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公开(公告)号：US5147587A
公开(公告)日：1992-09-15
申请号：US657151
申请日：1991-02-19
IPC分类号： B05C19/00 , B22F3/00 , B22F3/105 , B22F7/02 , B23K26/08 , B23K26/34 , B29C35/04 , B29C41/12 , B29C41/46 , B29C67/00 , C23C24/08 , C23C24/10 , C23C26/02 , G05B19/41
CPC分类号： G05B19/41 , B05C19/008 , B22F3/004 , B22F3/105 , B22F3/1055 , B22F7/02 , B23K26/08 , B23K26/082 , B23K26/34 , B29C41/12 , B29C41/46 , B29C67/0077 , C23C24/08 , C23C24/10 , C23C26/02 , B05C19/00 , B22F2003/1052 , B22F2998/00 , B22F2998/10 , B29C35/045 , G05B2219/49013 , G05B2219/49018 , Y02P10/295 , Y02P90/265
摘要： 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. A ceramic part, such as a mold for investment casting, may be formed according to the method, where a first material (e.g., ammonium dihydrogen phosphate) has a melting point sufficiently low that it is melted so as to bind the second material (e.g., alumina). Subsequent heat treatment enables chemical reaction of the two materials to form a ceramic (e.g., aluminum phosphate) capable of withstanding high temperatures.
摘要翻译： 一种用于选择性地烧结一层粉末以产生包括多个烧结层的部分的方法和装置。 该装置包括控制激光以将激光能量引导到粉末上以产生烧结块的计算机。 计算机确定或编程了该部分所需横截面区域的边界。 对于每个横截面，激光束的目的是在一层粉末上扫描，并且光束被接通以仅在横截面的边界内烧结粉末。 施加粉末并连续层烧结直到形成完整的部分。 优选地，粉末包含具有不同解离或结合温度的多种材料。 粉末优选包括混合或涂覆的材料，包括在照射位置处形成质量的前体材料，并且由于激光热能或在稍后的热处理中反应以形成具有不同于前体的性质的化合物。 公开了其中形成具有比一种或多种前体粉末的熔点显着更高的熔点的化合物的实例。 可以根据以下方法形成陶瓷部件，例如用于熔模铸造的模具，其中第一材料（例如，磷酸二氢铵）具有足够低的熔点，使其熔化以结合第二材料（例如， ，氧化铝）。 随后的热处理使得两种材料的化学反应能够形成能承受高温的陶瓷（例如，磷酸铝）。
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2.发明授权
公开(公告)号：US5749041A
公开(公告)日：1998-05-05
申请号：US542977
申请日：1995-10-13
CPC分类号： C04B35/622 , B22F3/1055 , C04B35/64 , B22F2998/10 , B22F2999/00 , Y02P10/295
摘要： A method of fabricating articles, such as prototype parts and prototype tooling for injection molding, is disclosed. The method begins with the fabrication of the article in a "green" state by the selective laser sintering, or another additive thermal process, applied to a composite powder, preferably a powder of metal particles coated with a thermoplastic polymer. Both the green article and also an aqueous emulsion of a thermosetting material are then preheated to a temperature below the glass transition temperature of the thermoplastic polymer, and the green article is then infiltrated with the aqueous emulsion. The thermosetting material may be a thermosetting polymer with an appropriate cross-linking agent, or may be a cross-linking agent that will react with the thermoplastic binder polymer. After infiltration, the article is dried, and a rigid skeleton of a thermosetting material is now present within the structure of the article. Further processing may now be performed. The article may be heated beyond the decomposition temperature of the polymers so as to drive off the polymer and sinter the metal particles to one another; alternatively, a resin may be added to the article to form a metal-polymer composite article. High strength articles may thus be formed in a manner which preserves the dimensional accuracy of the article relative to its CAD representation.
摘要翻译： 公开了一种制造制品的方法，例如原型件和用于注模的原型模具。 该方法开始于通过选择性激光烧结或另一种添加剂热处理在“绿色”状态下制造的制品，其应用于复合粉末，优选涂覆有热塑性聚合物的金属颗粒的粉末。 然后将绿色制品和热固性材料的水性乳液预热至低于热塑性聚合物的玻璃化转变温度的温度，然后用水性乳液渗透绿色制品。 热固性材料可以是具有合适的交联剂的热固性聚合物，或者可以是将与热塑性粘合剂聚合物反应的交联剂。 渗透后，制品被干燥，热固性材料的刚性骨架现在存在于制品的结构内。 现在可以进行进一步的处理。 可以将物品加热到超过聚合物的分解温度以驱离聚合物并将金属颗粒彼此烧结; 或者，可以向制品中加入树脂以形成金属 - 聚合物复合制品。 因此，可以以保持制品相对于其CAD表示的尺寸精度的方式形成高强度制品。
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3.发明授权Method of producing parts by selective beam interaction of powder with gas phase reactant 失效通过粉末与气相反应物的选择性束相互作用来生产部件的方法
公开(公告)号：US5182170A
公开(公告)日：1993-01-26
申请号：US692172
申请日：1991-04-26
CPC分类号： C04B35/64 , B22F3/004 , B22F3/1055 , B23K26/34 , B29C67/0077 , B29C67/0088 , C04B35/622 , C23C24/10 , C23C8/06 , B22F2003/1052 , G05B2219/49013 , Y02P10/295 , Y10T428/12049 , Y10T428/29
摘要： 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 each layer of the powder to produce a sintered mass corresponding to a cross-section 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. Also disclosed is a method of forming a part by interaction of material in the powder layer with reactants in the surrounding atmosphere, at locations of the powder irradiated by the energy, or laser, beam. The reaction may be nitridation, oxidation or carburization of the powder, with the product being a chemical compound of one or more constituents in the powder with one or more gases in the atmosphere. Alternatively, reduction of the powder may be so enabled by the energy beam so that a metallic phase product is formed at the irradiated locations. Particular benefits of the invention include the densification of the material of the part as a result of the reaction, and the ability to form high temperature materials by way of a relatively low temperature process.
摘要翻译： 一种用于选择性地烧结一层粉末以产生包括多个烧结层的部分的方法和装置。 该装置包括控制激光器的计算机，以将激光能量引导到粉末的每一层上，以产生对应于该部件的横截面的烧结块。 对于每个横截面，激光束的目的是在一层粉末上扫描，并且光束被接通以仅在横截面的边界内烧结粉末。 施加粉末并连续层烧结直到形成完整的部分。 还公开了通过粉末层中的材料与周围环境中的反应物，在被能量或激光束照射的粉末的位置处的相互作用形成部分的方法。 该反应可以是粉末的氮化，氧化或渗碳，产物是粉末中一种或多种组分的化合物，其中一种或多种气体在大气中。 或者，可以通过能量束来实现粉末的还原，使得在照射位置处形成金属相产物。 本发明的特别优点包括作为反应的结果的部件的材料的致密化以及通过相对低的温度过程形成高温材料的能力。
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