Method for fabricating components using hybrid additive manufacturing and consolidation process

Abstract

A method of fabricating a near net shape component includes forming a sacrificial shell from a pulverant material using an additive manufacturing process, the shell having an aperture. The method further includes filling the shell with a second pulverant material, subjecting the filled shell to a consolidation process, and removing the shell from the consolidated second pulverant material.

1 . A system for fabricating a component, the system comprising:
 a sacrificial shell formed from a first material and comprising an aperture;   a second material contained within the hollow shell, the second material being a pulverant material; and   means for consolidating the second material within the hollow shell.   
     
     
         2 . The system of  claim 1  and further comprising: chemical or mechanical means for removing the hollow shell from the consolidated second material. 
     
     
         3 . The system of  claim 2 , wherein chemical means for removing the hollow shell comprises a chemical etchant. 
     
     
         4 . The system of  claim 2 , wherein mechanical means for removing the hollow shell comprises at least one of a cutting, milling, and grinding process. 
     
     
         5 . The system of  claim 1 , wherein the means for consolidating the second material comprises an isostatic pressing process. 
     
     
         6 . The system of  claim 1 , wherein the first material is different from the second material. 
     
     
         7 . The system of  claim 1 , wherein the shell comprises a first region with a first shell thickness, and a second region with a second shell thickness different from the first shell thickness. 
     
     
         8 . The system of  claim 1 , wherein the shell has an inner surface geometry complementary to a component geometry. 
     
     
         9 . The system of  claim 1  and further comprising: a solid base portion attached to the sacrificial shell and formed from the first material. 
     
     
         10 . The system of  claim 1  and further comprising: a solid component portion formed from the first material and integral to the sacrificial shell.