process for energy beam solid-state metallurgical bonding of wires having two or more flat surfaces
First Claim
1. A process and apparatus for energy beam assisted solid-state metallurgical bonding of a wire, having two or more flat surfaces, to a substrate, for the purpose of substrate coating, 3-Dimensional component buildup, restoration and component surface improvement, and comprising the steps of:
- applying of a continuously fed wire to a substrate such that the bottom of the wire flat surface(s) are tangential to the substrate such that the contact of the wire with the substrate constitute substantially a surface(s);
an energy beam (for example Laser or Electron Beam) is simultaneously applied to the wire, with a magnitude controlled to be sufficient to produce a sudden compressive shock wave and heat at the surface of the wire to propagate through the wire and the top surface of the substrate;
whilst some material particles of the wire are carried with the shock wave and are penetrating (forged-in) into the substrate, producing a strong metallurgical bond without substantial liquefaction of the substrate (solid-state bonding)
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Abstract
An energy beam assisted solid-state welding welds a wire material to a substrate. A wire of coating or repairing material is placed in contact with a surface or surfaces of a substrate. A beam is directed into an outer flat surface of the wire, which heats the wire through flat outer surface of the wire with beam energy. Beam energy produces compression stress-waves that drive molecules of the material flat wire into a surface of the substrate, joining the material and the substrate with strong wave shaped interfaces.
59 Citations
13 Claims
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1. A process and apparatus for energy beam assisted solid-state metallurgical bonding of a wire, having two or more flat surfaces, to a substrate, for the purpose of substrate coating, 3-Dimensional component buildup, restoration and component surface improvement, and comprising the steps of:
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applying of a continuously fed wire to a substrate such that the bottom of the wire flat surface(s) are tangential to the substrate such that the contact of the wire with the substrate constitute substantially a surface(s); an energy beam (for example Laser or Electron Beam) is simultaneously applied to the wire, with a magnitude controlled to be sufficient to produce a sudden compressive shock wave and heat at the surface of the wire to propagate through the wire and the top surface of the substrate; whilst some material particles of the wire are carried with the shock wave and are penetrating (forged-in) into the substrate, producing a strong metallurgical bond without substantial liquefaction of the substrate (solid-state bonding) - View Dependent Claims (2, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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3. The process and apparatus of clam 1 further including a means of controlling energy beam and its energy and power densities and pulse duration to achieve various temperature gradients through the wire material and the top layer of the substrate material to produce the desired amount of penetration of wire material into (forge-in depth) the substrate material.
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4. The process and apparatus of clam 1, further including a means of controlling energy beam'"'"'s power and energy densities and pulse time duration to achieve the required temperature gradient through the wire. It is controlled such that, while the part of the top surface of the flat wire is liquefied, the surface of the wire adjacent to the substrate can be maintained in a solid or semisolid state at the temperatures below the liquefaction temperature of the substrate material.
Specification