US5126529A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method and apparatus for fabrication of three-dimensional articles by thermal spray deposition
Assignee: Individual
•
Filing: 1990-12-03
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Granted: 1992-06-30
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Expires: 2010-12-03
Abstract
Abstract A method and apparatus for forming a three-dimensional object by thermal spraying utilizes a plurality of masks positioned and removed over a work surface in accordance with a predetermined sequence. The masks correspond to cross sections normal to a centerline through the workpiece. One set of masks defines all cross sections through the workpiece. A second set of masks contains at least one masks which corresponds to each mask of the first set. Masks from each set are alternatively placed above a work surface and sprayed with either a deposition material from which the workpiece will be made or a complementary material. In this manner, layers of material form a block of deposition material and complementary material. Then, the complementary material which serves as a support structure during forming is removed. Preferably, the complementary material has a lower melting temperature than the deposition material and is removed by heating the block. Alternatively, one could mask only for the deposition material and remove complementary material overlying the deposition material after each spraying of complementary material.
Inventors
- 👤 Lee E. Weiss
- 👤 Fritz R. Prinz
- 👤 E. Levent Gursoz
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 22:22
CPC Classifications
B; B22; B22F; B22F3/00; B22F3/115; B23; B23P; B23P17/00; B23P23/00; B23P23/04; B29; B29C; B29C64/00; B29C64/10; B29C64/141; B29C64/40; B33; B33Y; B33Y10/00; B33Y30/00; B23P2700/00; B23P2700/12; G; G05; G05B; G05B2219/00; G05B2219/30; G05B2219/49; G05B2219/49016; G05B2219/49039; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/4998; Y10T29/49982; Y10T29/49986
Claims Analysis
Total Claims: 40
Claim 1
Independent Claim
216 words
A method for the fabrication of a three dimensional article comprising the steps of a) creating a first set of masks, each mask corresponding to at least a portion of a cross section through the article such that there is at least one mask in the first set for every parallel cross section through the article normal to a centerline through the article; b) creating a second set of masks, each mask corresponding to at least one mask from the first set of masks and defining a complement to the cross section defined by a corresponding mask from the first set of masks; c) alternatively placing on a work surface at least one mask from the first set and then at least one mask from the second set in accordance with a predetermined sequence; d) spraying deposition material over each mask from the first set of masks and one of the work surface and deposition material on the work surface; e) removing the mask after spraying the deposition material; f) spraying a complementary material over each mask from the second set of masks and one of the work surface and complementary material on the work surface; g) removing the mask after spraying the complementary material; and h) removing the complementary material from the sprayed deposition material.
Claim 2
Independent Claim
216 words
A method for the fabrication of a three dimensional article comprising the steps of a) creating a first set of masks, each mask corresponding to at least a portion of a cross section through the article such that there is at least one mask in the first set for every parallel cross section through the article normal to a centerline through the article; b) creating a second set of masks, each mask corresponding to at least one mask from the first set of masks and defining a complement to the cross section defined by a corresponding mask from the first set of masks; c) alternatively placing on a work surface at least one mask from the first set and then at least one mask from the second set in accordance with a predetermined sequence; d) spraying deposition material over each mask from the first set of masks and one of the work surface and deposition material on the work surface; e) removing the mask after spraying the deposition material; f) spraying a complementary material over each mask from the second set of masks and one of the work surface and complementary material on the work surface; g) removing the mask after spraying the complementary material; and h) removing the complementary material from the sprayed deposition material.
Claim 3
Dependent Claim
21 words
The method of claim 1 wherein the complementary material has a melting point below a melting point of the deposition material.
Claim 4
Dependent Claim
29 words
The method of claim 2 wherein the complementary material is metal alloy having a melting temperature between approximately 150° to 340° F. and the deposition material is a steel.
Claim 5
Dependent Claim
22 words
The method of claim 1 wherein the deposition material is one of a metal, a ceramic, a plastic and a composite thereof.
Claim 6
Dependent Claim
18 words
The method of claim 1 wherein the masks are one of foil, plastic, paper and pressure sensitive paper.
Claim 7
Dependent Claim
36 words
The method of claim 1 where pa of masks from the first set of masks define at least some of the cross sections through the article with each pair of masks defining a single cross section.
Claim 8
Dependent Claim
55 words
The method of claim 6 wherein the masks in each pair of masks have a corresponding edge and the pairs of masks are placed in a manner so that the corresponding edges for each pair of masks will not be placed along the same line as the corresponding edges of the next pair of masks.
Claim 9
Dependent Claim
17 words
The method of claim 1 wherein the masks are cut from a continuous roll of mask material.
Claim 10
Dependent Claim
22 words
The method of claim 8 also comprising the step of removing portions cut away from the mask material with a suction device.
Claim 11
Dependent Claim
18 words
The method of claim 1 wherein at least two different materials are also used for the deposition material.
Claim 12
Dependent Claim
26 words
The method of claim 1 also comprising the step of applying a sticky material to at least some of the masks prior to placing the masks.
Claim 13
Dependent Claim
35 words
The method of claim 1 wherein at least one of the deposition material and the complementary material are applied with a spray source that is moved over the work surface according to a predetermined path.
Claim 14
Dependent Claim
40 words
The method of claim 12 wherein the spray source produces a thermal spray pattern having a Gaussian distribution having a standard deviation and the path is such that passes of the spray gun are spaced apart by 1.5 standard deviations.
Claim 15
Dependent Claim
28 words
The method of claim 1 wherein at least one of the deposition material and the complementary material are applied through a plurality of spaced apart thermal spray sources.
Claim 16
Dependent Claim
38 words
The method of claim 14 wherein the thermal spray sources produce thermal spray patterns having a Gaussian distribution having a standard deviation wherein the spray sources are positioned and moved in parallel paths separated by 1.5 standard distributions.
Claim 17
Dependent Claim
21 words
The method of claim 1 also comprising the step of shot peening at least a portion of the sprayed deposition material.
Claim 18
Dependent Claim
20 words
The method of claim 1 also comprising the step of heating at least a portion of the sprayed deposition material.
Claim 19
Independent Claim
160 words
A method for fabrication of a three-dimensional article comprising the steps of: a) creating a first set of masks, each mask corresponding to at least a portion of a cross section through the article such that there is at least one mask in the first set for every parallel cross section through the article normal to a centerline through the article; b) placing at least one mask over a work surface; c) spraying a deposition material over the work surface and mask placed thereover; d) removing the at least one mask; e) spraying a complementary material over the work surface and deposition material sprayed thereon to form a layer of deposition material and complementary material; f) machining the layer to a selected thickness thereby removing all complementary material from an exposed top surface of the deposition material; g) repeating steps b thru f as necessary to build up the article; and h) removing the complementary material from the deposition material.
Claim 20
Independent Claim
160 words
A method for fabrication of a three-dimensional article comprising the steps of: a) creating a first set of masks, each mask corresponding to at least a portion of a cross section through the article such that there is at least one mask in the first set for every parallel cross section through the article normal to a centerline through the article; b) placing at least one mask over a work surface; c) spraying a deposition material over the work surface and mask placed thereover; d) removing the at least one mask; e) spraying a complementary material over the work surface and deposition material sprayed thereon to form a layer of deposition material and complementary material; f) machining the layer to a selected thickness thereby removing all complementary material from an exposed top surface of the deposition material; g) repeating steps b thru f as necessary to build up the article; and h) removing the complementary material from the deposition material.
Claim 21
Dependent Claim
21 words
The method of claim 18 wherein the complementary material has a melting point below a melting point of the deposition material.
Claim 22
Dependent Claim
29 words
The method of claim 19 wherein the complementary material is metal alloy having a melting temperature between approximately 150° to 340° F. and the deposition material is a steel.
Claim 23
Dependent Claim
22 words
The method of claim 18 wherein the deposition material is one of a metal, a ceramic, a plastic and a composite thereof.
Claim 24
Dependent Claim
18 words
The method of claim 18 wherein the masks are one of foil, plastic, paper and pressure sensitive paper.
Claim 25
Dependent Claim
14 words
The method of claim 18 wherein the masks are created over the work surface.
Claim 26
Independent Claim
98 words
An apparatus for forming an integral three-dimensional article by thermally spraying layers of material comprising: a) a work surface; b) means for supplying to the work surface masks corresponding to cross sections through the article; c) means for placing the masks over the work surface and removing them therefrom in accordance with a predetermined sequence; d) means for thermally spraying a deposition material over the masks, the work surface, and material deposited on a work surface, and e) means for thermally spraying a complementary material over the masks, the work surface and material deposited on the mask surface.
Claim 27
Independent Claim
98 words
An apparatus for forming an integral three-dimensional article by thermally spraying layers of material comprising: a) a work surface; b) means for supplying to the work surface masks corresponding to cross sections through the article; c) means for placing the masks over the work surface and removing them therefrom in accordance with a predetermined sequence; d) means for thermally spraying a deposition material over the masks, the work surface, and material deposited on a work surface, and e) means for thermally spraying a complementary material over the masks, the work surface and material deposited on the mask surface.
Claim 28
Dependent Claim
34 words
The apparatus of claim 24 wherein the masks are in roll form and the means for supplying the masks is comprised of a supply spool and a take-up spool between which the masks pass.
Claim 29
Dependent Claim
18 words
The apparatus of claim 25 also comprising means for forming masks connected to the means for supplying masks.
Claim 30
Dependent Claim
16 words
The apparatus of claim 26 wherein the means for forming the masks is a laser cutter.
Claim 31
Dependent Claim
35 words
The apparatus of claim 24 also comprising a head positioned above the work surface to which are attached the means for thermally spraying a deposition material and the means for thermally spraying a complementary material.
Claim 32
Dependent Claim
15 words
The apparatus of claim 28 also comprising means for forming masks mounted on the head.
Claim 33
Dependent Claim
30 words
The apparatus of claim 24 wherein a single spray nozzle is used as the means for thermally spraying a deposition material and the means for thermally spraying a complementary material.
Claim 34
Dependent Claim
28 words
The apparatus of claim 24 also comprising means for applying a sticky material to at least some of the masks positioned near the means for placing the masks.
Claim 35
Dependent Claim
17 words
The apparatus of claim 24 wherein the work surface is movable in x, y and z planes.
Claim 36
Dependent Claim
20 words
The apparatus of claim 24 wherein the means for placing the masks and removing the masks includes a suction device.
Claim 37
Dependent Claim
24 words
The apparatus of claim 24 also comprising a shot peener positioned above the work surface for shot peening deposition material on the work surface.
Claim 38
Dependent Claim
22 words
The apparatus of claim 24 also comprising means for removing deposition material and complementary material to create layers of substantially uniform thickness.
Claim 39
Dependent Claim
21 words
The apparatus of claim 35 wherein the means for removing deposition material and complementary material is at least one grinding wheel.
Claim 40
Dependent Claim
28 words
The apparatus of claim 24 also comprising a heater positioned above the work surface for heating at least a portion of the deposition material on the work surface.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1995-06-30 | 1995-12-30 | 1996-06-30 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1999-06-30 | 1999-12-30 | 2000-06-30 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2003-06-30 | 2003-12-30 | 2004-06-30 | $7700.00 | Window Closed / Lapsed |