US 11,865,619 B2
Structures and components having composite unit cell matrix construction
Evan John Dozier, Niskayuna, NY (US); and Rajendra Madhukar Kelkar, Mason, OH (US)
Assigned to General Electric Company, Schenectady, NY (US)
Filed by General Electric Company, Schenectady, NY (US)
Filed on Jul. 21, 2021, as Appl. No. 17/381,361.
Application 17/381,361 is a continuation of application No. 15/836,337, filed on Dec. 8, 2017, granted, now 11,097,348.
Prior Publication US 2021/0346956 A1, Nov. 11, 2021
Int. Cl. B22F 3/11 (2006.01); B22F 3/15 (2006.01); B33Y 10/00 (2015.01); B33Y 80/00 (2015.01); B22F 1/052 (2022.01); B22F 10/12 (2021.01); B22F 10/14 (2021.01); B22F 10/18 (2021.01); B22F 10/25 (2021.01); B22F 10/28 (2021.01); B33Y 50/02 (2015.01); B29C 64/153 (2017.01); G06F 30/17 (2020.01); G06F 30/23 (2020.01); B22F 12/44 (2021.01)
CPC B22F 3/1115 (2013.01) [B22F 1/052 (2022.01); B22F 3/156 (2013.01); B22F 12/44 (2021.01); B29C 64/153 (2017.08); B33Y 10/00 (2014.12); B33Y 50/02 (2014.12); B33Y 80/00 (2014.12); G06F 30/17 (2020.01); G06F 30/23 (2020.01); B22F 10/12 (2021.01); B22F 10/14 (2021.01); B22F 10/18 (2021.01); B22F 10/25 (2021.01); B22F 10/28 (2021.01); B22F 2003/153 (2013.01); B22F 2301/15 (2013.01); B22F 2998/10 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method of fabricating a composite component, the composite component comprising a first material, a second material, and a third material, said method comprising:
depositing the first material and the third material onto a surface; and
operating a consolidating device of an additive manufacturing system to consolidate the first material and the third material using a first process to form:
a first section comprising the first material, said first section comprising a plurality of first section unit cells joined together;
a third section comprising the third material, said third section surrounding the first section; and
depositing the second material within the third section and within and surrounding each unit cell of the plurality of first section unit cells; and
consolidating the second material using a second consolidation process different from the first process to form a second, solid section within the third section and within and surrounding each unit cell of the plurality of first section unit cells;
wherein the first material and the third material are harder than the second material, and the first material and the third material have a smaller grain size than the second material when the second material is deposited.