Casting shapes
First Claim
1. A method of casting a shape comprising directing a laser or electron gun at fusible powder in a fluidized bed, where said beam melts said powder and said melted powder fuses and solidifies on a surface, forming said shape.
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Accused Products
Abstract
Disclosed is a method of casting a shape. A laser or electron gun is directed at a fusible powder in a fluidized bed. The beam melts the powder and the melted powder fuses and solidifies on a surface to form the shape. Also disclosed is apparatus for casting a shape. The apparatus includes a fluidized bed containing a fluidized powder, a surface within the bed on which the shape is cast, an electron beam or laser directed at the surface, which has an energy sufficient to fuse the powder, means for controlling the level of the powder in the fluidized bed relative to the surface, and means for controlling the horizontal position of the surface relative to the beam.
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Citations
126 Claims
- 1. A method of casting a shape comprising directing a laser or electron gun at fusible powder in a fluidized bed, where said beam melts said powder and said melted powder fuses and solidifies on a surface, forming said shape.
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40. A method of casting a near net shape comprising:
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(A) fluidizing a laser-fusible powder in a fluidized bed to a level slightly higher than the level of a surface within said fluidized bed; (B) stopping said fluidizing of said powder, whereby a layer of said powder is deposited on said surface; (C) directing a laser beam downward at said layer of powder while changing the horizontal position of said surface relative to said laser beam, whereby said powder fuses on said surface; (D) fluidizing said powder to a level slightly higher than the top of said fused powder; and (E) repeating steps (B), (C), and (D) until said near net shape is completed. - View Dependent Claims (44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75)
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41. A method of forming a metal casting of a near net shape comprising:
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(A) fluidizing metal powder in a fluidized bed to a level about 1/32 to about 1 inch above the level of a horizontal surface within said fluidized bed; (B) stopping said fluidizing of said powder, whereby a layer of said powder is deposited on said surface; (C) directing a C02 laser beam having a power sufficient to melt said metal powder downward at said layer of powder, while changing the horizontal position of said horizontal surface relative to said laser beam, whereby said melted powder fuses on said surface and solidifies, forming a horizontal cross-section of said near net shape; (D) fluidizing said powder in said fluidized bed so that said level is about 1/32 to about 1 inch above the top of said horizontal cross section; and (E) repeating steps (B), (C), and (D) until said metal casting is formed. - View Dependent Claims (42, 43, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101)
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102. Apparatus for casting a shape comprising:
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(A) a fluidized bed; (B) a surface within said bed; (C) an electron gun or a laser having an energy sufficient to fuse powder within said fluidized bed, where the output beam of said electron gun or said laser is directed at said surface; (D) means for controlling the level of powder in said fluidized bed relative to said surface; (E) means for controlling the horizontal position of said surface relative to said beam. - View Dependent Claims (103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124)
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125. Apparatus for casting a near net shape comprising:
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(A) a fluidized bed having surface therein; (B) means for fluidizing powder within said bed to a level slightly above the level of said surface; (C) a laser, the beam of which is directed downward at said surface; (D) means for changing the horizontal position of said surface relative to said laser beam; and (E) means for changing the level of said powder in said fluidized bed relative to said surface.
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126. Apparatus for forming a metal casting of a near net shape comprising:
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(A) a fluidized bed; (B) a horizontal surface within said fluidized bed; (C) means for fluidizing metal powder in said fluidized bed to a level about 1/32 to about 1 inch above said horizontal surface; (D) a C02 laser that produces a laser beam having a power sufficient to melt said fluidized metal powder above said horizontal surface; (E) means for directing said laser beam at said surface; (F) means for changing the horizontal position of said horizontal surface relative to said laser beam; and (G) means for changing the level of said metal powder in said fluidized bed relative to said horizontal surface.
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Specification