Laser net shape manufacturing and repair using a medial axis toolpath deposition method

Abstract

A method is disclosed for laser net shape manufacturing a part or repairing an area of a part comprising providing a CAD model of the part to be manufactured or repaired, digitally slicing the CAD model into a plurality of deposition layers, determining a medial axis for each of the deposition layers of the part or repair area; and depositing a bead of a material in a pattern centered upon the medial axis of each of the deposition layers so as to build-up the material by each of the deposition layer until the part is manufactured or repaired.

1 . A method for laser net shape manufacturing a part, comprising:
 providing a CAD model of the part;   digitally slicing the CAD model into a plurality of deposition layers;   determining a medial axis for each of the deposition layers; and   depositing a bead of a material in a pattern centered upon the medial axis of each of the deposition layers so as to build-up the material by each of the deposition layer until the part is manufactured.   
     
     
         2 . The method of  claim 1 , wherein the pattern comprises a zigzag pattern or a zig pattern about the medial axis. 
     
     
         3 . The method of  claim 1 , wherein the pattern comprises a single bead centered upon the medial axis. 
     
     
         4 . The method of  claim 1 , wherein the bead of material is a mixture of different materials. 
     
     
         5 . The method of  claim 1 , wherein the bead of material is formed of a single material. 
     
     
         6 . The method of  claim 1 , wherein the bead of material is formed of different materials. 
     
     
         7 . The method of  claim 1 , wherein a first layer of the deposited material is deposited upon a substrate. 
     
     
         8 . The method of  claim 1 , wherein the deposited material is selected from a group comprising metals, metal alloys, ceramics, and plastics. 
     
     
         9 . The part formed by the method of  claim 1 . 
     
     
         10 . The method of  claim 1 , wherein the part is a BLISK, turbine blade, compressor blade or turbine component. 
     
     
         11 . A method for laser net shape repairing a part comprising:
 providing a part with an area to be repaired;   shaping the area by removing the area to be repaired to provide a smooth and continuous surface;   comparing the removed area to be repaired to a baseline shape to determine a material deposition area;   digitally slicing the determined material deposition area into a plurality of deposition layers;   determining a medial axis for each of the deposition layers; and   depositing a material in a pattern centered upon the medial axis of each of the deposition layers so as to build-up the material by each of the deposition layers until the part is repaired.   
     
     
         12 . The method of  claim 11 , wherein the pattern comprises a zigzag pattern about the medial axis. 
     
     
         13 . The method of  claim 11 , wherein the pattern comprises a zig pattern about the medial axis. 
     
     
         14 . The method of  claim 11 , wherein the pattern comprises a single bead centered upon the medial axis. 
     
     
         15 . The method of  claim 11 , wherein the deposited material is selected from a group comprising metals, metal alloys, ceramics, and plastics. 
     
     
         16 . The method of  claim 11 , wherein the deposited material comprises more than one material. 
     
     
         17 . The method of  claim 11 , wherein the part is a BLISK, turbine blade, compressor blade or turbine component. 
     
     
         18 . The method of  claim 11 , wherein a first layer of the deposited material is deposited upon a BLISK compressor disk. 
     
     
         19 . A BLISK, turbine blade, compressor blade or turbine component fabricated by the method of  claim 1 . 
     
     
         20 . A BLISK, turbine blade, compressor blade or turbine component repaired by the method of  claim 11 .