US5156697A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Selective laser sintering of parts by compound formation of precursor powders
Assignee: The University of Texas System
•
Filing: 1990-12-07
•
Granted: 1992-10-20
•
Expires: 2010-12-07
Abstract
Abstract A method and apparatus for selectively sintering a layer of powder to produce a part comprising a plurality of sintered layers. The apparatus includes a computer controlling a laser to direct the laser energy onto the powder to produce a sintered mass. The computer either determines or is programmed with the boundaries of the desired cross-sectional regions of the part. For each cross-section, the aim of the laser beam is scanned over a layer of powder and the beam is switched on to sinter only the powder within the boundaries of the cross-section. Powder is applied and successive layers sintered until a completed part is formed. Preferably, the powder comprises a plurality of materials having different dissociation or bonding temperatures. The powder preferably comprises blended or coated materials, including precursor materials which are formed into a mass at the irradiated locations, and which either react due to the laser thermal energy or in a later heat treatment to form a compound with properties different than the precursors. Examples are disclosed wherein a compound is formed which has a significantly higher melting point than that of one or more of the precursor powders.
Inventors
- 👤 David L. Bourell
- 👤 Harris L. Marcus
- 👤 Wendy L. Weiss
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 21:59
CPC Classifications
B; B29; B29C; B29C67/00; C; C04; C04B; C04B35/00; C04B35/622; C04B35/64; B22; B22F; B22F10/00; B22F10/20; B22F10/28; B22F3/00; B22F3/004; B22F3/23; B23; B23K; B23K26/00; B23K26/34; B23K35/00; B23K35/02; B23K35/0222; B23K35/0244; B23K35/22; B23K35/24; B23K35/26; B23K35/262; B23K35/30; B23K35/302; B23K35/36; B23K35/365; B28; B28B; B28B11/00; B28B11/24; B29C64/00; B29C64/10; B29C64/141; B29C64/153; B33; B33Y; B33Y10/00; B33Y70/00; B22F10/30; B22F10/36; B22F10/366; B22F10/60; B22F10/64; B22F12/00; B22F12/40; B22F12/41; B22F12/43; B22F12/44; B22F12/49; B22F3/10; B22F3/105; B22F2003/1052; B22F2999/00; G; G05; G05B; G05B2219/00; G05B2219/30; G05B2219/49; G05B2219/49013; Y; Y02; Y02P; Y02P10/00; Y02P10/25
Claims Analysis
Total Claims: 26
Claim 1
Independent Claim
61 words
A method of producing a part, comprising: depositing a powder onto a target surface, said powder comprising first and second materials; heating a selected portion of said powder to define a cross-sectional region of the part; and reacting the first and second materials in said cross-sectional region of the part to form a chemical compound of said first and second materials.
Claim 2
Independent Claim
61 words
A method of producing a part, comprising: depositing a powder onto a target surface, said powder comprising first and second materials; heating a selected portion of said powder to define a cross-sectional region of the part; and reacting the first and second materials in said cross-sectional region of the part to form a chemical compound of said first and second materials.
Claim 3
Dependent Claim
31 words
The method of claim 1, wherein said heating step heats said powder to a temperature between the melting point of said first material and the melting point of said second material.
Claim 4
Dependent Claim
23 words
The method of claim 2, wherein the melting point of said chemical compound is higher than the melting point of said first material.
Claim 5
Dependent Claim
32 words
The method of claim 3, wherein the melting point of said chemical compound is higher than the temperature to which the selected portion of the powder is heated in said heating step
Claim 6
Dependent Claim
38 words
The method of claim 1, further comprising: depositing a second layer of said powder after said heating step; and heating a selected portion of said second layer of powder to define a second cross-sectional region of the part.
Claim 7
Dependent Claim
41 words
The method of claim 5, wherein said reacting step comprises: removing portions of the powder not within the defined cross-section of the part, after said step of heating said second layer of powder; and heating the part after said removing step.
Claim 8
Dependent Claim
15 words
The method of claim 1, wherein said reacting step is performed during said heating step.
Claim 9
Dependent Claim
20 words
The method of claim 1, wherein said heating step comprises: directing an energy beam at selected portions of said powder.
Claim 10
Dependent Claim
20 words
The method of claim 8, wherein the directing step comprises: directing a laser beam at selected portions of said powder.
Claim 11
Independent Claim
10 words
The method of claim wherein said first material comprises tin.
Claim 12
Dependent Claim
11 words
The method of claim 10, wherein said second material comprises nickel.
Claim 13
Dependent Claim
11 words
The method of claim 1, wherein said second material comprises nickel.
Claim 14
Dependent Claim
11 words
The method of claim 12, wherein said first material comprises aluminum.
Claim 15
Dependent Claim
13 words
The method of claim 1, wherein said first and second materials are metals.
Claim 16
Dependent Claim
13 words
The method of claim 1, wherein said first and second materials are ceramics.
Claim 17
Dependent Claim
18 words
The method of claim 1, wherein the chemical compound formed by said reacting step is a stable compound.
Claim 18
Dependent Claim
18 words
The method of claim 1, wherein the chemical compound formed by said reacting step is a metastable compound.
Claim 19
Dependent Claim
64 words
A part produced by the method comprising the steps of: depositing a powder onto a target surface, said powder comprising first and second materials; heating a selected portion of said powder to define a cross-sectional region of the part; and reacting the first and second materials in said cross-sectional region of the part to form a chemical compound of said first and second materials.
Claim 20
Dependent Claim
64 words
A part produced by the method comprising the steps of: depositing a powder onto a target surface, said powder comprising first and second materials; heating a selected portion of said powder to define a cross-sectional region of the part; and reacting the first and second materials in said cross-sectional region of the part to form a chemical compound of said first and second materials.
Claim 21
Dependent Claim
59 words
The part of claim 18, wherein said heating step heats said powder to a temperature between the melting point of said first material and the melting point of said second material; and wherein the melting point of said chemical compound is higher than the temperature to which the selected portion of the powder is heated in said heating step.
Claim 22
Dependent Claim
78 words
The part of claim 18, wherein the method further comprises: depositing a second layer of said powder after said heating step; and heating a selected portion of said second layer of powder to define a second cross-sectional region of the part; and wherein said reacting step comprises: removing portions of the powder not within the defined cross-section of the part, after said step of heating said second layer of powder; and heating the part after said removing step.
Claim 23
Dependent Claim
15 words
The part of claim 18, wherein said reacting step is performed during said heating step.
Claim 24
Dependent Claim
13 words
The part of claim 18, wherein said first and second materials are metals.
Claim 25
Dependent Claim
25 words
The part of claim 22, wherein said compound is an intermetallic compound having a melting point higher than the melting point of said first material.
Claim 26
Dependent Claim
13 words
The part of claim 18, wherein said first and second materials are ceramics.
References Cited (Backward Citations)
US4117302A
Cited
US4300474A
Cited
US4323756A
Cited
US4474861A
Cited
US4575330A
Cited
US4575330B1
Cited
JPS61296976A
Cited
EP0221276A1
Cited
US4752352A
Cited
US4863538A
Cited
WO1988002677A2
Cited
US4938816A
Cited
US4944817A
Cited
EP0283003A2
Cited
WO1990011845A1
Cited
EP0431924B1
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1995-10-20 | 1996-04-20 | 1996-10-20 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1999-10-20 | 2000-04-20 | 2000-10-20 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2003-10-20 | 2004-04-20 | 2004-10-20 | $7700.00 | Window Closed / Lapsed |