Method of fabricating nozzle blades for lasers

Claim 1

A method of fabricating nozzle blades for lasers comprising the following steps: (a) forming an annular-shaped blade core of a rigid, chemically resistant material, (b) forming a pair of opposed circumferentially located grooves in said annular-shaped core, (c) machining an open-ended exit nozzle on the outside diameter of said core intermediate said grooves, (d) pressing said exit nozzle into its final configuration; (e) placing a chemically resistant, nonconductive, low melting point material within said exit nozzle, (f) machining a plurality of pairs of cutout portions within said core, (g) electric discharge machining a first set of passageways within said core adjacent said cutout portions in order to interconnect said cutout portions, (h) placing a chemically resistant, nonconductive, low melting point material within said cutout portions and said first set of passageways, (i) electrodepositing said core with a closure of chemically resistant material, (j) removing said chemically resistant, nonconductive, low melting point material from said cutout portions, said first set of passageways and said exit nozzle, thereby forming the coolant channels, injection manifolds and trip manifolds of said nozzle, (k) electric discharge machining a centrally located feed hole within said core opposite said exit nozzle, said feed hole being operably connected to said coolant channels, injection manifolds and trip manifolds, and (l) electric discharge machining a second set of passageways in said closure adjacent said exit nozzle, thereby forming additional trip manifolds.

Claim 2

A method of fabricating nozzle blades for lasers comprising the following steps: (a) forming an annular-shaped blade core of a rigid, chemically resistant material, (b) forming a pair of opposed circumferentially located grooves in said annular-shaped core, (c) machining an open-ended exit nozzle on the outside diameter of said core intermediate said grooves, (d) pressing said exit nozzle into its final configuration; (e) placing a chemically resistant, nonconductive, low melting point material within said exit nozzle, (f) machining a plurality of pairs of cutout portions within said core, (g) electric discharge machining a first set of passageways within said core adjacent said cutout portions in order to interconnect said cutout portions, (h) placing a chemically resistant, nonconductive, low melting point material within said cutout portions and said first set of passageways, (i) electrodepositing said core with a closure of chemically resistant material, (j) removing said chemically resistant, nonconductive, low melting point material from said cutout portions, said first set of passageways and said exit nozzle, thereby forming the coolant channels, injection manifolds and trip manifolds of said nozzle, (k) electric discharge machining a centrally located feed hole within said core opposite said exit nozzle, said feed hole being operably connected to said coolant channels, injection manifolds and trip manifolds, and (l) electric discharge machining a second set of passageways in said closure adjacent said exit nozzle, thereby forming additional trip manifolds.