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United States Patent 5,837,960
Lewis, et. al. Nov. 17, 1998

Laser production of articles from powders

Abstract

Method and apparatus for forming articles from materials in particulate form in which the materials are melted by a laser beam and deposited at points along a tool path to form an article of the desired shape and dimensions. Preferably the tool path and other parameters of the deposition process are established using computer-aided design and manufacturing techniques. A controller comprised of a digital computer directs movement of a deposition zone along the tool path and provides control signals to adjust apparatus functions, such as the speed at which a deposition head which delivers the laser beam and powder to the deposition zone moves along the tool path.


Inventors: Lewis; Gary K. (Los Alamos, NM); Milewski; John O. (Santa Fe, NM); Cremers; David A. (Los Alamos, NM); Nemec; Ronald B. (White Rock, NM); Barbe; Michael R. (White Rock, NM).
Assignee: The Regents of the University of California (Oakland, CA).
Appl. No.: 566,430
Filed: Nov. 30, 1995
Intl. Cl. : B23K 26/00
Current U.S. Cl.: 219/121.63; 219/121.64; 219/121.65; 219/121.66; 219/121.85; 364/468.26
Field of Search: 219/121.63, 121.64, 121.65, 121.66, 121.84, 121.85; 427/554, 555, 556, 596, 597; 364/468.26, 474.08; 264/497; 118/620; 156/272.8; 419/61; 75/10.13

References Cited | [Referenced By]

U.S. Patent Documents
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4,603,257Jul., 1986Packer et al. 250/358.1
4,665,492May, 1987Masters 364/468.26
4,724,299Feb., 1988Hammeke
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4,863,538Sept., 1989Deckard 156/62.2
4,927,992May, 1990Whitlow et al. 219/121.65
4,938,816Jul., 1990Beaman et al. 156/62.2
4,944,817Jul., 1990Bourell et al. 156/62.2
5,017,753May, 1991Deckard et al. 219/121.63
5,038,014Aug., 1991Pratt et al. 219/121.64
5,043,548Aug., 1991Whitney et al. 219/121.47
5,111,021May, 1992Jolys et al. 219/121.6
5,132,143Jul., 1992Deckard et al. 427/197
5,135,695Aug., 1992Marcus 264/141
5,155,324Oct., 1992Deckard et al. 219/121.64
5,160,822Nov., 1992Aleshin 219/121.64
5,182,430Jan., 1993Lagain 219/121.63
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5,252,264Oct., 1993Forderhase et al.
5,398,193Mar., 1995deAngelis 364/468.26
5,418,350May, 1995Freneaux et al. 219/121.84
5,477,026Dec., 1995Buongiorno 219/121.84
5,512,162Apr., 1996Sachs et al. 156/272.8 X
5,530,221Jun., 1996Benda et al. 219/121.83
5,578,227Nov., 1996Rabinovich 219/121.63
5,607,730Mar., 1997Ranalli 427/512
5,647,931Jul., 1997Retallick et al. 156/73.6

Foreign Patent Documents
0370967May, 1990EP
0490146Dec., 1990EP
1-87713Mar., 1989JP
4-84684Mar., 1992JP 219/121.63
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Other References

Frenk et al., "Laser Cladding with Cobalt-Based Hardfacing Alloys," Journal De Physique V, vol. 1, pp. C7-65 through C7-68, Dec. 1991.

Jasim, et al., "Thermal Barrier Coatings Produced by Laser Cladding," Journal of Materials Science, vol. 25, pp. 4943-4948, 1990.

Subramanian et al., "Laser Cladding of Zirconium on Magnesium for Improved Corrosion Properties," Journal of Materials Science, vol. 26, pp. 951-956, 1991.

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Schanwald, "Two Powder Stream Diagnostics for Laser Deposition Processes," ICALEO '95, 1995.

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Dateline Los Alamos, Sep. 1994 (2 pages). Distributed by Los Alamos National Laboratory.

Synopsis "Directed Light Fabrication" and Transmittal Letter (3 pages). Undated, handed out after publications of the documents. Referenced in Transmittal Letter.

R and D 100 Announcement, Sep. 1994, Los Alamos National Laboratory.

Abstract "Directed Light Fabrication". For ICALEO '94, 13th International Congress on Applications of Laser and Electro-Optics, Oct. 17-20, 1994.

ICALEO '94--Proceedings of the 13th International Congress on Applications of Lasers and Electro-Optics, Oct. 17-20, 1994.

"Direct Laser Metal Deposition Process Fabricates Near-Net-Shape Components Rapidly" by Gary K. Lewis, Materials Technology, vol. 10, Nos. 3/4, Mar./Apr. 1995.

"Direct Production of Metallic Parts by Rapid Prototyping" by J. P. Kruth et al. Proceedings of the 12th International Congress (LASER '95).

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Keicher, D.M. and John E. Smugeresky, "Overview: The Laser Forming of Metallic Components Using Particulate Materials," JOM, vol. 49, No. 5, May 1997.

Mazumder, J., J. Choi, K. Nagarathnam, J. Koch, and D. Hetzner, "Research Summary: The Direct Metal Deposition of H13 Tool Steel for 3-D Components," JOM, vol. 49, No. 5, May 1997.

Lewis, Gary K. (editor), "Directed Light Fabrication," Los Alamos National Laboratory, Jun. 1996.


Primary Examiner: Mills; Gregory L.
Attorney, Agent or Firm: Gemma Morrison Bennett
30 Claims, 20 Drawing Figures

This invention was made with government support under Contract No. W-7405-ENG-36 awarded by the U.S. Department of Energy. The government has certain rights in the invention.


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