Nozzle for laser net shape manufacturing

• US 20070193981A1
• Filed: 02/22/2006
• Published: 08/23/2007
• Est. Priority Date: 02/22/2006
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Huang, Xiaoping, Chen, Xiaobin, Li, Yanmin, Azer, Magdi, Peng, Zhixue
• Granted Patent: US 7,358,457 B2
• Time in Patent Office: Days
• US Class Current: 219/121.33
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 12/20 Cooling means
• CPC Class Codes: B22F 12/53 Nozzles
• CPC Class Codes: B22F 12/70 Gas flow means
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B23K 26/144 the fluid stream containing particles, e.g. powder
• CPC Class Codes: B23K 26/1476 Features inside the nozzle for feeding the fluid stream through the nozzle
• CPC Class Codes: B23K 26/1482 Detachable nozzles, e.g. exchangeable or provided with breakaway lines
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

Methods, apparatuses, devices, and/or systems for laser net shape manufacturing are described may make use of a nozzle that includes a main body with a thermal channel, a conducting channel and a gas distribution head. The thermal channel is at least partially within the main body and includes an aperture for passing thermal energy therethrough. The conducting channel includes a conducting outlet aperture that is a located adjacent to the thermal outlet aperture, and powder material can be passed through the conducting outlet aperture. The gas distribution head is capable of distributing shielding gas in a distribution path surrounding the conducting outlet aperture.

Claims

1. (canceled)

6. An apparatus, comprising:

a main body;

a thermal channel located at least partially within the main body, wherein the thermal channel comprises a thermal outlet aperture capable of passing thermal energy therethrough;

a conducting channel located at least partially within the main body, wherein the conducting channel comprises at least one conducting outlet aperture located adjacent the thermal outlet aperture, and wherein the conducting outlet aperture is a single point outlet aperture capable of dispersing powder material therethrough; and

a first gas distribution head capable of distributing shielding gas in a first distribution path surrounding the conducting outlet aperture.

2. The apparatus of claim 6, further comprising a first conducting head containing the conducting outlet aperture and at least a portion of the conducting channel, wherein the first conducting head is capable of dispersing powder material in a first dispersing path.

3. The apparatus of claim 2, further comprising a recess portion located in the first conducting head, wherein the at least one conducting outlet aperture is located on said recess portion.

4. The apparatus of claim 3, wherein the thermal outlet aperture is located on said recess portion, and wherein the recess portion has a generally concave shape.

5. The apparatus of claim 2, further comprising a second conducting head containing the conducting outlet aperture and at least a portion of the conducting channel, wherein the second conducting head is capable of dispersing powder material in a second dispersing path different from the first dispersing path, and wherein the second conducting head and the first conducting head are interchangeably attachable to the main body.

7. The apparatus of claim 6, further comprising a second gas distribution head capable of distributing shielding gas in a second distribution path surrounding the conducting outlet aperture different from the first distribution path, and wherein the first gas distribution head and the second gas distribution head are interchangeably attachable to the main body.

8. The apparatus of claim 6, wherein the thermal energy comprises energy from one or more of the following:

a laser source, an electron beam source, an ion beam source, or an arc welding torch, or combinations thereof.

9. (canceled)

13. An apparatus, comprising:

a main body;

a conducting channel located at least partially within the main body, wherein the conducting channel comprises at least one conducting outlet aperture capable of passing powder material therethrough;

a first conducting head containing the conducting outlet aperture and at least a portion of the conducting channel, wherein the first conducting head is capable of dispersing powder material in a first dispersing path;

a recess portion located in the first conducting head, wherein the at least one conducting outlet aperture is located on said recess portion; and

a first gas distribution head capable of distributing shielding gas in a first distribution path surrounding the conducting outlet aperture.

10. The apparatus of claim 13, further comprising a thermal channel located at least partially within the main body, wherein the thermal channel comprises a thermal outlet aperture capable of passing thermal energy therethrough;

and wherein the conducting channel is located adjacent the thermal outlet aperture.

11. The apparatus of claim 10, wherein the thermal outlet aperture is located on said recess portion, and wherein the recess portion has a generally concave shape.

12. The apparatus of claim 13, further comprising a second conducting head containing the conducting outlet aperture and at least a portion of the conducting channel, wherein the second conducting head is capable of dispersing powder material in a second dispersing path different from the first dispersing path, and wherein the second conducting head and the first conducting head are interchangeably attachable to the main body.

14. The apparatus of claim 13, further comprising a second gas distribution head capable of distributing shielding gas in a second distribution path surrounding the conducting outlet aperture different from the first distribution path, and wherein the first gas distribution head and the second gas distribution head are interchangeably attachable to the main body.

15. The apparatus of claim 10, wherein the thermal energy comprises energy from one or more of the following:

a laser source, an electron beam source, an ion beam source, or an arc welding torch, or combinations thereof.

16. (canceled)

18. An apparatus, comprising:

a main body;

a conducting channel located at least partially within the main body, wherein the conducting channel comprises at least one conducting outlet aperture capable of passing powder material therethrough;

a first conducting head containing the conducting outlet aperture and at least a portion of the conducting channel, wherein the first conducting head is capable of dispersing powder material in a first dispersing path;

a second conducting head containing the conducting outlet aperture and at least a portion of the conducting channel, wherein the second conducting head is capable of dispersing powder material in a second dispersing path different from the first dispersing path, and wherein the second conducting head and the first conducting head are interchangeably attachable to the main body; and

a first gas distribution head capable of distributing shielding gas in a first distribution path surrounding the conducting outlet aperture.

17. The apparatus of claim 18, further comprising a thermal channel located at least partially within the main body, wherein the thermal channel comprises a thermal outlet aperture capable of passing thermal energy therethrough;

and wherein the conducting channel is located adjacent the thermal outlet aperture.

19. The apparatus of claim 18, further comprising a second gas distribution head capable of distributing shielding gas in a second distribution path surrounding the conducting outlet aperture different from the first distribution path, and wherein the first gas distribution head and the second gas distribution head are interchangeably attachable to the main body.

20. The apparatus of claim 19, wherein the thermal energy comprises energy from one or more of the following:

a laser source, an electron beam source, an ion beam source, or an arc welding torch, or combinations thereof.

21. An apparatus, comprising:

a main body;

a conducting channel located at least partially within the main body, wherein the conducting channel comprises at least one conducting outlet aperture capable of passing powder material therethrough;

a first gas distribution head capable of distributing shielding gas in a first distribution path surrounding the conducting outlet aperture; and

a second gas distribution head capable of distributing shielding gas in a second distribution path surrounding the conducting outlet aperture different from the first distribution path, and wherein the first gas distribution head and the second gas distribution head are interchangeably attachable to the main body.

22. The apparatus of claim 21, further comprising a thermal channel located at least partially within the main body, wherein the thermal channel comprises a thermal outlet aperture capable of passing thermal energy therethrough;

and wherein the conducting channel is located adjacent the thermal outlet aperture.

23. The apparatus of claim 22, wherein the thermal energy comprises energy from one or more of the following:

a laser source, an electron beam source, an ion beam source, or an arc welding torch, or combinations thereof.

24. (canceled)

29. A system, comprising:

a thermal source;

a powder material feeder;

a coolant source;

a shielding gas source; and

a nozzle operatively associated with the thermal source, the powder material feeder, the coolant source, and the shielding gas source, the nozzle comprising;

a main body,

a thermal channel located at least partially within the main body, wherein the thermal channel comprises a thermal outlet aperture capable of passing thermal energy therethrough, and

a conducting channel located at least partially within the main body, wherein the conducting channel comprises at least one conducting outlet aperture located adjacent the thermal outlet aperture, and wherein the conducting outlet aperture is a single point outlet aperture capable of dispersing powder material therethrough; and

a first gas distribution head capable of distributing shielding gas in a first distribution path surrounding the conducting outlet aperture.

25. The system of claim 29, further comprising a first conducting head containing the conducting outlet aperture and at least a portion of the conducting channel, wherein the first conducting head is capable of dispersing powder material in a first dispersing path.

26. The system of claim 25, further comprising a recess portion located in the first conducting head, wherein the at least one conducting outlet aperture is located on said recess portion.

27. The system of claim 26, wherein the thermal outlet aperture is located on said recess portion, and wherein the recess portion has a generally concave shape.

28. The system of claim 25, further comprising a second conducting head containing the conducting outlet aperture and at least a portion of the conducting channel, wherein the second conducting head is capable of dispersing powder material in a second dispersing path different from the first dispersing path, and wherein the second conducting head and the first conducting head are interchangeably attachable to the main body.

30. The system of claim 29, further comprising a second gas distribution head capable of distributing shielding gas in a second distribution path surrounding the conducting outlet aperture different from the first distribution path, and wherein the first gas distribution head and the second gas distribution head are interchangeably attachable to the main body.

31. The system of claim 29, wherein the thermal source comprises one or more of the following:

a laser source, an electron beam source, an ion beam source, or an arc welding torch, or combinations thereof.

32. A method, comprising:

directing thermal energy towards a substrate;

dispersing powder material from at least two single point outlet apertures directed towards the thermal energy;

depositing the powder material onto the substrate;

distributing shielding gas in a first distribution path surrounding the at least two single point outlet apertures.

33. The method of claim 32, further comprising using energy from one or more of the following:

a laser source, a an electron beam source, an ion beam source, or an arc welding torch, or combinations thereof, to supply at least a portion of the thermal energy.

34. The method of claim 32, wherein said at least two single point outlet apertures comprise four single point outlet apertures.

35. The method of claim 32, wherein said depositing the powder material onto the substrate comprises laser cladding or laser consolidation.

36. The method of claim 32, wherein both said directing of thermal energy towards a substrate and said dispersing of powder material from at least two single point outlet apertures are performed via a single nozzle.