Method and apparatus for metal solid freeform fabrication utilizing partially solidified metal slurry

• US 5,893,404 A
• Filed: 09/20/1996
• Issued: 04/13/1999
• Est. Priority Date: 11/22/1994
• Status: Expired due to Fees

• Current Assignee: Veryst Engineering, LLC
• Original Assignee: SEMI Solid Technologies Incorporated
• Inventors: Brown, Stuart B., Mendez, Patricio F.
• Primary Examiner(s): Lin, Kuang Y.
• Application Number:
  US08/717,271
• Time in Patent Office: 935 Days
• Field of Search: 164/71.1, 164/900, 164/468, 228/256, 228/257
• US Class Current: 164/71.1
• CPC Class Codes: B22D 11/00 Continuous casting of metals, i.e. casting in indefinite lengths metal drawing, metal extruding B21C
• CPC Class Codes: B22D 11/0631 formed by a travelling straight surface, e.g. through-like moulds, a belt
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: Y10S 164/90 Rheo-casting

Abstract

Disclosed is a method and apparatus for rapidly producing a metal component from partially solidified metal slurry. A source of metal alloy slurry is provided and maintained under conditions to maintain the slurry state, for example by shearing at a temperature between a liquidus and solidus thereof. The slurry is dispensed through a source nozzle and deposited upon a substrate or upon previously dispensed slurry in a predetermined, controlled manner to produce a component of desired geometry. The substrate may be planar or contoured and may comprise an element of the component being produced. A temperature, pressure or chemical composition controlled deposition environment may be provided to facilitate producing a component having desired characteristics.

Claims

1. An apparatus for joining a plurality of elements utilizing partially solidified material slurry comprising:

a source of partially solidified material slurry;

a nozzle having an orifice with a minimum dimension of at least 250 microns attached to said source through which said slurry is dispensed;

a substrate upon which said plurality of elements are mounted, said elements being oriented to form a space between which slurry is dispensed; and

a controller for controlling relative movement between said nozzle and said substrate.

2. The apparatus according to claim 1 wherein:

said plurality of elements are joined by a bead of said slurry.

3. The apparatus according to claim 1 wherein:

said plurality of elements are joined by multiple layers of said slurry.

4. The apparatus according to claim 1 wherein:

temperature of at least a portion of said plurality of elements is controlled in a predetermined manner.

5. The apparatus according to claim 4 further comprising:

an environmental enclosure for preheating and controlling the temperature of said plurality of elements.

6. An apparatus for producing a component at least in part from partially solidified material slurry comprising:

a source of partially solidified material slurry;

a nozzle having an orifice with a minimum dimension of at least 250 microns attached to said source through which said slurry is dispensed;

a substrate;

a solid phase element mounted to said substrate upon which dispensed slurry is at least partially deposited, said element being movable relative to said nozzle; and

a controller for controlling relative movement between said nozzle and said element.

7. The apparatus according to claim 6 wherein:

temperature of at least a portion of said element is controlled in a predetermined manner.

8. The apparatus according to claim 6 further comprising:

an environmental enclosure for preheating and controlling the temperature of said element.

9. The apparatus according to claim 6 wherein:

a surface of said element defines a cavity into which slurry is deposited.

10. The apparatus according to claim 6 wherein:

said slurry is deposited to increase a dimension of said element.

11. A method for joining a plurality of elements utilizing partially solidified material slurry comprising the steps of:

providing a source of partially solidified material slurry;

dispensing said slurry through a nozzle of said source, said nozzle having an orifice with a minimum dimension of at least 250 microns;

orientating said plurality of elements to form a groove between said plurality of elements; and

depositing said slurry in said groove by coordinating relative movement between said nozzle and said elements in a predetermined manner.

12. The method according to claim 11 wherein:

the step of providing a source of partially solidified material slurry comprises the steps of;

providing a source of molten material; and

simultaneously shearing and cooling at least a portion of said molten material to a temperature between a solidus and a liquidus thereof.

13. The method according to claim 11 wherein:

the step of providing a source of partially solidified material slurry comprises the steps of;

providing a source of molten material; and

simultaneously shearing and controlling heat flux of at least a portion of said molten material at a transition temperature thereof.

14. The method according to claim 11 further comprising the step of:

providing a temperature controlled environment within which said dispensed slurry is deposited.

15. The method according to claim 11 further comprising the step of:

providing temperature control of at least one of said plurality of elements.

16. The method according to claim 11 further comprising the step of:

providing an environment having a predetermined chemical composition within which said dispensed slurry is deposited.

17. A method for producing a component utilizing partially solidified material slurry comprising the steps of:

providing a source of partially solidified material slurry;

dispensing said slurry through a nozzle of said source, said nozzle having an orifice with a minimum dimension of at least 250 microns;

providing a solid element;

orientating said solid element relative to said nozzle by coordinating relative movement between said nozzle and said solid element in a predetermined manner; and

depositing said slurry onto said solid element to increase a dimension thereof.

18. The method according to claim 17 further comprising the step of:

repairing said solid element.

19. The method according to claim 17 further comprising the step of:

filling a void in said solid element.

20. The method according to claim 17 wherein:

the step of providing a source of partially solidified material slurry comprises the steps of;

providing a source of molten material; and

simultaneously shearing and cooling at least a portion of said molten material to a temperature between a solidus and a liquidus thereof.

21. The method according to claim 17 wherein:

the step of providing a source of partially solidified material slurry comprises the steps of;

providing a source of molten material; and

simultaneously shearing and controlling heat flux of at least a portion of said molten material at a transition temperature thereof.

22. The method according to claim 17 further comprising the step of:

providing a temperature controlled environment within which dispensed slurry is deposited.

23. The method according to claim 17 further comprising the step of:

providing temperature control of at least one of said plurality of elements.

24. The method according to claim 17 further comprising the step of:

providing an environment having a predetermined chemical composition within which dispensed slurry is deposited.