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US5207371A
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Method and apparatus for fabrication of three-dimensional metal articles by weld deposition
Assignee: Individual
•
Filing: 1991-07-29
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Granted: 1993-05-04
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Expires: 2011-07-29
Abstract
Abstract In a method and apparatus for forming a three-dimensional object, successive layers (2) of metal are welded together to build the object. After each weld deposited layer (2) is formed, a complementary material (6) is placed adjacent the layer. In this manner, layers of material form a block of welded metal and complementary material. Then, all or a portion of the complementary material (6) which serves as a support structure during forming, can be removed. The welded layers (2) are milled to a final shape either after each layer (2) is formed or after all layers (2) have been made. Existing CNC machines (20) can be easily modified to practice the method. <IMAGE>
Inventors
- 👤 Fritz B. Prinz
- 👤 Lee E. Weiss
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 14:04
CPC Classifications
G; G05; G05B; G05B19/00; G05B19/02; G05B19/18; G05B19/4097; G05B19/4099; B; B22; B22F; B22F10/00; B22F10/10; B22F10/14; B22F10/50; B23; B23K; B23K9/00; B23K9/02; B23K9/0216; B23K9/04; B23P; B23P23/00; B23P23/04; B29; B29C; B29C64/00; B29C64/10; B29C64/106; B29C64/188; B29C64/40; B33; B33Y; B33Y10/00; B22F12/00; B22F12/10; G05B2219/00; G05B2219/30; G05B2219/49; G05B2219/49015; Y; Y02; Y02P; Y02P90/00; Y02P90/02; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/4998; Y10T29/49982; Y10T29/49986
Claims Analysis
Total Claims: 26
Claim 1
Independent Claim
71 words
A method for fabrication of a three dimensional metal article comprising the steps of a) positioning a substrate in a work area; b) welding successive layers of metal onto the substrate each layer corresponding to a cross section through the article; c) placing successive layers of a complementary material so that the complementary material is adjacent to each layer of metal; d) removing the complementary material; and e) removing the substrate.
Claim 2
Independent Claim
71 words
A method for fabrication of a three dimensional metal article comprising the steps of a) positioning a substrate in a work area; b) welding successive layers of metal onto the substrate each layer corresponding to a cross section through the article; c) placing successive layers of a complementary material so that the complementary material is adjacent to each layer of metal; d) removing the complementary material; and e) removing the substrate.
Claim 3
Dependent Claim
17 words
The method of claim 1 also comprising the step of milling a plurality of the successive layers.
Claim 4
Dependent Claim
25 words
The method of claim 2 wherein each layer is contoured such that at least a portion of the article does not have a vertical edge.
Claim 5
Dependent Claim
19 words
The method of claim 1 wherein at least one layer is milled before a successive layer is welded thereon.
Claim 6
Dependent Claim
20 words
The method of claim 1 wherein at least one of the complementary material and the substrate are removed by etching.
Claim 7
Dependent Claim
31 words
The method of claim 1 wherein at least one of the complementary material and the substrate are removed by one of milling, vibration, ultrasonic vibration and thermal expansion of the article.
Claim 8
Dependent Claim
21 words
The method of claim 1 wherein the complementary material has one of very high electrical conductivity and very low electrical conductivity.
Claim 9
Dependent Claim
20 words
The method of claim 7 wherein the complementary material is one of a ceramic, a cermet, copper and copper alloys.
Claim 10
Dependent Claim
28 words
The method of claim 1 wherein the deposition material is at least one of an iron-based alloy, a nickel-based alloy, an aluminum-based alloy and a titanium based alloy.
Claim 11
Independent Claim
89 words
A method for the fabrication of a three dimensional metal article comprising the steps of a) positioning a substrate in a work area; b) welding successive layers of metal onto the substrate each layer corresponding to a cross section through the article; c) placing a complementary powder so that a portion of the powder is near the successive layers and bound together into a mass adjacent the successive layers and another portion of the powder is not bound together; d) removing the complementary material; and e) removing the substrate.
Claim 12
Independent Claim
89 words
A method for the fabrication of a three dimensional metal article comprising the steps of a) positioning a substrate in a work area; b) welding successive layers of metal onto the substrate each layer corresponding to a cross section through the article; c) placing a complementary powder so that a portion of the powder is near the successive layers and bound together into a mass adjacent the successive layers and another portion of the powder is not bound together; d) removing the complementary material; and e) removing the substrate.
Claim 13
Dependent Claim
19 words
The method of claim 10 also comprising the step of hardening at least a portion of the complementary powder.
Claim 14
Dependent Claim
28 words
The method of claim 11 wherein at least a portion of the complementary powder is hardened by one of adding a binder, using a catalyst and applying heat.
Claim 15
Dependent Claim
32 words
The method of claim 10 also comprising the step of placing a frame around the successive layers such that the complementary powder can be placed between the frame and the successive layers.
Claim 16
Dependent Claim
17 words
The method of claim 1 wherein at least two different materials are used for the welded layers.
Claim 17
Dependent Claim
15 words
The method of claim 1 also comprising the step of skimming away excess complementary material.
Claim 18
Dependent Claim
28 words
The method of claim 1 wherein the complementary material is applied with at least one of a spray source, a gravity feed device and a manually operated device.
Claim 19
Dependent Claim
20 words
The method of claim 1 also comprising the step of shot peening at least a portion of the successive layers.
Claim 20
Dependent Claim
19 words
The method of claim 1 also comprising the step of heating at least a portion of the successive layers.
Claim 21
Independent Claim
75 words
A method for the fabrication of a three dimensional metal article comprising the steps of a) positioning a substrate in a work area; b) welding successive layers of metal onto the substrate each layer corresponding to a cross section through the article; c) placing a complementary material so that the complementary material is adjacent to each layer of metal; d) skimming away excess complementary material; e) removing the complementary material; and f) removing the substrate.
Claim 22
Independent Claim
75 words
A method for the fabrication of a three dimensional metal article comprising the steps of a) positioning a substrate in a work area; b) welding successive layers of metal onto the substrate each layer corresponding to a cross section through the article; c) placing a complementary material so that the complementary material is adjacent to each layer of metal; d) skimming away excess complementary material; e) removing the complementary material; and f) removing the substrate.
Claim 23
Independent Claim
85 words
A method for the fabrication of a three dimensional metal article comprising the steps of: a) positioning a substrate in a work area; b) welding successive layers of metal onto the substrate each layer corresponding to a cross section through the article; c) using one of a spray source, a gravity feed device and a manually operated device to place a complementary material so that the complementary material is adjacent to each layer of metal; d) removing the complementary material; and e) removing the substrate.
Claim 24
Independent Claim
85 words
A method for the fabrication of a three dimensional metal article comprising the steps of: a) positioning a substrate in a work area; b) welding successive layers of metal onto the substrate each layer corresponding to a cross section through the article; c) using one of a spray source, a gravity feed device and a manually operated device to place a complementary material so that the complementary material is adjacent to each layer of metal; d) removing the complementary material; and e) removing the substrate.
Claim 25
Independent Claim
85 words
A method for the fabrication of a three dimensional metal article comprising the steps of a) positioning a substrate in a work area; b) welding successive layers of metal onto the substrate each layer corresponding to a cross section through the article; c) placing successive layers of a complementary material so that the complementary material is adjacent to each layer of metal; d) shot peening at least a portion of the successive layers of metal; e) removing the complementary material; and f) removing the substrate.
Claim 26
Independent Claim
85 words
A method for the fabrication of a three dimensional metal article comprising the steps of a) positioning a substrate in a work area; b) welding successive layers of metal onto the substrate each layer corresponding to a cross section through the article; c) placing successive layers of a complementary material so that the complementary material is adjacent to each layer of metal; d) shot peening at least a portion of the successive layers of metal; e) removing the complementary material; and f) removing the substrate.
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USPTO Annuity & Maintenance Windows
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| 3.5 Years (Year 4) | 1996-05-03 | 1996-11-02 | 1997-05-04 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2000-05-03 | 2000-11-02 | 2001-05-04 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2004-05-03 | 2004-11-02 | 2005-05-04 | $7700.00 | Window Closed / Lapsed |