Methods of forming a layer of cladding material on a component, and a related system

Abstract

A method of forming a layer of cladding material on a component includes performing a metal deposition process to deposit cladding material onto a surface of the component and onto a mold member. A metallurgical bond is formed between the cladding material and the component, but not between the cladding material and the mold member. The mold member may be removed after the metal deposition process, and the layer of cladding material can be processed to modify its shape.

What is claimed is: 
     
         1 . A method of processing a component, comprising:
 performing a metal deposition process to deposit a layer of cladding material onto a surface of the component and onto a support surface of a mold member, the mold member being different from the component, and   forming a metallurgical bond between the cladding material and the component.   
     
     
         2 . The method of  claim 1 , further comprising:
 removing the mold member from a position adjacent to the component after performing the metal deposition process.   
     
     
         3 . The method of  claim 1 , further comprising:
 moving the mold member to a position adjacent to the component before performing the metal deposition process.   
     
     
         4 . The method of  claim 3 , further comprising:
 removing the mold member from the position adjacent to the component after performing the metal deposition process.   
     
     
         5 . The method of  claim 3 , wherein moving the mold member includes providing a space between the mold member and the component. 
     
     
         6 . The method of  claim 3 , wherein moving the mold member includes positioning the support surface in substantial alignment with the surface of the component. 
     
     
         7 . The method of  claim 1 , wherein the metal deposition process is a laser cladding process. 
     
     
         8 . The method of  claim 1 , further comprising:
 preventing a metallurgical bond from forming between the cladding material and the mold member.   
     
     
         9 . The method of  claim 1 , further comprising:
 processing the layer of cladding material to provide a substantially uniform thickness of cladding material above the surface of the component.   
     
     
         10 . The method of  claim 1 , wherein the surface of the component extends to an edge, and further comprising:
 removing cladding material that extends laterally beyond the edge.   
     
     
         11 . The method of  claim 1 , wherein the surface of the component extends to an edge, and further comprising:
 removing cladding material that extends above the surface of the component and does not extend laterally beyond the edge.   
     
     
         12 . The method of  claim 11 , further comprising:
 removing cladding material that extends laterally beyond the edge.   
     
     
         13 . The method of  claim 1 , wherein the mold member includes (1) a polished surface, (2) a cooled surface, or (3) a contact material selected from the group consisting of graphite, ceramics, and polymers, for preventing a metallurgical bond from forming between the cladding material and the mold member. 
     
     
         14 . A method of forming a layer of cladding material on a surface of a component, the surface extending from a first edge to a second edge, the method comprising:
 positioning a first mold member adjacent to the first edge of the component, the first mold member including a first support surface,   positioning a second mold member adjacent to the second edge of the component, the second mold member including a second support surface,   performing a metal deposition process to deposit a layer of cladding material onto the surface of the component between the first and second edges and onto the first and second support surfaces of the first and second mold members, the layer of cladding material extending laterally beyond the first and second edges where the cladding material is deposited onto the first and second support surfaces, and   forming a metallurgical bond between the cladding material and the component.   
     
     
         15 . The method of  claim 14 , further comprising:
 removing cladding material above the surface of the component, and   removing cladding material that extends laterally beyond the first and second edges.   
     
     
         16 . The method of  claim 14 , further comprising:
 removing the first and second mold members from adjacent to the component after performing the metal deposition process.   
     
     
         17 . The method of  claim 14 , wherein positioning the first and second mold members includes positioning the first and second support surfaces in substantial alignment with the surface of the component. 
     
     
         18 . The method of  claim 14 , wherein the first and second mold members include a (1) a polished surface, (2) a cooled surface, or (3) a contact material selected from the group consisting of graphite, ceramics, and polymers, for preventing a metallurgical bond from forming between the cladding material and the first and second mold members. 
     
     
         19 . The method of  claim 14 , wherein the metal deposition process is a laser cladding process. 
     
     
         20 . A system for forming a layer of cladding material on a component, comprising:
 a mold member configured for cooperating with the component during a metal deposition process,   a fixture configured for holding the component during the metal deposition process, and   a metal deposition system configured for performing the metal deposition process to deposit cladding material onto the mold member and the component,   the mold member including (1) a polished surface, (2) a cooled surface, or (3) a contact material selected from the group consisting of graphite, ceramics, and polymers for preventing a metallurgical bond from forming between the cladding material and the mold member.