Method for manufacturing a component using an additive process

Abstract

A method for additively manufacturing components includes additively printing a metallic preform such that the preform contains a predetermined amount of porosity. Furthermore, the method includes working the additively printed preform such that the preform incurs a predetermined amount of deformation. Moreover, the method includes heat treating the worked preform to form a final component.

1 . A method for additively manufacturing a component having a recrystallized grain structure with a target grain size, the method comprising:
 forming a metallic preform by an additive manufacturing process and controlling process parameters of the additive manufacturing process to impart a predetermined amount of porosity to the metallic preform, the metallic preform comprising a material having an initial grain structure different from the target grain size;   working the metallic preform isostatically to uniformly impart a predetermined amount of deformation to the material; and   thereafter, heat treating the metallic preform to recrystallize the material and form a final component having the target grain size.   
     
     
         2 . The method of  claim 1 , further comprising:
 selecting the predetermined amount of porosity and the predetermined amount of deformation that, in combination, will produce the target grain size in the final component upon heat treating the metallic preform.   
     
     
         3 . The method of  claim 1 , wherein controlling the process parameters comprises controlling a speed at which an electromagnetic radiation beam used to additively print the metallic preform is moved relative to the metallic preform. 
     
     
         4 . The method of  claim 1 , wherein controlling the process parameters comprises controlling a number of passes across the metallic preform by an electromagnetic radiation beam used to additively print the metallic preform. 
     
     
         5 . The method of  claim 1 , wherein controlling the process parameters comprises controlling an energy of an electromagnetic radiation beam used to additively print the metallic preform. 
     
     
         6 . The method of  claim 1 , wherein working the metallic preform isostatically comprises cold isostatic pressing the metallic preform to impart a percent cold work in a range of 2% to 60%. 
     
     
         7 . The method of  claim 1 , wherein a grain size of the final component is based on the predetermined amount of porosity contained by the metallic preform and the predetermined amount of deformation incurred by the metallic preform. 
     
     
         8 . The method of  claim 1 , wherein forming the metallic preform by the additive manufacturing process comprises additively printing the metallic preform using a powder bed fusion technique. 
     
     
         9 . The method of  claim 8 , wherein additively printing the metallic preform comprises controlling a speed at which an electromagnetic radiation beam used to additively print the metallic preform is moved relative to the metallic preform such that the metallic preform contains the predetermined amount of porosity. 
     
     
         10 . The method of  claim 8 , wherein additively printing the metallic preform comprises controlling a number of passes across the metallic preform that an electromagnetic radiation beam used to additively print the metallic preform makes such that the metallic preform contains the predetermined amount of porosity. 
     
     
         11 . The method of  claim 8 , wherein additively printing the metallic preform comprises controlling an energy of an electromagnetic radiation beam used to additively print the metallic preform such that the metallic preform contains the predetermined amount of porosity. 
     
     
         12 . The method of  claim 1 , wherein forming the metallic preform by the additive manufacturing process comprises:
 additively printing a first portion of the metallic preform such that the first portion has a first predetermined amount of porosity; and   additively printing a second portion of the metallic preform such that the second portion has a second predetermined amount of porosity, the second predetermined amount of porosity being different than the first predetermined amount of porosity.   
     
     
         13 . The method of  claim 1 , wherein working the metallic preform comprises cold working the metallic preform such that the metal preform incurs the predetermined amount of deformation. 
     
     
         14 . The method of  claim 1 , wherein working the metallic preform comprises isostatically working the metallic preform such that the metallic preform incurs the predetermined amount of deformation. 
     
     
         15 . The method of  claim 1 , wherein working the metallic preform comprises cold isostatic pressing the metallic preform such that the metallic preform incurs the predetermined amount of deformation. 
     
     
         16 . The method of  claim 1 , further comprising:
 selecting the predetermined amount of porosity and the predetermined amount of deformation that, in combination, will impart a desired grain structure in the final component upon heat treating the metallic preform.   
     
     
         17 . The method of  claim 1 , wherein the final component is a turbomachine component. 
     
     
         18 . The method of  claim 17 , wherein the turbomachine component comprises at least one of a gas turbine engine blade or a gas turbine engine vane. 
     
     
         19 . The method of  claim 1 , wherein forming a metallic preform by an additive manufacturing process and controlling process parameters of the additive manufacturing process to impart a predetermined amount of porosity to the metallic preform comprises:
 controlling a speed at which an electromagnetic radiation beam used to form the metallic preform is moved relative to the metallic preform such that the metallic preform contains the predetermined amount of porosity,   controlling a number of passes across the metallic preform that the electromagnetic radiation beam makes such that the metallic preform contains the predetermined amount of porosity, and   controlling an energy of the electromagnetic radiation beam such that the metallic preform contains the predetermined amount of porosity.   
     
     
         20 . An additively manufactured component formed according to the method of  claim 1 .