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11. 发明授权

US07431881B2 Wear-resistant alloys particularly suited to aluminum-engine head-valve seats 有权
标题翻译：耐磨合金特别适用于铝制发动机顶阀座
公开(公告)号：US07431881B2
公开(公告)日：2008-10-07
申请号：US10784433
申请日：2004-02-23
申请人： Jyoti Mazumder
发明人： Jyoti Mazumder
IPC分类号： C22C9/05
CPC分类号： C22C9/06 , C22C9/05 , Y10T428/1275
摘要： A thermally conductive, wear-resistant alloy is particularly suited to cladding aluminum engine head valve seats. In the preferred embodiments, the alloys are metallurgically compatible with the cast Al—Si alloy used for the engine head. Three alternative embodiments are disclosed, namely, copper-based alloys; aluminum silicon-based alloys; and two-layer systems.
摘要翻译：导热耐磨合金特别适用于铝合金发动机头阀座。在优选实施例中，合金与用于发动机头的铸造Al-Si合金在冶金学上相容。公开了三种替代实施例，即铜基合金; 铝硅基合金; 和两层系统。

12. 发明申请

US20160052086A1 SMART ADDITIVE MANUFACTURING SYSTEM (SAMS) 审中-公开
标题翻译：智能添加剂制造系统（SAMS）
公开(公告)号：US20160052086A1
公开(公告)日：2016-02-25
申请号：US14834806
申请日：2015-08-25
申请人： Jyoti Mazumder , Lijun Song
发明人： Jyoti Mazumder , Lijun Song
IPC分类号： B23K26/03 , B23K26/342 , B23K31/12 , B29C67/00 , G06N5/04
CPC分类号： B23K26/032 , B23K26/342 , B23K31/125 , B23K2101/34 , B23K2103/04 , B29C64/386 , B33Y50/02 , G06N5/047
摘要： An additive manufacturing process is monitored, in situ, using optical emission spectroscopy to analyze the composition, phase transformation or manufacturing defects. The system or method may include an analysis of contours of the plasma line intensity, or pre-processing of the plasma spectral line including signal-to-noise ratio analysis, baseline removal, line identification, line de-convolution and fitting. Improvements may additionally involve consideration of plasma parameters such as plasma spectral line intensity, line ratio, plasma temperature and electron density using high-resolution optical emission spectroscopy in both visible and ultraviolet regions. Parameters of the plasma may be determined using an intensity ratio of the ions or atoms emission lines, a FWHM of the line profile for electron density estimation, or a Boltzmann plot for plasma temperature estimation. One or more techniques may be used to monitor when there is a lack of deposition.
摘要翻译：使用光发射光谱法原位监测添加剂制造过程以分析组成，相变或制造缺陷。该系统或方法可以包括对等离子体线强度的轮廓的分析，或包括信噪比分析，基线去除，线识别，线解卷积和拟合等离子体谱线的预处理。改进可以另外涉及在可见光和紫外区域中使用高分辨率光发射光谱来考虑等离子体参数，例如等离子体谱线强度，线比，等离子体温度和电子密度。可以使用离子或原子发射线的强度比，用于电子密度估计的线轮廓的FWHM或等离子体温度估计的玻尔兹曼图来确定等离子体的参数。可以使用一种或多种技术来监测何时存在沉积。

13. 发明授权

US09044827B2 Real-time implementation of generalized predictive algorithm for direct metal deposition (DMD) process control 有权
标题翻译：实时直接金属沉积（DMD）过程控制的广义预测算法
公开(公告)号：US09044827B2
公开(公告)日：2015-06-02
申请号：US12130351
申请日：2008-05-30
申请人： Lijun Song , Jyoti Mazumder
发明人： Lijun Song , Jyoti Mazumder
IPC分类号： B23K26/34 , B23K26/14 , B23K26/03 , B23K26/12
CPC分类号： B23K26/1411 , B23K26/03 , B23K26/032 , B23K26/034 , B23K26/0344 , B23K26/123 , B23K26/144
摘要： A direct metal deposition (DMD) process is stabilized by monitoring the temperature and the shape of the melt pool during deposition, applying a recursive least square (RLS) model estimation algorithm to adaptively identify process characteristics in accordance with the temperature and the shape of the melt pool, and delivering the process characteristics to a generalized predictive controller with input constraints to control the process. The process may be controlled by adjusting laser power or by adjusting the speed of the movement of the laser. In the preferred embodiment the temperature is monitored using a two-color pyrometer, and the shape of the melt pool is monitored by detecting the edge of the melt pool with a camera and/or photodetector.
摘要翻译：通过在沉积期间监测熔池的温度和形状来稳定直接金属沉积（DMD）工艺，应用递归最小二乘（RLS）模型估计算法，以根据温度和形状来自适应地识别工艺特性熔池，并将过程特性提供给具有输入约束的广义预测控制器以控制过程。该过程可以通过调整激光功率或通过调节激光器的移动速度来控制。在优选实施例中，使用双色高温计监测温度，并且通过用照相机和/或光电检测器检测熔池的边缘来监测熔池的形状。

14. 发明申请

US20080296270A1 REAL-TIME IMPLEMENTATION OF GENERALIZED PREDICTIVE ALGORITHM FOR DIRECT METAL DEPOSITION (DMD) PROCESS CONTROL 有权
标题翻译：用于直接金属沉积（DMD）过程控制的广义预测算法的实时实现
公开(公告)号：US20080296270A1
公开(公告)日：2008-12-04
申请号：US12130351
申请日：2008-05-30
申请人： Lijun Song , Jyoti Mazumder
发明人： Lijun Song , Jyoti Mazumder
IPC分类号： B23K26/00
CPC分类号： B23K26/1411 , B23K26/03 , B23K26/032 , B23K26/034 , B23K26/0344 , B23K26/123 , B23K26/144
摘要： A direct metal deposition (DMD) process is stabilized by monitoring the temperature and the shape of the melt pool during deposition, applying a recursive least square (RLS) model estimation algorithm to adaptively identify process characteristics in accordance with the temperature and the shape of the melt pool, and delivering the process characteristics to a generalized predictive controller with input constraints to control the process. The process may be controlled by adjusting laser power or by adjusting the speed of the movement of the laser. In the preferred embodiment the temperature is monitored using a two-color pyrometer, and the shape of the melt pool is monitored by detecting the edge of the melt pool with a camera and/or photodetector.
摘要翻译：通过在沉积期间监测熔池的温度和形状来稳定直接金属沉积（DMD）工艺，应用递归最小二乘（RLS）模型估计算法，以根据温度和形状来自适应地识别工艺特性熔池，并将过程特性提供给具有输入约束的广义预测控制器以控制过程。该过程可以通过调整激光功率或通过调节激光器的移动速度来控制。在优选实施例中，使用双色高温计监测温度，并且通过用照相机和/或光电检测器检测熔池的边缘来监测熔池的形状。

15. 发明申请

US20080223832A1 REAL TIME IMPLEMENTATION OF GENERALIZED PREDICTIVE CONTROL ALGORITHM FOR THE CONTROL OF DIRECT METAL DEPOSITION (DMD) PROCESS 审中-公开
标题翻译：用于控制直接金属沉积（DMD）工艺的通用预测控制算法的实时实现
公开(公告)号：US20080223832A1
公开(公告)日：2008-09-18
申请号：US11941664
申请日：2007-11-16
申请人： Lijun Song , Jyoti Mazumder
发明人： Lijun Song , Jyoti Mazumder
IPC分类号： B23K26/34 , G01J5/00
CPC分类号： B23K26/34 , B23K26/03 , B23K26/032 , B23K26/034 , B23K26/0344 , B23K26/123 , B23K26/32 , B23K35/0244 , B23K2103/50 , G01J5/004 , G01J5/0044 , G01J5/02 , G01J5/025 , G01J5/60
摘要： A linear model based generalized predictive control system controls the molten pool temperature during a Direct Metal Deposition (DMD) process. The molten pool temperature is monitored by a two-color pyrometer. A single-input single-output linear system that describes the dynamics between the molten pool temperature and the laser power is identified and validated. The incremental generalized predictive control algorithm with Kalman filter estimation is used to control the molten pool temperature.
摘要翻译：基于线性模型的广义预测控制系统控制直接金属沉积（DMD）过程中的熔池温度。熔池温度由双色高温计监测。描述熔池温度和激光功率之间的动态特性的单输入单输出线性系统被识别和验证。使用卡尔曼滤波估计的增量广义预测控制算法来控制熔池温度。

16. 发明授权

US06710280B2 Focusing optics for adaptive deposition in rapid manufacturing 有权
标题翻译：聚焦光学用于快速制造中的自适应沉积
公开(公告)号：US06710280B2
公开(公告)日：2004-03-23
申请号：US10152762
申请日：2002-05-22
申请人： Jyoti Mazumder , Timothy Skszek , Dwight Morgan
发明人： Jyoti Mazumder , Timothy Skszek , Dwight Morgan
IPC分类号： B23K2636
CPC分类号： B23K26/06 , B23K26/064 , B23K26/0643 , B23K26/0732 , B23K26/0738 , B23K26/32 , B23K26/34 , B23K2101/006 , B23K2103/50 , B29C64/00 , B33Y50/02 , C23C24/10 , C23C26/02
摘要： Continuously adjustable focusing optics for use in laser-assisted direct metal deposition (DMD™) processes provide for adaptive deposition width to increase deposition rate while maintaining the dimensional tolerances. The focusing optics and method may be adapted for variable deposition road width under closed-loop feedback, so that complicated features may be fabricated with close tolerance, stress and microstructure control to improve the lead-time and design flexibility. The preferred embodiment uses adaptive mirror arrangements and beam movement for variable deposition width and geometry. Conceptually, an infinite number of mirror arrangements can be made to adapt to a particular deposit shape.
摘要翻译：用于激光辅助直接金属沉积（DMD（TM））工艺的连续可调节的聚焦光学器件提供适应性沉积宽度以增加沉积速率同时保持尺寸公差。聚焦光学元件和方法可适用于闭环反馈下的可变沉积道路宽度，从而可以采用紧公差，应力和微结构控制来制造复杂的特征，从而提高交货时间和设计灵活性。优选实施例使用自适应反射镜布置和光束移动来实现可变沉积宽度和几何形状。在概念上，可以制造无限数量的镜子布置以适应特定的沉积形状。

17. 发明授权

US06410105B1 Production of overhang, undercut, and cavity structures using direct metal depostion 有权
标题翻译：使用直接金属沉积生产悬垂，底切和腔结构
公开(公告)号：US06410105B1
公开(公告)日：2002-06-25
申请号：US09570986
申请日：2000-05-15
申请人： Jyoti Mazumder , Timothy Skszek , Joseph K. Kelly , Joohyun Choi
发明人： Jyoti Mazumder , Timothy Skszek , Joseph K. Kelly , Joohyun Choi
IPC分类号： B05D300
CPC分类号： B23K26/032 , B23K26/034 , B23K26/32 , B23K26/34 , B23K35/002 , B23K35/004 , B23K35/007 , B23K35/38 , B23K2103/04 , B23K2103/10 , B23K2103/12 , B23K2103/50 , B32B15/012 , B32B15/015 , B33Y10/00 , B33Y70/00 , B33Y80/00 , C23C4/12
摘要： Overhang and undercut features, as well as cavities, channels, pipes and three-dimensional voids and other structures are fabricated using a laser-aided direct-metal deposition (DMD) processes. In the preferred embodiment, this is accomplished through the selective deposition of a lower melting point sacrificial material. Following the integrated deposition of both sacrificial and non-sacrificial materials using DMD, the part is soaked in a furnace at a temperature sufficiently high to melt out the sacrificial material. As preferred options, the heating is performed in an inert gas environment to minimize oxidation, with a gas spray also being used to blow out remaining deposits. Using this technique, articles having integral sensors and cooling channels may be used as part of an automated system for controlling the temperature, stress and strain during the shaping or forming of a product using the resultant smart die or mold. Such a system would preferably include means of controlling the inlet flow of coolant and means for controlling or terminating the forming or injection process. The control is preferably mediated through a computer which analyzes and evaluates the inputs from the sensors and transmits the resulting information to a flow controller and to a process controller or logic gate, so that appropriate actions are carried out on a continuous basis.
摘要翻译：使用激光辅助直接金属沉积（DMD）工艺制造悬垂和底切特征以及空腔，通道，管道和三维空隙以及其它结构。在优选实施例中，这通过选择性沉积低熔点牺牲材料来实现。在使用DMD的牺牲和非牺牲材料的集成沉积之后，将该部分在足够高的温度下在炉中浸泡以熔化牺牲材料。作为优选的选择，在惰性气体环境中进行加热以最小化氧化，气体喷射也用于吹出剩余的沉积物。使用这种技术，具有整体传感器和冷却通道的物品可以用作自动化系统的一部分，用于在使用所得智能模具或模具成型或成型产品期间控制温度，应力和应变。这种系统将优选地包括控制冷却剂入口流动的装置和用于控制或终止成形或注入过程的装置。该控制优选通过计算机进行介导，该计算机分析和评估来自传感器的输入，并将所得到的信息传送到流量控制器和过程控制器或逻辑门，使得在持续的基础上执行适当的动作。

18. 发明授权

US10160127B2 Method of manufacturing of cutting knives using direct metal deposition 有权
公开(公告)号：US10160127B2
公开(公告)日：2018-12-25
申请号：US13949755
申请日：2013-07-24
申请人： Bhaskar Dutta , Harshad Natu , W. Swenson , Jyoti Mazumder
发明人： Bhaskar Dutta , Harshad Natu , W. Swenson , Jyoti Mazumder
IPC分类号： B26D1/00 , B26B9/00 , C23C24/10
摘要： Direct metal deposition (DMD) is used to fabricate knife edges with extended service life. A metal alloy powder is deposited along a blank and melted with a laser beam so that the powder solidifies into a strip of material having a hardness and/or wear resistance greater than that of the starting material. The piece is then finished to produce a sharp edge in the solidified material. The powder may be melted while it is being deposited, or it may be melted after being deposited. A slot or groove may be formed in the blank with the metal alloy powder being deposited into the slot or groove. A hardened steel alloy powder is deposited onto a mild steel blank. For example, a tool steel or vanadium steel powder may be deposited onto a 1018 steel blank. An invention line-beam nozzle may be used for deposition and/or powder melting.

19. 发明授权

US07139633B2 Method of fabricating composite tooling using closed-loop direct-metal deposition 有权
标题翻译：使用闭环直接金属沉积制造复合模具的方法
公开(公告)号：US07139633B2
公开(公告)日：2006-11-21
申请号：US10652260
申请日：2003-08-29
申请人： Jyoti Mazumder , Frank A. DiPietro
发明人： Jyoti Mazumder , Frank A. DiPietro
IPC分类号： G06F19/00
CPC分类号： B23K26/34 , B22F3/1055 , B22F2005/002 , B22F2998/00 , B23K26/32 , B23K31/025 , B23K2103/08 , B23K2103/10 , B23K2103/18 , B23K2103/50 , Y02P10/295 , B22F7/04
摘要： Manufacturing tools having a base and a working surface, such as trim steels, flange steels and die inserts, are formed by fabricating or casting a substrate out of a relatively ductile, low wear-resistant metal and forming the working surfaces such as cutting edges, flanging surfaces, die surfaces and die inserts by depositing layers of relatively hard, wear-resistant materials to the substrate by closed-loop direct-metal deposition or laser cladding. A multi-axis numerically controlled robot may be used to position and move a beam and deposition material over large substrates in forming such tooling.
摘要翻译：通过从相对延性低的耐磨金属中制造或铸造基材而形成具有底座和工作表面的制造工具，例如修边钢，法兰钢和模具嵌入件，并形成工作表面，例如切削刃，通过将相对硬的耐磨材料层通过闭环直接金属沉积或激光熔覆沉积到衬底上，从而将表面，模具表面和模具插入件翻转。可以使用多轴数控机器人来将梁和沉积材料定位和移动到大的基板上以形成这种工具。

20. 发明授权

US06937921B1 Production of smart dies and molds using direct metal deposition 有权
标题翻译：使用直接金属沉积生产智能模具和模具
公开(公告)号：US06937921B1
公开(公告)日：2005-08-30
申请号：US09526631
申请日：2000-03-16
申请人： Jyoti Mazumder
发明人： Jyoti Mazumder
IPC分类号： B23K26/03 , B23K26/34 , G06F19/00
CPC分类号： B23K26/032 , B23K26/034 , B23K26/34
摘要： A laser-aided, direct metal deposition (DMD) fabrication process is used for dies and molds having integrated sensors for monitoring and controlling characteristics that determine the quality of an article being processed. A method of fabricating such devices, as well as the “smart” devices themselves are disclosed. A system of manufacturing articles uses smart dies or smart molds so that various characteristics that affect the quality of the finished article are monitored during the die-forming or injection-molding process. The sensors, which are an integral part of the product-shaping devices, include simple thermocouples for measuring the temperature in various locations, as well as piezoelectric sensors and strain gages to monitor the build-up of stress and strain history caused by fluctuations in temperature during the fabrication process. This information is transmitted to a computer, where it is analyzed or compared with standardized histories obtained either through calibration experiments or through theoretical calculations.
摘要翻译：激光辅助的直接金属沉积（DMD）制造工艺用于具有集成传感器的模具和模具，用于监测和控制确定待处理物品质量的特性。公开了制造这种装置的方法以及“智能”装置本身。制造制品的系统使用智能模具或智能模具，使得在模具成形或注射成型过程期间监测影响成品的质量的各种特性。传感器是产品成型装置的组成部分，包括用于测量各种位置温度的简单热电偶以及压电传感器和应变计，用于监测由温度波动引起的应力和应变历史的累积在制造过程中。该信息被传送到计算机，在此被分析或与通过校准实验或通过理论计算获得的标准化历史进行比较。

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