Patent ID: 11865642
Assignee: ROLLS-ROYCE CORPORATION
Field: Materials, metallurgy (Chemistry)
Classification: CPC B  C  Y | IPC B  C

Claim 1:
2. A method comprising:
removing a damaged portion of a substrate to form an exposed surface of the substrate, wherein the damaged portion removed from the substrate includes a case hardened material,
depositing, using a laser directed energy deposition process, a plurality of tracks on the exposed surface of the substrate to form at least a portion of a component, the substrate comprising a first ferrous material, wherein depositing the plurality of tracks on the exposed surface includes:
directing, by a material delivery device, a second ferrous material and a carbon-based material to the exposed surface of the substrate, wherein the second ferrous material is directed to the exposed surface of the substrate by the material delivery device in the form of a wire filament or in the form a powder blown to the surface of the substrate with a carrier gas, and
directing, by a laser, an energy toward a volume of the second ferrous material to join at least some of the second ferrous material and the carbon-based material to the exposed surface of the substrate to form a respective track of the plurality of tracks; and

heat treating the respective track of the plurality of tracks joined to the exposed surface of the substrate to case-harden the respective track of the plurality of tracks, wherein the respective track at least partially replaces the case hardened material of the damaged portion of the substrate.