material, thereby forming a first layer of a first material deposit on the interface layer.

1 - 24 . (canceled) 
     
     
         25 . A method for depositing material on a component, the method comprising:
 forming an excavation in a target area of the component;   applying an interface layer on the excavation by flowing the interface layer on the excavation or by spraying a thermal spray on the excavation; and   forming a first layer of a first material deposit on the interface layer.   
     
     
         26 . The method of  claim 25 , further comprising forming a first layer of a second material deposit on the interface layer adjacent the first material deposit. 
     
     
         27 . The method of  claim 25 , further comprising forming a second layer of the first material deposit on the first layer of the first material deposit. 
     
     
         28 . The method of  claim 25 , further comprising:
 forming a first layer of a second material deposit on the interface layer adjacent the first material deposit; and   forming a second layer of the first material deposit on the first layer of the first material deposit after forming the first layer of the second material deposit.   
     
     
         29 . The method of  claim 25 , further comprising:
 forming a second layer of the first material deposit on the first layer of the first material deposit; and   forming a first layer of a second material deposit on the interface layer adjacent the first material deposit after forming the second layer of the first material deposit.   
     
     
         30 . The method of  claim 25 , further comprising:
 determining a depth of the first layer of the first material deposit;   comparing the depth to a target depth; and   forming, based on the comparison of the depth to the target depth, a second layer of the first material deposit on the first layer of the first material deposit.   
     
     
         31 . The method of  claim 25 , further comprising:
 determining a depth of the first layer of the first material deposit;   comparing the depth to a target depth; and   forming, based on the comparison of the depth to the target depth, a second layer of a second material deposit on the interface layer adjacent the first material deposit.   
     
     
         32 . The method of  claim 25 , wherein forming the first layer of the first material deposit on the interface layer comprises forming the first layer of the first material deposit within the excavation. 
     
     
         33 . The method of  claim 25 , further comprising analyzing the component to determine desired changes to the component;
 wherein at least one of:
 the excavation is formed based on the desired changes; 
 the interface layer is applied based on the desired changes; or 
 the first layer of the first material deposit is formed based on the desired changes. 
   
     
     
         34 . The method of  claim 25 , further comprising performing a finishing operation on the first material deposit. 
     
     
         35 . The method of  claim 25 , wherein the component is a cast component. 
     
     
         36 . The method of  claim 25 , wherein a controller causes an excavation machine to form the excavation in the target area. 
     
     
         37 . The method of  claim 25 , wherein a controller causes a pretreating machine to apply the interface layer on the excavation. 
     
     
         38 . The method of  claim 25 , wherein a controller causes an additive manufacturing machine to form the first layer of the first material deposit on the interface layer. 
     
     
         39 . The method of  claim 25 , further comprising:
 forming a first layer of a second material deposit on the interface layer such that the second material deposit is separated from the first material deposit by a portion of the interface layer;   forming a second layer of the second material deposit on the interface layer such that the second material deposit is separated from the first material deposit by the portion of the interface layer; and   forming a second layer of the first material deposit on the interface layer such that the first material deposit is separated from the second material deposit by the portion of the interface layer.   
     
     
         40 . A system comprising:
 a controller;   an excavation machine coupled to the controller, the excavation machine comprising an excavator configured to selectively remove material from a component so as to form an excavation;   a pretreating machine coupled to the controller, the pretreating machine comprising a pretreater configured to selectively form an interface layer on the excavation by spraying a thermal spray on the excavation; and   an additive manufacturing machine coupled to the controller, the additive manufacturing machine configured to selectively form a first deposit of a first amount of material on the interface layer.   
     
     
         41 . The system of  claim 40 , wherein the additive manufacturing machine is further configured to selectively form a second deposit of a second amount of material on the interface layer and separated from the first deposit by a portion of the interface layer. 
     
     
         42 . The system of  claim 40 , wherein the additive manufacturing machine is further configured to selectively form a second deposit of a second amount of material: (i) on the first deposit or (ii) on the interface layer adjacent the first deposit. 
     
     
         43 . The system of  claim 42 , wherein the interface layer has a first thickness and the first deposit has a second thickness, the first thickness less than the second thickness;
 wherein the first amount of material comprises a first nickel-based alloy; and   wherein the second amount of material comprises a second nickel-based alloy different from the first nickel-based alloy.   
     
     
         44 . The system of  claim 40 , wherein the additive manufacturing machine is configured to selectively form the first deposit of the first amount of material within the excavation.