English to French Tech/Engineering Manufacturing PROCESS FOR FABRICATING A COMPOSITE

The substrate may be a substrate layer. The functional body may be a functional layer. Alternatively the functional body may be three-dimensional (eg columnar or pillar-like or a complex 3D structure or build). The build of functional material may be a layer of functional material.

In the step of selective melting, the substrate and build of functional material may be static or in motion (eg in rotary motion). In the step of selective melting, the directed energy beam may be static or in motion. Preferably the substrate and build of functional materials is rotated and the source of the directed energy beam (eg laser) is moved radially to-and-fro. This advantageously produces a functional body with a spiral configuration defining paths which might usefully carry dissimilar fluids (eg coolants).

Figure 2 is a schematic representation of an MCP Realizer and shows successive layers of powder 103 being deposited (the first layer being deposited onto the substrate 102) and spread uniformly by a wiper and powder deposition mechanism 100. For this purpose, a supporting table 104 supporting the substrate 102 drops down synchronously with the action of the wiper and powder deposition mechanism 100. A 100W Ytterbium fibre laser (wavelength 1068-1095 nm) 101 melts the successive layers of powder 103 according to a specific computer generated pattern. Single component powder particular 106 are fully or partially melted by the laser beam as it draws the design over the successive layers of power 103. Build thickness can be as high as 200pm per pass. The molten material is then solidified and the resultant fabrication 105 is fully dense.

A process as claimed in any preceding claim wherein the step of selectively melting the build of nickel-titanium alloy is carried out off-axis.

A process as claimed in any preceding claim wherein, during the step of selectively melting the build of nickel-titanium with the directed energy beam, either the substrate and build of nickel-titanium are in motion or the directed energy beam is in motion.

A selective energy beam melting process for fabricating a composite functional body/substrate comprising:
a plurality of sequential steps of localising a build of a material capable of being melted by a directed energy beam onto a substrate;
a plurality of sequential steps of selectively melting the build of material with the directed energy beam wherein the sequential steps of localising a build of the material alternate with the sequential steps of selectively melting the build of material with the directed energy beam; and
allowing the melted material to form the body of the composite functional body/substrate, characterised in that the material is a nickel-titanium alloy,