Method for producing a laminated object and apparatus for producing the same

• US 6,054,192 A
• Filed: 01/22/1998
• Issued: 04/25/2000
• Est. Priority Date: 01/29/1997
• Status: Expired due to Term

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Sato, Hiromoto, Ozaki, Motoaki, Otsuka, Yukio
• Primary Examiner(s): Padgett, Marianne
• Application Number:
  US09/010,855
• Time in Patent Office: 824 Days
• Field of Search: 427/512, 427/554, 427/555, 427/556, 427/596, 427/559, 156/272.8, 156/58, 264/401, 264/497, 264/112, 264/113, 419/8, 419/9
• US Class Current: 427/555
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/366 Scanning parameters, e.g. hatch distance or scanning strategy
• CPC Class Codes: B22F 10/37 of powder bed aspects, e.g. density
• CPC Class Codes: B22F 12/224 for motion along a direction within the plane of a layer
• CPC Class Codes: B22F 12/41 characterised by the type, e.g. laser or electron beam
• CPC Class Codes: B22F 12/44 characterised by the configuration of the radiation means
• CPC Class Codes: B22F 12/49 Scanners
• CPC Class Codes: B22F 12/50 Means for feeding of material, e.g. heads
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B23K 26/066 by using masks
• CPC Class Codes: B23K 26/082 Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
• CPC Class Codes: B23K 26/0821 using multifaceted mirrors, e.g. polygonal mirror
• CPC Class Codes: B29C 2035/0838 using laser
• CPC Class Codes: B29C 41/36 Feeding the material on to the mould, core or other substrate
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

A method for producing a laminated object repeats a depositing step and an irradiating step alternatively. The irriating step comprises the operations of: covering a deposited layer with a mask having a pattern configuration for penetrating the laser beam; and scanning the lader beam on the desposited layer covered with the mask in such a manner that the laser beam depicts an irradiated continous wave trace being wider than the pattern configuration of the mask, by moving the laser beam in the Y-direction with a Y-rotating mirror, while repeating oscillations of the laser beam in the X-direction with a X-rotating nirror, The laminated object may be a casting mold.

Claims

1. A method of producing a laminated mold for casting having three dimensions and formed of a plurality of piled solid layers, which method comprises the steps of:

(a) depositing on a setting surface a deposited layer of a material capable of becoming hardened and forming a solid layer when irradiated by a laser beam, said material being formed of grains or a powder covered with thermosetting resin and;

(b) irradiating said deposited layer with a laser beam to form a solid layer having a two-dimensional horizontal surface extending in an X-direction and a Y-direction transverse to the X-direction, wherein the irradiating step includes;

(i) covering said deposited layer with a mask having a first portion not to be penetrated by said laser beam and a second portion to be penetrated by said laser beam, and

(ii) scanning said laser beam on said deposited layer covered with said mask in such a manner that said laser beam depicts a continuous wave trace which extends beyond the periphery of said second portion by moving said laser beam in said Y-direction with a Y-rotating mirror for moving said laser beam in said Y-direction while repeating oscillations of said laser beam in said X-direction with an X-rotating mirror for oscillating said laser beam in said X-direction, so that said laser beam is moved to penetrate said second portion of said mask and to form the continuous wave trace on said deposited layer; and

(c) repeating steps (a) and (b) alternately to form said laminated mold for casting.

2. The method according to claim 1, wherein said depositing step is conducted using a depositing means which includes a storing container for storing said material, and a cutting roller rotatable disposed on said storing container, said cutting roller having a plurality of grooves for discharging said material from said storing container, and said depositing means is moved apart from said deposited layer while rotating said cutting roller, so that said depositing means does not come into contact with said deposited layer while said material is being deposited.

3. The method for producing a laminated object according to claim 1, wherein a frequency of oscillations of said X-rotating mirror is in a range from 20 to 100 oscillations per second, and a spot diameter of said laser beam is in a range from 5 to 40 mm.

4. The method for producing a laminated object according to claim 1, wherein a spot diameter of said laser beam is in a range from 0.2 to 100 mm.

5. The method for producing a laminate mold for casting according to claim 1, wherein each of said deposited layers is formed into said solid layer by repeated cycles of forming of said continuous wave trace, the repeated cycles per each deposited layer is in the range of from 2 to 7 cycles, and the repeated cycles are determined in accordance with the following formula:

space="preserve" listing-type="equation">P=B/(T·

Hx),N=D/P

where T is a required irradiation time, in seconds, based on a required irradiation area determined by the horizontal sectional area of the deposited layer to be irradiated;

B is a length, in millimeters, of said required irradiation area in said Y-direction;

Hx is a frequency, in oscillations per second, for said laser beam to oscillate in said X-direction;

P is a scan pitch distance between centers of a spot diameter in the Y-direction, in millimeters;

D is a spot diameter, in millimeters, of said laser beam; and

N is the number of the repeated cycles in which the laser beam passes through the a given location.

6. The method for producing a laminated mold for casting according to claim 1, wherein said deposited layer has an over thickness portion and a normal thickness portion, and said over thickness portion has a thickness which is greater than that of said normal thickness portion,

said depositing step further including:

using a thickness correcting means to correct the thickness of said over thickness portion, and during the depositing of said material, maintaining said depositing means so that said thickness correcting means contacts said over thickness portion but does not contact said normal thickness portion so as to correct the thickness of said over thickness portion to the thickness of said normal thickness portion.

7. The method for producing a laminated mold for casting according to claim 2, wherein a rotational speed of said cutting roller is larger than a moving speed of said depositing means.