Hybrid additive manufacturing method

Abstract

Methods, systems, and apparatus, for hybrid additive manufacturing of parts. In one aspect, a method includes providing a workpiece and manufacturing multiple additive layers on a surface of the workpiece. Manufacturing each of the multiple additive layers includes forming one or more formed layers on a surface of the workpiece by depositing a quantity of powder material on a growth surface, the growth surface inclusive of at least one of a first surface of the workpiece and a second surface of a previously formed layer, and applying a first amount of energy to the quantity of powder material to fuse the particles of the powder material into a formed layer fused to the growth surface, where the formed layer includes a formed surface, and further applying a secondary process to a particular area of the formed surface of the one or more formed layers on the workpiece.

What is claimed is: 
     
         1 - 20 . (canceled) 
     
     
         21 . A hybrid additive manufacturing method comprising:
 manufacturing a plurality of additive layers on a surface of a workpiece, wherein manufacturing the plurality of additive layers comprises:
 forming a formed layer on a surface of the workpiece, wherein forming each of the formed layers comprises: 
 depositing a quantity of powder material on a growth surface, the growth surface comprised of at least one of a first surface of the workpiece and a second surface of a previously formed layer; and 
 applying a first amount of energy from an energy source to the quantity of powder material to fuse particles of the powder material into a formed layer fused to the growth surface, wherein the formed layer comprises a formed surface; and 
 applying a secondary process from a surface treatment source to a particular area of the formed surfaces of a plurality of the formed layers on the workpiece, the secondary process comprising a cold working process of selective ones of the formed layers and selective portions of the formed layers. 
   
     
     
         22 . The method of  claim 21 , wherein the workpiece comprises a reactive metal. 
     
     
         23 . The method of  claim 21 , wherein the workpiece comprises a Magnesium-based alloy. 
     
     
         24 . The method of  claim 21 , wherein the secondary process further comprises one or more of a laser peening, shot peening, burnishing, or deep-rolling process. 
     
     
         25 . The method of claim  1 , wherein the secondary process comprises a laser peening process that generates a plasma within the particular area on the formed surfaces. 
     
     
         26 . The method of  claim 25 , wherein the generated plasma propagates a pressure wave through one or more of the formed layers and the workpiece. 
     
     
         27 . The method of  claim 26 , wherein the propagating pressure wave results in clustered arrays of dislocations at one or more interfaces between the formed layers. 
     
     
         28 . The method of  claim 21 , wherein the secondary process induces one or more mechanical, physical, electrical, and chemical alterations within one or more of the formed layers and the workpiece. 
     
     
         29 . The method of  claim 26 , wherein the secondary process results in grain reorientation and grain size reduction within one or more of the formed layers and workpiece. 
     
     
         30 . The method of  claim 21 , wherein the secondary process forms a region having compressive residual stress extending from the formed surfaces within the particular area and through the formed layers. 
     
     
         31 . The method of  claim 21 , wherein the secondary process is applied to selective ones of the formed layers and to selective portions of the formed layers in both a periodic and non-periodic manner. 
     
     
         32 . The method of  claim 21 , wherein applying the secondary process to the particular area of the formed layers further comprises:
 for a first of the formed layers, applying the secondary process within a first area of the first formed layer, and   for a second of the formed layers, applying the secondary process within a second area of the second formed layer,   wherein a region of the first area does not overlap with the second area in a direction orthogonal to the surface of the workpiece.   
     
     
         33 . The method of  claim 21 , wherein the energy source is a sintering energy source. 
     
     
         34 . A hybrid additive manufacturing system comprising:
 an energy source;   a surface treatment source;   a powder distribution source; and   a controller configured to control the operations of the energy source, secondary treatment source, and powder distribution source to manufacture a plurality of additive layers on a surface of a workpiece, wherein the manufacturing of the plurality of additive layers comprises:
 forming a formed layer on the surface of the workpiece, wherein forming each of the formed layers comprises:
 depositing, by the powder distribution source, a quantity of powder material on a growth surface, the growth surface comprised of at least one of a first surface of the workpiece and a second surface of a previously formed layer; and 
 applying, by the energy source, a first amount of energy to the quantity of powder material to fuse particles of the powder material into a formed layer fused to the growth surface, wherein the formed layer comprises a formed surface; and 
 
 applying, by the surface treatment source and to a particular area of the formed surfaces of the plurality of formed layers on the workpiece, a secondary process comprising a cold working process of selective ones of the formed layers and selective portions of the formed layers. 
   
     
     
         35 . The system of  claim 34 , wherein the workpiece comprises a reactive metal. 
     
     
         36 . The system of  claim 34 , wherein the workpiece comprises a Magnesium-based alloy. 
     
     
         37 . The system of  claim 34 , wherein the secondary process further comprises one or more of a laser peening, shot peening, burnishing, or deep-rolling process. 
     
     
         38 . The system of  claim 34 , wherein the secondary process further comprises a sub-surface treatment applied through one or more of the formed layers and workpiece and results in grain reorientation and grain size reduction within one or more of the formed layers and workpiece. 
     
     
         39 . The system of  claim 34 , wherein the secondary process forms a region having compressive residual stress extending from the formed surfaces within the particular area and through the formed layers. 
     
     
         40 . The system of  claim 34 , wherein the secondary process is applied to selective ones of the formed layers and to selective portions of the formed layers in both a periodic and non-periodic manner. 
     
     
         41 . The system of  claim 34 , wherein the energy source is a sintering energy source. 
     
     
         42 . The system of  claim 34 , wherein applying the secondary process to the particular area of the formed layers further comprises:
 for a first of the formed layers, applying the secondary process within a first area of the first formed layer, and   for a second of the formed layers, applying the secondary process within a second area of the second formed layer,   wherein a region of the first area does not overlap with the second area in a direction orthogonal to the surface of the workpiece.