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1. 发明申请

US20050121112A1 Fabrication of customized, composite, and alloy-variant components using closed-loop direct metal deposition 审中-公开
标题翻译：使用闭环直接金属沉积制造定制的，复合的和合金变体的组件
公开(公告)号：US20050121112A1
公开(公告)日：2005-06-09
申请号：US10999730
申请日：2004-11-30
申请人： Jyoti Mazumder , Dwight Morgan , Timothy Skszek
发明人： Jyoti Mazumder , Dwight Morgan , Timothy Skszek
IPC分类号： C23C4/12 , C23C24/10 , C23C26/02 , C23C2/00 , C21D1/00 , C22F1/00 , C23F1/00
CPC分类号： C23C4/12 , C23C24/10 , C23C26/02
摘要： A laser-assisted, direct metal deposition (DMD™), preferably in a closed-loop arrangement, is used to fabricate designed articles and tools such as molds and tools with improved properties. According to the method of the invention, a substrate is provided having a surface, onto which a layer of a material is deposited having the desired characteristic using the laser-assisted DMD process. In different embodiments, the substrate/layer combination may be tailored for improved wear resistance, thermal conductivity, density/hardness, corrosion and/or resistance to corrosion, oxidation or other undesirable effects. Alternatively, the layer of material may be tailored to have a phase which is different from that of the substrate. In particular, the layer material itself may be chosen to promote a phase which is different from that of the substrate. In the preferred embodiment, a closed-loop, laser-assisted DMD process is deployed to build the substrate on an incremental basis. To enhance throughput, the substrate and/or outer layer(s) of material may be fabricated using a robotic closed-loop DMD arrangement. In concert with the improvements made possible through the tailored outer layer(s), the method may further include the step of incorporating one or more conformal cooling channels within the component or the formation of one or more conductive heat sinks or thermal barriers during the DMD fabrication of the component itself.
摘要翻译：激光辅助的直接金属沉积（DMD TM）优选地以闭环布置方式被用于制造设计的制品和工具，例如具有改进性能的模具和工具。根据本发明的方法，提供了具有表面的基板，使用激光辅助DMD工艺在其上沉积具有期望特性的材料层。在不同的实施方案中，衬底/层组合可以被定制以改善耐磨性，导热性，密度/硬度，腐蚀和/或抗腐蚀，氧化或其它不期望的效果。或者，材料层可以被调整为具有不同于基底的相。特别地，可以选择层材料本身以促进与衬底不同的相。在优选实施例中，部署了一个闭环激光辅助DMD工艺以逐渐建立基板。为了提高生产量，可以使用机器人闭环DMD布置来制造材料的基底和/或外层。与通过定制的外层可能实现的改进一致，该方法还可以包括在DMD期间将一个或多个保形冷却通道结合到部件内或形成一个或多个导电散热器或热障壁的步骤组件本身的制造。

2. 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。

3. 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。

4. 发明申请

US20050224209A1 Fabrication of alloy variant structures using direct metal deposition 有权
标题翻译：使用直接金属沉积制造合金变体结构
公开(公告)号：US20050224209A1
公开(公告)日：2005-10-13
申请号：US11140752
申请日：2005-05-31
申请人： Timothy Skszek , Mathew Lowney , Dwight Morgan
发明人： Timothy Skszek , Mathew Lowney , Dwight Morgan
IPC分类号： B22D23/00 , B23K26/34 , B29C33/38 , B29C45/27 , B29C45/37 , C23C4/00 , C23C4/02 , C23C4/12 , C23C24/10 , C23C26/02
CPC分类号： B22C3/00 , B29C33/38 , B29C45/2708 , B29C45/37 , C23C4/00 , C23C4/01 , C23C4/02 , C23C4/12 , C23C24/10 , C23C26/02
摘要： Direct-metal deposition (DMD), preferably under closed-loop control, is used to fabricate alloy-variant material structures which provide a combination of desirable physical and mechanical properties. Use of the invention facilitates the production of high-strength, high-wear, and impact-resistant structures which decrease the likelihood of erosion, heat checking and brittle failure in injection molds, die casting, thixomolding and other, more exotic tooling. The invention uses DMD to deposit a first material or alloy in an area exposed to high wear, such as the tooling gate area, with a second material or alloy being used elsewhere in the tool for greater impact resistance. Advantageously, the areas may be of a user-defined thickness to further improve longevity. The resulting composite material structure has mechanical properties (i.e., yield strength, hardness and abrasion resistance) which exceed that of the homogeneous compositions currently used for mold materials, thereby enhancing productivity while improving part quality in these and other applications.
摘要翻译：直接金属沉积（DMD），优选在闭环控制下，用于制造提供所需物理和机械性质的组合的合金变体材料结构。使用本发明有助于生产高强度，高耐磨和耐冲击的结构，这降低了注射模具中的侵蚀，热检查和脆性破坏的可能性，压铸，触变成型和其他更加异国情调的工具。本发明使用DMD在暴露于高磨损的区域（例如模具浇口区域）中沉积第一材料或合金，其中第二材料或合金在工具中的其它地方使用，以提高耐冲击性。有利地，这些区域可以是用户限定的厚度以进一步改善寿命。所得到的复合材料结构具有超过目前用于模具材料的均匀组合物的机械性能（即屈服强度，硬度和耐磨性），从而在提高这些和其它应用中的零件质量的同时提高生产率。

5. 发明申请

US20070271793A1 Hybrid Component 有权
标题翻译：混合组分
公开(公告)号：US20070271793A1
公开(公告)日：2007-11-29
申请号：US10576377
申请日：2004-10-20
申请人： Jeffrey Mellis , Frank Gabbianelli , Erryn Langlois , Daniel Sulisz , Mark Werner , Timothy Skszek , Frank Horton , Warren Young , Seetarama Kotagiri , P. Kiselis , DeWayne Egle
发明人： Jeffrey Mellis , Frank Gabbianelli , Erryn Langlois , Daniel Sulisz , Mark Werner , Timothy Skszek , Frank Horton , Warren Young , Seetarama Kotagiri , P. Kiselis , DeWayne Egle
IPC分类号： B21D47/00 , B21D53/00 , B21D7/00 , B60R19/04
CPC分类号： B22D19/00 , B22D17/007 , B22D19/04 , B22D19/16 , B22D23/00 , Y10T29/49622
摘要： A hybrid component for lightweight, structural uses, including a steel member formed of a high strength steel; and a cast coupling member cast on a portion of the steel member by casting-in-place a semi-solid aluminum about the portion of the steel member, thereby positively and rigidly securing the coupling member to the steel member. A method of forming a hybrid component for lightweight, structural uses, including: forming a steel member formed of a high strength steel into a predetermined configuration; and casting a coupling member on a portion of the steel member by casting-in-place a semi-solid aluminum about the portion of the steel member, thereby positively and rigidly securing the coupling member to the steel member.
摘要翻译：用于轻质结构用途的混合部件，包括由高强度钢制成的钢构件; 以及通过在钢构件的部分周围浇铸半固体铝，铸造在钢构件的一部分上的铸造联接构件，从而将联接构件正向且刚性地固定在钢构件上。一种形成用于轻量化结构用途的混合部件的方法，包括：将由高强度钢形成的钢构件形成为预定构型; 并且通过在钢构件的部分周围浇铸半固体铝将钢结构件的一部分上铸造连接构件，从而将联结构件牢固且刚性地固定在钢构件上。

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