Part-geometry independent real time closed loop weld pool temperature control system for multi-layer dmd process
First Claim
1. A method of forming a metal section on a metal substrate by depositing a plurality of superimposed layers using a laser generating a heating beam and a powdered metal source operative to feed metal powder into the beam and moving the substrate relative to the beam under numerical control over a programmed path to provide an advancing melt pool, comprising:
- sensing parameters of the melt pool at a plurality of selected coordinates during the generation of a plurality of metallic layers, storing the sensed parameters of the pool at each of the selected coordinates, and processing the stored parameters to determine an appropriate laser power for use during the deposition of a subsequent layer.
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Accused Products
Abstract
In a direct metal deposition system which builds up a metallic overlay on a substrate by moving the substrate relative to a laser in a metallic powder feed, the laser power is adjusted for successive layers by sensing the weld pool in a plurality of selected points in each layer and adjusting the power during successive layers to maintain a weld pool that corresponds to those achieved during deposition of a lower optimal layer. This compensates for heating of the substrate resulting from the deposition which tends to increase the pool size or temperature in the higher layers.
57 Citations
13 Claims
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1. A method of forming a metal section on a metal substrate by depositing a plurality of superimposed layers using a laser generating a heating beam and a powdered metal source operative to feed metal powder into the beam and moving the substrate relative to the beam under numerical control over a programmed path to provide an advancing melt pool, comprising:
- sensing parameters of the melt pool at a plurality of selected coordinates during the generation of a plurality of metallic layers, storing the sensed parameters of the pool at each of the selected coordinates, and processing the stored parameters to determine an appropriate laser power for use during the deposition of a subsequent layer.
- View Dependent Claims (2, 3, 4, 5, 6, 7)
- 8. A method of forming a metal section on a metal substrate by depositing a plurality of superimposed layers by using a power source generating a heating beam and a metal source operative to feed metal powder into the beam and moving the substrate relative to the beam over the section to provide an advancing melting pool, comprising sensing parameters of the melt pool at a plurality of selected coordinates during the generation of a plurality of metallic layers, storing the sensed parameters of the pool at each of the coordinates, and processing the stored parameters to determine an appropriate laser power for use during deposition of a subsequent layer.
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12. A method of forming a metal section on a metal substrate by depositing a plurality of superimposed layers using a heating beam and a powdered metal source operative to feed metal powder into the beam and moving the substrate relative to the beam under numerical control over a programed path to provide an advancing melting pool, comprising:
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depositing a first layer in contact with the substrate using a first heating beam power;
depositing a second layer over the first layer using the same heating beam power as used in the first layer and sensing parameters of the melt pool at a plurality of selected coordinates during the generation of said second layer;
depositing a third layer using the same heating beam power as employed in the first two layers and sensing parameters of the melt pool at said selected coordinates during generation of the third layer; and
using the stored parameters of the melt pool during generation of the second and third layers to determine an appropriate heating beam power for use during deposition of subsequent layers. - View Dependent Claims (13)
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Specification