US4818562A
Expired / Lapsed
US
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Casting shapes
Assignee: Westinghouse Electric Corp
•
Filing: 1988-03-24
•
Granted: 1989-04-04
•
Expires: 2008-03-24
Abstract
Abstract Disclosed is a method of casting a shape. A laser or electron gun is directed at a fusible powder in a fluidized bed. The beam melts the powder and the melted powder fuses and solidifies on a surface to form the shape. Also disclosed is apparatus for casting a shape. The apparatus includes a fluidized bed containing a fluidized powder, a surface within the bed on which the shape is cast, an electron beam or laser directed at the surface, which has an energy sufficient to fuse the powder, means for controlling the level of the powder in the fluidized bed relative to the surface, and means for controlling the horizontal position of the surface relative to the beam.
Inventors
- 👤 Frank G. Arcella
- 👤 Gerald G. Lessmann
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-24 19:38
CPC Classifications
C; C23; C23C; C23C26/00; C23C26/02; B; B22; B22D; B22D23/00; B22D23/06; B22F; B22F10/00; B22F10/20; B22F10/28; B22F12/00; B22F12/10; B22F12/17; B22F12/40; B22F12/49; B22F3/00; B22F3/004; B29; B29C; B29C41/00; B29C41/02; B29C41/08; B29C41/10; B29C64/00; B29C64/10; B29C64/141; B29C64/153; B22F12/41; B22F2998/00; B22F2998/10; B22F2999/00; Y; Y02; Y02P; Y02P10/00; Y02P10/25; Y10; Y10S; Y10S118/00; Y10S118/05
Claims Analysis
Total Claims: 132
Claim 1
Independent Claim
39 words
A method of casting a shape comprising directing a laser or electron gun at fusible powder in a fluidized bed, where said beam melts said powder and said melted powder fuses and solidifies on a surface, forming said shape.
Claim 2
Independent Claim
39 words
A method of casting a shape comprising directing a laser or electron gun at fusible powder in a fluidized bed, where said beam melts said powder and said melted powder fuses and solidifies on a surface, forming said shape.
Claim 3
Dependent Claim
22 words
A method according to claim 1 wherein said powder is selected from the group consisting of metals, ceramics, plastics, and mixtures thereof.
Claim 4
Dependent Claim
17 words
A method according to claim 1 wherein said powder is a mixture of different kinds of particles.
Claim 5
Dependent Claim
18 words
A method according to claim 3 wherein said powder is a mixture of metal particles and ceramic particles.
Claim 6
Dependent Claim
12 words
A method according to claim 2 wherein said powder is metal powder.
Claim 7
Dependent Claim
18 words
A method according to claim 5 wherein said powder is a mixture of at least two different metals.
Claim 8
Dependent Claim
11 words
A method according to claim 5 wherein said powder comprises titanium.
Claim 9
Dependent Claim
26 words
A method according to claim 7 wherein said titanium is contaminated with an element selected from the group consisting of sodium, magnesium, chlorine, and mixtures thereof.
Claim 10
Dependent Claim
12 words
A method according to claim 5 wherein said metal is an alloy.
Claim 11
Dependent Claim
14 words
A method according to claim 9 wherein said alloy is an alloy of titanium.
Claim 12
Dependent Claim
17 words
A method according to claim 10 wherein said alloy has the approximate composition 90% Ti-6% Al-4% V.
Claim 13
Dependent Claim
11 words
A method according to claim 5 wherein said powder comprises tungsten.
Claim 14
Dependent Claim
19 words
A method according to claim 1 wherein the composition of said powder is changed as said shape is formed.
Claim 15
Dependent Claim
14 words
A method according to claim 1 wherein said powder in said bed is heated.
Claim 16
Dependent Claim
20 words
A method according to claim 14 wherein said powder is heated by an electrical resistance heater in said fluidized bed.
Claim 17
Dependent Claim
23 words
A method according to claim 1 wherein said powder is fluidized with a gas that reacts with said powder when it is fused.
Claim 18
Dependent Claim
23 words
A method according to claim 16 wherein said gas is methane and said powder is a metal, whereby a metal carbide is formed.
Claim 19
Dependent Claim
23 words
A method according to claim 17 wherein said gas is nitrogen and said powder is a metal, whereby a metal nitride is formed.
Claim 20
Dependent Claim
15 words
A method according to claim 1 wherein said powder is fluidized with an inert gas.
Claim 21
Dependent Claim
13 words
A method according to claim 1 wherein said beam is a laser beam.
Claim 22
Dependent Claim
16 words
A method according to claim 20 wherein said laser beam is from a C0 2 laser.
Claim 23
Dependent Claim
16 words
A method according to claim 1 wherein said powder is not fluidized when it is melted.
Claim 24
Dependent Claim
17 words
A method according to claim 1 wherein said beam is directed downward at 90° to said surface.
Claim 25
Dependent Claim
17 words
A method according to claim 1 wherein more than one beam is directed at the same powder.
Claim 26
Dependent Claim
33 words
A method according to claim 1 wherein a single beam is split and is directed at powder in different areas of said fluidizing bed, whereby two identical shapes are formed on said surface.
Claim 27
Dependent Claim
31 words
A method according to claim 1 wherein at least two beams are directed at powder in different areas of said fluidized bed, whereby two identical shapes are formed on said surface.
Claim 28
Dependent Claim
33 words
A method according to claim 1 wherein said shape is lowered in said fluidized bed as it forms, so that the top of said powder in said bed is higher than said shape.
Claim 29
Dependent Claim
33 words
A method according to claim 1 wherein the level of said powder in said fluidized bed is raised as said shape forms so that said level is above the top of said shape.
Claim 30
Dependent Claim
30 words
A method according to claim 28 wherein the level of said powder in said fluidized bed is raised by increasing the pressure of the gas used to fluidize said powder.
Claim 31
Dependent Claim
24 words
A method according to claim 28 wherein the level of said powder in said fluidized bed is raised by adding powder to said bed.
Claim 32
Dependent Claim
22 words
A method according to claim 1 wherein said powder that forms said shape is replaced by adding more powder to said bed.
Claim 33
Dependent Claim
20 words
A method according to claim 1 wherein the level of said powder above said shape is determined by a sensor.
Claim 34
Dependent Claim
16 words
A method according to claim 1 wherein said beam is fixed and said surface moves horizontally.
Claim 35
Dependent Claim
12 words
A method according to claim 33 wherein said surface, is moved manually.
Claim 36
Dependent Claim
18 words
A method according to claim 33 wherein the horizontal movement of said surface is controlled by a computer.
Claim 37
Dependent Claim
20 words
A method according to claim 1 wherein said surface is fixed and said beam is moved relative to said surface.
Claim 38
Dependent Claim
12 words
A method according to claim 36 wherein said beam is moved manually.
Claim 39
Dependent Claim
17 words
A method according to claim 36 wherein the movement of said beam is controlled by a computer.
Claim 40
Dependent Claim
13 words
A method according to claim 1 wherein said surface is horizontal and flat.
Claim 41
Independent Claim
113 words
A method of casting a near net shape comprising: (A) fluidizing a laser-fusible powder in a fluidized bed to a level slightly higher than the level of a surface within said fluidized bed; (B) stopping said fluidizing of said powder, whereby a layer of said powder is deposited on said surface; (C) directing a laser beam downward at said layer of powder while changing the horizontal position of said surface relative to said laser beam, whereby said powder fuses on said surface; (D) fluidizing said powder to a level slightly higher than the top of said fused powder; and (E) repeating steps (B), (C), and (D) until said near net shape is completed.
Claim 42
Independent Claim
113 words
A method of casting a near net shape comprising: (A) fluidizing a laser-fusible powder in a fluidized bed to a level slightly higher than the level of a surface within said fluidized bed; (B) stopping said fluidizing of said powder, whereby a layer of said powder is deposited on said surface; (C) directing a laser beam downward at said layer of powder while changing the horizontal position of said surface relative to said laser beam, whereby said powder fuses on said surface; (D) fluidizing said powder to a level slightly higher than the top of said fused powder; and (E) repeating steps (B), (C), and (D) until said near net shape is completed.
Claim 43
Independent Claim
155 words
A method of forming a metal casting of a near net shape comprising: (A) fluidizing metal powder in a fluidized bed to a level about 1/32 to about 1 inch above the level of a horizontal surface within said fluidized bed; (B) stopping said fluidizing of said powder, whereby a layer of said powder is deposited on said surface; (C) directing a C0 2 laser beam having a power sufficient to melt said metal powder downward at said layer of powder, while changing the horizontal position of said horizontal surface relative to said laser beam, whereby said melted powder fuses on said surface and solidifies, forming a horizontal cross-section of said near net shape; (D) fluidizing said powder in said fluidized bed so that said level is about 1/32 to about 1 inch above the top of said horizontal cross section; and (E) repeating steps (B), (C), and (D) until said metal casting is formed.
Claim 44
Independent Claim
155 words
A method of forming a metal casting of a near net shape comprising: (A) fluidizing metal powder in a fluidized bed to a level about 1/32 to about 1 inch above the level of a horizontal surface within said fluidized bed; (B) stopping said fluidizing of said powder, whereby a layer of said powder is deposited on said surface; (C) directing a C0 2 laser beam having a power sufficient to melt said metal powder downward at said layer of powder, while changing the horizontal position of said horizontal surface relative to said laser beam, whereby said melted powder fuses on said surface and solidifies, forming a horizontal cross-section of said near net shape; (D) fluidizing said powder in said fluidized bed so that said level is about 1/32 to about 1 inch above the top of said horizontal cross section; and (E) repeating steps (B), (C), and (D) until said metal casting is formed.
Claim 45
Dependent Claim
16 words
A method according to claim 41 wherein said level is maintained by lowering said horizontal surface.
Claim 46
Dependent Claim
18 words
A method according to claim 42 wherein said level is maintained by raising the level of said powder.
Claim 47
Dependent Claim
22 words
A method according to claim 40 wherein said powder is selected from the group consisting of metals, ceramics, plastics, and mixtures thereof.
Claim 48
Dependent Claim
17 words
A method according to claim 40 wherein said powder is a mixture of different kinds of particles.
Claim 49
Dependent Claim
18 words
A method according to claim 45 wherein said powder is a mixture of metal particles and ceramic particles.
Claim 50
Dependent Claim
13 words
A method according to claim 44 wherein said powder is a metal powder.
Claim 51
Dependent Claim
18 words
A method according to claim 47 wherein said powder is a mixture of at least two different metals.
Claim 52
Dependent Claim
11 words
A method according to claim 47 wherein said powder comprises titanium.
Claim 53
Dependent Claim
26 words
A method according to claim 49 wherein said titanium is contaminated with an element selected from the group consisting of sodium, magnesium, chlorine, and mixtures thereof.
Claim 54
Dependent Claim
12 words
A method according to claim 47 wherein said metal is an alloy.
Claim 55
Dependent Claim
14 words
A method according to claim 51 wherein said alloy is an alloy of titanium.
Claim 56
Dependent Claim
17 words
A method according to claim 52 wherein said alloy has the approximate composition 90% Ti-6% Al-4% V.
Claim 57
Dependent Claim
11 words
A method according to claim 47 wherein said powder comprises tungsten.
Claim 58
Dependent Claim
19 words
A method according to claim 40 wherein the composition of said powder is changed as said shape is formed.
Claim 59
Dependent Claim
14 words
A method according to claim 40 wherein said powder in said bed is heated.
Claim 60
Dependent Claim
20 words
A method according to claim 56 wherein said powder is heated by an electrical resistance heater in said fluidized bed.
Claim 61
Dependent Claim
23 words
A method according to claim 40 wherein said powder is fluidized with a gas that reacts with said powder when it is fused.
Claim 62
Dependent Claim
23 words
A method according to claim 58 wherein said gas is methane and said powder is a metal, whereby a metal carbide is formed.
Claim 63
Dependent Claim
23 words
A method according to claim 59 wherein said gas is nitrogen and said powder is a metal, whereby a metal nitride is formed.
Claim 64
Dependent Claim
15 words
A method according to claim 40 wherein said powder is fluidized with an inert gas.
Claim 65
Dependent Claim
16 words
A method according to claim 40 wherein said laser beam is from a C0 2 laser.
Claim 66
Dependent Claim
17 words
A method according to claim 40 wherein said beam is directed downward at 90° to said surface.
Claim 67
Dependent Claim
33 words
A method according to claim 40 wherein said laser beam is split and is directed at powder in different areas of said fluidizing bed, whereby two indentical shapes are formed on said surface.
Claim 68
Dependent Claim
30 words
A method according to claim 40 wherein the level of said powder in said fluidized bed is rasied by increasing the pressure of the gas used to fluidize said powder.
Claim 69
Dependent Claim
24 words
A method according to claim 40 wherein the level of said powder in said fluidized bed is raised by adding powder to said bed.
Claim 70
Dependent Claim
22 words
A method according to claim 40 wherein said powder that forms said shape is replaced by adding more powder to said bed.
Claim 71
Dependent Claim
20 words
A method according to claim 40 wherein the level of said powder above said shape is determined by a sensor.
Claim 72
Dependent Claim
16 words
A method according to claim 40 wherein said beam is fixed and said surface moves horizontally.
Claim 73
Dependent Claim
12 words
A method according to claim 69 wherein said surface is moved manually.
Claim 74
Dependent Claim
18 words
A method according to claim 69 wherein the horizontal movement of said surface is controlled by a computer.
Claim 75
Dependent Claim
21 words
A method according to claim 40 wherein said surface is fixed and said laser beam is moved relative to said surface.
Claim 76
Dependent Claim
12 words
A method according to claim 72 wherein said beam is moved manually.
Claim 77
Dependent Claim
18 words
A method according to claim 72 wherein the movement of said laser beam is controlled by a computer.
Claim 78
Dependent Claim
13 words
A method according to claim 40 wherein said surface is horizontal and flat.
Claim 79
Dependent Claim
19 words
A method according to claim 41 wherein said metal powder is a mixture of at least two different metals.
Claim 80
Dependent Claim
11 words
A method according to claim 41 wherein said powder comprises titanium.
Claim 81
Dependent Claim
26 words
A method according to claim 77 wherein said titanium is contaminated with an element selected from the group consisting of sodium, magnesium, chlorine, and mixtures thereof.
Claim 82
Dependent Claim
12 words
A method according to claim 41 wherein said metal is an alloy.
Claim 83
Dependent Claim
14 words
A method according to claim 79 wherein said alloy is an alloy of titanium.
Claim 84
Dependent Claim
17 words
A method according to claim 80 wherein said alloy has the approximate composition 90% Ti-6% Al-4% V.
Claim 85
Dependent Claim
12 words
A method according to claim 41 wherein said metal powder comprises tungsten.
Claim 86
Dependent Claim
20 words
A method according to claim 41 wherein the composition of said metal powder is changed as said shape is formed.
Claim 87
Dependent Claim
15 words
A method according to claim 41 wherein said metal powder in said bed is heated.
Claim 88
Dependent Claim
21 words
A method according to claim 84 wherein said metal powder is heated by an electrical resistance heater in said fludized bed.
Claim 89
Dependent Claim
25 words
A method according to claim 41 wherein said metal powder is fluidized with a gas that reacts with said metal powder when it is fused.
Claim 90
Dependent Claim
17 words
A method according to claim 86 wherein said gas is methane, whereby a metal carbide is formed.
Claim 91
Dependent Claim
17 words
A method according to claim 86 wherein said gas is nitrogen, whereby a metal nitride is formed.
Claim 92
Dependent Claim
16 words
A method according to claim 41 wherein said metal powder is fluidized with an inert gas.
Claim 93
Dependent Claim
17 words
A method according to claim 41 wherein said beam is directed downward at 90° to said surface.
Claim 94
Dependent Claim
33 words
A method according to claim 41 wherein said laser beam is split and is directed at powder in different areas of said fluidizing bed, whereby two identical shapes are formed on said surface.
Claim 95
Dependent Claim
32 words
A method according to claim 41 wherein the level of said metal powder in said fluidized bed is raised by increasing the pressure of the gas used to fluidize said metal powder.
Claim 96
Dependent Claim
26 words
A method according to claim 92 wherein the level of said metal powder in said fluidized bed is raised by adding metal powder to said bed.
Claim 97
Dependent Claim
24 words
A method according to claim 41 wherein said metal powder that forms said shape is replaced by adding more metal powder to said bed.
Claim 98
Dependent Claim
21 words
A method according to claim 41 wherein the level of said metal powder above said shape is determined by a sensor.
Claim 99
Dependent Claim
16 words
A method according to claim 41 wherein said beam is fixed and said surface moves horizontally.
Claim 100
Dependent Claim
12 words
A method according to claim 96 wherein said surface is moved manually.
Claim 101
Dependent Claim
18 words
A method according to claim 96 wherein the horizontal movement of said surface is controlled by a computer.
Claim 102
Dependent Claim
20 words
A method according to claim 41 wherein said surface is fixed and said beam is moved relative to said surface.
Claim 103
Dependent Claim
12 words
A method according to claim 99 wherein said beam is moved manually.
Claim 104
Dependent Claim
17 words
A method according to claim 99 wherein the movement of said beam is controlled by a computer.
Claim 105
Dependent Claim
80 words
Apparatus for casting a shape comprising: (A) a fluidized bed; (B) a surface within said bed; (C) an electron gun or a laser having an energy sufficient to fuse powder within said fluidized bed, where the output beam of said electron gun or said laser is directed at said surface; (D) means for controlling the level of powder in said fluidized bed relative to said surface; (E) means for controlling the horizontal position of said surface relative to said beam.
Claim 106
Dependent Claim
80 words
Apparatus for casting a shape comprising: (A) a fluidized bed; (B) a surface within said bed; (C) an electron gun or a laser having an energy sufficient to fuse powder within said fluidized bed, where the output beam of said electron gun or said laser is directed at said surface; (D) means for controlling the level of powder in said fluidized bed relative to said surface; (E) means for controlling the horizontal position of said surface relative to said beam.
Claim 107
Dependent Claim
22 words
Apparatus according to claim 102 including means for changing the composite of power in said fluidized bed as said shape is cast.
Claim 108
Dependent Claim
13 words
Apparatus according to claim 102 including means for heating powder in said bed.
Claim 109
Dependent Claim
22 words
Apparatus according to claim 104 wherein said means for heating said powder is an electrical resistance heater placed in said fluidized bed.
Claim 110
Dependent Claim
12 words
Apparatus according to claim 102 wherein said beam is a laser beam.
Claim 111
Dependent Claim
21 words
Apparatus according to claim 104 including means for rapidly oscillating said laser beam over said surface as said surface moves horizontally.
Claim 112
Dependent Claim
15 words
Apparatus according to claim 102 wherein said laser beam is from a C0 2 laser.
Claim 113
Dependent Claim
16 words
Apparatus according to claim 102 wherein said beam is directed downward at 90° to said surface.
Claim 114
Dependent Claim
15 words
Apparatus according to claim 102 wherein more than one beam is directed at said surface.
Claim 115
Dependent Claim
41 words
Apparatus according to claim 102 including means for splitting a single beam into at least two beams, and for directing each beam at different areas of said surface in said fluidizing bed, whereby identical shapes can be formed on said surface.
Claim 116
Dependent Claim
33 words
Apparatus according to claim 102 wherein at least two beams can be directed at different areas of said surface in said fluidized bed, whereby two identical shapes can be formed on said surface.
Claim 117
Dependent Claim
19 words
Apparatus according to claim 102 including means for lowering said shape in said fluidized bed as it is formed.
Claim 118
Dependent Claim
22 words
Apparatus according to claim 102 including means for raising the level of powder in said fluidized bed as said shape is formed.
Claim 119
Dependent Claim
33 words
Apparatus according to claim 114 wherein said means for raising the level of said powder in said fluidized bed is means for increasing the pressure of the gas used to fluidize said powder.
Claim 120
Dependent Claim
13 words
Apparatus according to claim 102 including means for adding powder to said bed.
Claim 121
Dependent Claim
23 words
Apparatus according to claim 102 including sensor means for determining the level of powder in said fluidized bed that is above said shape.
Claim 122
Dependent Claim
16 words
Apparatus according to claim 102 wherein said beam is fixed and said surface is horizontally moveable.
Claim 123
Dependent Claim
11 words
Apparatus according to claim 118 wherein said surface is manually moveable.
Claim 124
Dependent Claim
17 words
Apparatus according to claim 118 wherein the horizontal movement of said surface is controlled by a computer.
Claim 125
Dependent Claim
19 words
Apparatus according to claim 102 wherein said surface is fixed and said beam is moveable relative to said surface.
Claim 126
Dependent Claim
11 words
Apparatus according to claim 121 wherein said beam is manually moveable.
Claim 127
Dependent Claim
16 words
Apparatus according to claim 121 wherein the movement of said beam is controlled by a computer.
Claim 128
Dependent Claim
12 words
Apparatus according to claim 102 wherein said surface is horizontal and flat.
Claim 129
Dependent Claim
79 words
Apparatus for casting a near net shape comprising: (A) a fluidized bed having surface therein; (B) means for fluidizing powder within said bed to a level slightly above the level of said surface; (C) a laser, the beam of which is directed downward at said surface; (D) means for changing the horizontal position of said surface relative to said laser beam; and (E) means for changing the level of said powder in said fluidized bed relative to said surface.
Claim 130
Dependent Claim
79 words
Apparatus for casting a near net shape comprising: (A) a fluidized bed having surface therein; (B) means for fluidizing powder within said bed to a level slightly above the level of said surface; (C) a laser, the beam of which is directed downward at said surface; (D) means for changing the horizontal position of said surface relative to said laser beam; and (E) means for changing the level of said powder in said fluidized bed relative to said surface.
Claim 131
Dependent Claim
117 words
Apparatus for forming a metal casting of a near net shape comprising: (A) a fluidized bed; (B) a horizontal surface within said fluidized bed; (C) means for fluidizing metal powder in said fluidized bed to a level about 1/32 to about 1 inch above said horizontal surface; (D) a C0 2 laser that produces a laser beam having a power sufficient to melt said fluidized metal powder above said horizontal surface; (E) means for directing said laser beam at said surface; (F) means for changing the horizontal position of said horizontal surface relative to said laser beam; and (G) means for changing the level of said metal powder in said fluidized bed relative to said horizontal surface.
Claim 132
Dependent Claim
117 words
Apparatus for forming a metal casting of a near net shape comprising: (A) a fluidized bed; (B) a horizontal surface within said fluidized bed; (C) means for fluidizing metal powder in said fluidized bed to a level about 1/32 to about 1 inch above said horizontal surface; (D) a C0 2 laser that produces a laser beam having a power sufficient to melt said fluidized metal powder above said horizontal surface; (E) means for directing said laser beam at said surface; (F) means for changing the horizontal position of said horizontal surface relative to said laser beam; and (G) means for changing the level of said metal powder in said fluidized bed relative to said horizontal surface.
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