Method and apparatus for fabrication of three-dimensional metal articles by weld deposition

• US 5,207,371 A
• Filed: 07/29/1991
• Issued: 05/04/1993
• Est. Priority Date: 07/29/1991
• Status: Expired due to Fees

• Current Assignee: Fritz B. Prinz, Lee E. Weiss
• Original Assignee: Fritz B. Prinz, Lee E. Weiss
• Inventors: Prinz, Fritz B., Weiss, Lee E.
• Primary Examiner(s): Ramsey, Kenneth J.
• Application Number:
  US07/737,229
• Time in Patent Office: 645 Days
• Field of Search: 228/119, 228/159, 228/125, 164/46, 219/76.1, 219/76.14, 219/76.15, 219/76.12, 219/73.11, 219/76.16
• US Class Current: 228/125
• CPC Class Codes: B22F 10/14 by jetting of binder onto a bed of metal powder
• CPC Class Codes: B22F 10/50 Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
• CPC Class Codes: B22F 12/10 Auxiliary heating means
• CPC Class Codes: B23K 9/0216 Seam profiling, e.g. weaving, multilayer
• CPC Class Codes: B23K 9/04 Welding for other purposes than joining, e.g. built-up welding
• CPC Class Codes: B23P 23/04 for both machining and other metal-working operations
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 2219/49015 Wire, strang laying, deposit fluid, welding, adhesive, hardening, solidification, fuse
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y10T 29/49986 Subsequent to metal working

Abstract

In a method and apparatus for forming a three-dimensional object, successive layers of metal are welded together to build the object. After each layer is formed a complementary material is placed adjacent the layer. In this manner, layers of material form a block of welded metal and complementary material. Then, all or a portion of the complementary material which serves as a support structure during forming can be removed. The welded layers are milled to a final shape either after each layer is formed or after all layers have been made. Existing CNG machines can be easily modified to practice the method.

Claims

1. A method for fabrication of a three dimensional metal article comprising the steps of

a) positioning a substrate in a work area;

b) welding successive layers of metal onto the substrate each layer corresponding to a cross section through the article;

c) placing successive layers of a complementary material so that the complementary material is adjacent to each layer of metal;

d) removing the complementary material; and

e) removing the substrate.

2. The method of claim 1 also comprising the step of milling a plurality of the successive layers.

3. The method of claim 2 wherein each layer is contoured such that at least a portion of the article does not have a vertical edge.

4. The method of claim 1 wherein at least one layer is milled before a successive layer is welded thereon.

5. The method of claim 1 wherein at least one of the complementary material and the substrate are removed by etching.

6. The method of claim 1 wherein at least one of the complementary material and the substrate are removed by one of milling, vibration, ultrasonic vibration and thermal expansion of the article.

7. The method of claim 1 wherein the complementary material has one of very high electrical conductivity and very low electrical conductivity.

8. The method of claim 7 wherein the complementary material is one of a ceramic, a cermet, copper and copper alloys.

9. The method of claim 1 wherein the deposition material is at least one of an iron-based alloy, a nickel-based alloy, an aluminum-based alloy and a titanium based alloy.

14. The method of claim 1 wherein at least two different materials are used for the welded layers.

15. The method of claim 1 also comprising the step of skimming away excess complementary material.

16. The method of claim 1 wherein the complementary material is applied with at least one of a spray source, a gravity feed device and a manually operated device.

17. The method of claim 1 also comprising the step of shot peening at least a portion of the successive layers.

18. The method of claim 1 also comprising the step of heating at least a portion of the successive layers.

10. A method for the fabrication of a three dimensional metal article comprising the steps of

a) positioning a substrate in a work area;

b) welding successive layers of metal onto the substrate each layer corresponding to a cross section through the article;

c) placing a complementary powder so that a portion of the powder is near the successive layers and bound together into a mass adjacent the successive layers and another portion of the powder is not bound together;

d) removing the complementary material; and

e) removing the substrate.

11. The method of claim 10 also comprising the step of hardening at least a portion of the complementary powder.

12. The method of claim 11 wherein at least a portion of the complementary powder is hardened by one of adding a binder, using a catalyst and applying heat.

13. The method of claim 10 also comprising the step of placing a frame around the successive layers such that the complementary powder can be placed between the frame and the successive layers.

19. A method for the fabrication of a three dimensional metal article comprising the steps of

a) positioning a substrate in a work area;

b) welding successive layers of metal onto the substrate each layer corresponding to a cross section through the article;

c) placing a complementary material so that the complementary material is adjacent to each layer of metal;

d) skimming away excess complementary material;

e) removing the complementary material; and

f) removing the substrate.

20. A method for the fabrication of a three dimensional metal article comprising the steps of:

a) positioning a substrate in a work area;

b) welding successive layers of metal onto the substrate each layer corresponding to a cross section through the article;

c) using one of a spray source, a gravity feed device and a manually operated device to place a complementary material so that the complementary material is adjacent to each layer of metal;

d) removing the complementary material; and

e) removing the substrate.

21. A method for the fabrication of a three dimensional metal article comprising the steps of

a) positioning a substrate in a work area;

b) welding successive layers of metal onto the substrate each layer corresponding to a cross section through the article;

c) placing successive layers of a complementary material so that the complementary material is adjacent to each layer of metal;

d) shot peening at least a portion of the successive layers of metal;

e) removing the complementary material; and

f) removing the substrate.