• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    patent abstract for: “method and arrangement for constructing metallic objects by solid free-form fabrication”. The present invention relates to a method and arrangement for fabricating objects by solid freeform fabrication, especially titanium and titanium alloy objects, wherein the deposition rate is increased by providing the metallic feed material in the form of a wire and employ two gas transferred arcs, one plasma transferred arc to heat the deposit area in the base material and one plasma transferred arc to heat and melt the feed wire.
    公开号:BR112013025043B1
    申请号:R112013025043-7
    申请日:2012-03-30
    公开日:2019-04-02
    发明作者:Ferdinand Stempfer
    申请人:Norsk Titanium Components As；
    IPC主号:
    专利说明:

    [0001] The present invention relates to a method and apparatus for making solid freeform objects, especially titanium and titanium alloy objects.
    Background [0002] Structured metal parts made of titanium or titanium alloys are conventionally made by casting, forging or machining an ingot. These techniques have a disadvantage of high use of expensive titanium metal material and long supply times in manufacturing.
    [0003] Fully dense physical objects can be made by a manufacturing technology known as rapid prototype, rapid fabrication, layered fabrication or additive fabrication. This technique uses computer-aided design (CAD) software to first build a virtual model of the object to be made, and then transform the virtual model into thin parallel slices or layers, usually horizontally oriented. The physical object can then be made by arranging successive layers of raw material in the form of liquid paste, sheet material or powder that resembles the shape of the virtual layers until the entire object is formed. The layers are fused together to form a solid, dense object. In the case of depositing solid materials that are fused or welded together, the technique is also called solid free form fabrication.
    [0004] Solid freeform fabrication is a
    Petition 870180154878, of 11/26/2018, p. 29/55
    2/20 flexible technique that allows the creation of objects of almost any format at relatively fast production rates, typically ranging from a few hours to several days for each object. The technique is thus suitable for prototyping and small production series, but less suitable for large volume production.
    Background of the technique [0005] The layered manufacturing technique can be expanded to include deposit of parts of the building material, that is, each structural layer of the virtual model of the object is divided into a set of pieces that when placed side by side form the layer. This allows the formation of metallic objects by welding a wire over a substrate in successive strips forming each layer according to the virtual layered model of the object, and repeating the process for each layer until the entire physical object is formed. The precision of the welding technique is usually too coarse to allow the object to be directly formed with acceptable dimensions. The object formed in this way will normally be considered an object
    Green or preform that needs to be machined to precision
    dimensional acceptable. [0006] Taminger and Hafley [1] reveal a method and device to manufacture structural metal parts directly from drawing data aided by computer combined with free form manufacturing
    electron beam (EBF). The structural part is constructed by welding in successive layers of a metallic welding wire that is welded by the heat energy supplied by the
    Petition 870180154878, of 11/26/2018, p. 30/55
    3/20 electron beam. The process is shown schematically in figure 1, which is a copy of figure 1 in [1]. The EBF process involves feeding a metal wire into a pool of fusion made and maintained by an electron beam focused in a high vacuum environment. The positioning of the electron beam and welding wire is obtained by having the electron beam gun and the positioning system (the support substrate) movably articulated along one or more geometric axes (Z, Y, Z and rotation) and regulate the position of the electron beam gun and the supporting substrate by a four-axis motion control system. The process is claimed to be almost 100% efficient in material use and 95% efficient in energy consumption. The method can be used for both bulk metal deposits and finer detailed deposits, and the method is claimed to have a significant effect on reducing marginal time and lower machining and material costs compared to the conventional approach of machining parts of metal. The electron beam technology has a disadvantage of being dependent on a high vacuum of 10 -1 Pa or less in the deposit chamber.
    [0007] It is known to use a plasma arc to provide heat for welding metallic materials. This method can be used at atmospheric or higher pressures, and thus allows for simpler and cheaper process equipment. Such a method is known as gas tungsten arc welding (GTAW, also referred to as TIG) where a transferred arc plasma is formed
    Petition 870180154878, of 11/26/2018, p. 31/55
    4/20 between a non-consumable tungsten electrode and the welding area. The plasma arc is normally protected by a gas being fed through the plasma torch that forms a protective cover around the arc. TIG welding can include feeding a metal wire or metal powder into the plasma melting pool as a filler.
    [0008] From US 2010/0193480 it is known to use a TIG welding torch to build objects by solid free form manufacturing (SFFF), where successive layers of low feed ductile metal loading material are applied over a substrate. The plasma flow is created by energizing a flow gas using an arc electrode, the arc electrode having a variable magnitude current supplied to it. The plasma flow is directed to a predetermined target region to preheat the predetermined target region prior to deposit. The current is adjusted and the feed charge material is introduced into the plasma stream to deposit molten feed stock in the predetermined target region. The current is adjusted and the molten feed stock is slowly cooled to a high temperature, typically above the brittle to ductile transition temperature of the feed load material, in a cooling phase to minimize the occurrence of material stresses.
    [0009] Another example is US 2006/185473 which reveals the use of TIG torch in place of the expensive laser traditionally used in a free-form manufacturing process
    Petition 870180154878, of 11/26/2018, p. 32/55
    5/20 solid (SFFF) with relatively low cost feed material by combining titanium feed and alloying components in a way that considerably reduces the cost of raw materials. More particularly, in one aspect the present invention employs pure titanium wire (CP Ti) which is lower in cost than alloy formed wire, and combines CP Ti wire with powder alloying components on site in the process SFFF for combining CP Ti wire and powder alloying components in the melting of the welding torch or other high-power energy beam. In another embodiment, the invention employs titanium sponge material mixed with alloying elements and formed on a wire where it can be used in an SFFF process in combination with a plasma welding torch or other high power energy beam for produce titanium components in a liquid-like format.
    [00010] Titanium metal or titanium alloys heated above 400 ° C can be subjected to oxidation after contact with oxygen. Thus, it is necessary to protect the solder and heated object that is being formed by making layers against oxygen in the ambient atmosphere.
    [00011] A solution to this problem is known from WO 2011/0198287 which discloses a method for increasing the deposit rate by performing the manufacture of objects by solid freeform fabrication, especially titanium and titanium alloy objects, in a chamber reactor that is closed to the ambient atmosphere. For making the camera
    Petition 870180154878, of 11/26/2018, p. 33/55
    6/20 deposit sufficiently free of oxygen, the need to employ protective measures to avoid oxidizing the newly welded area by atmospheric atmospheric oxygen is no longer present, so that the welding process can proceed at a greater speed once the Welded probe can be allowed to have a higher temperature without risking excessive oxidation of the weld. For example, in the production of titanium or titanium alloy objects, there is no longer a need to cool the welded zone below 400 ° C to prevent oxidation.
    [00012] Another solution to increase the deposit rate is known from US 6,268,584 which reveals a deposit head assembly consisting of the following characteristics: a set of outlet powder nozzles to create a converging flow of powder into the deposit region , a central orifice that allows multiple beams to be focused on the deposit substrate, and coaxial gas flow to each of the powder nozzles to concentrate the flow of powders from those nozzles to provide a longer working distance between the nozzle and the deposit head assembly. The longest working distance is critical to ensure that molten metal particulate materials are not attached to the deposit device during processing. In particular, the invention includes a piping system designed into the deposit head assembly that can use more than one laser beam simultaneously for the deposit process. The deposit head assembly also incorporates a means to actively concentrate the powder flow from each orifice
    Petition 870180154878, of 11/26/2018, p. 34/55
    7/20 to increase material usage efficiency.
    [00013] WO 2006/133034 discloses the use of laser welding and combined gas metal arc to solve the problems associated with the reactive nature of Ti and its fused characteristics that make it very difficult to form DMD products. Gas metal arc techniques have several disadvantages that severely limit their application in Ti deposit. These disadvantages include instabilities in metal transfer, excessive splashing, and little control of the deposited layer shape, and high heat input that causes distortion of thin sections during deposit. Also, an increase in productivity is not possible due to the wandering of the cathode point that occurs during deposit. The solution to these problems according to WO 2006/133034 is a direct metal deposition process comprising the steps of providing a substrate and depositing a metal from a metal feed charge on the substrate. An electric arc is generated between the metal feed stock and the substrate and the arc is exposed to laser radiation to form a molten metal bath in the substrate. The molten metal bath is cooled to form a first layer of solid metal on the substrate.
    Purpose of the invention [00014] The main purpose of the invention is to provide a device for constructing metal by making solid free form.
    [00015] Another objective of the invention is to provide a method for rapid layer manufacturing of objects in
    Petition 870180154878, of 11/26/2018, p. 35/55
    8/20 titanium or titanium alloys.
    Description of the invention [00016] The invention is based on the perception that the deposit rate can be increased by supplying the metallic feed material in the form of a wire and employing two arcs transferred by gas, a plasma by arc transferred to heat the area of deposit in the base material and an arc plasma transferred to heat and fuse the feed wire.
    [00017] Thus in a first aspect, the present invention relates to a method for making a three-dimensional object from a metallic material by solid free-form fabrication, where the object is made by melting successive deposits of the metallic material on a substrate together retention,
    Characterized by the fact that the method comprises:
    - employ a retaining substrate made of a similar metallic material as the object is to be made, and
    - each successive deposit is obtained by:
    i) employ a first transferred arc plasma (PTA) to preheat and form a pool of fusion in the base material in the position in which the metallic material is to be deposited, ii) feed the metallic material to be deposited in the form of a wire to a position above the melt pool, iii) employ a second transferred arc plasma (PTA) to heat and melt the wire such that the molten metallic material is dripping into the melt pool, and
    Petition 870180154878, of 11/26/2018, p. 36/55
    9/20 iv) move the retaining substrate in relation to the position of the first and second PTA in a predetermined pattern such that successive deposits of molten metal material solidify and form the three-dimensional object.
    [00018] In a second aspect, the invention refers to an apparatus for manufacturing a three-dimensional object from a metallic material by solid free-form fabrication, where the apparatus comprises:
    - a welding torch with an integrated wire feeder that feeds a wire of metallic material,
    - a system for positioning and moving the retaining substrate in relation to the welding torch, and
    - a control system capable of reading a computer aided design (CAD) model of the object to be formed and employing the CAD model to regulate the position and movement of the system to position and move the retaining substrate and operate the torch welding with integrated wire feeder in such a way that a physical object is constructed by melting successive deposits of metallic material on the retaining substrate,
    Characterized by the fact that
    - the retaining substrate is made of a metallic material similar to the object to be made,
    - the welding torch comprises
    i) a first arc plasma torch (PTA) electrically connected to the base material and ii) a second arc plasma torch
    Petition 870180154878, of 11/26/2018, p. 37/55
    10/20 transferred (PTA) electrically connected to the metallic material feed wire,
    - the control system is capable of separately operating and regulating the first PTA torch to form and maintain a pool of melt in the base material in the position in which the metallic material is to be deposited, and
    - the control system is capable of separately operating and regulating the wire feeder and the second PTA torch to melt the metallic material feed in a position such that molten metallic material drips into the melt pool.
    [00019] The term similar metallic material ”as used here means that the metallic material is of the same
    metal or alloy of metal what the material metallic of reference.[00020] O material term base ”as used here means the material target for the heat of first
    torch PTA and that the melt pool should be formed. This will be the retention substrate when depositing the first layer of metallic material. When one or more layers of metallic material have been deposited on the retaining substrate, the base material will be the upper layer of deposited metallic material that must have deposited a new layer of metallic material.
    [00021] The term transferred arc plasma torch ”or PTA torch” as used interchangeably here means any device capable of heating and exciting a plasma inert gas flow by an arc flash and then transferring the gas flow
    Petition 870180154878, of 11/26/2018, p. 38/55
    11/20 plasma including the electrical arc out through an orifice (nozzle) to form a contracted plume that extends out of the orifice and transfers the intense heat from the arc to a target region. The electrode and target region is electrically connected to a direct current power source in such a way that the PTA torch electrode becomes the cathode and the target region becomes the anode. This will ensure that the plasma plume including electric arc is providing a highly concentrated heat flow to a small surface area of the target region with excellent control of the sand extension and magnitude of the heat flow being supplied from the PTA torch. A transferred arc plasma has the advantage of providing stable and consistent arcs with little wander and good tolerance for deviations in length between the cathode and anode. In this way, the PTA torch is suitable both to form a melt pool in the base material and to heat and melt the wire feed. The PTA torch can advantageously have an electrode made of tungsten and a nozzle made of copper. However, the invention is not linked to any specific choice or type of PTA torch. Any known or conceivable device capable of functioning as a PTA torch can be applied.
    [00022] The use of a first separately controlled PTA torch to preheat the base material and form the melt pool and a second PTA torch separately to melt the metallic material feed wire provides the advantage that it is possible to increase the supply of heat for feeding the metal wire
    Petition 870180154878, of 11/26/2018, p. 39/55
    12/20 regardless of the heat supply to the substrate in such a way that it becomes possible to increase the heat flow in the feed material without risk of creating a spray arc ”that generates splashing. In this way, it is possible to
    increase the deposit rate of the feed material metallic melted without simultaneously overheating the
    substrate and without risk of splashing or forming a pool of excessive melting and thus loosen control of the consolidation of the deposited material. This characteristic is obtained by connecting a current source of energy
    to be continued such that the electrode of the first torch
    PTA becomes negative polarity and the base material becomes
    make the positive polarity to define a circuit electric where electric charge is transferred by a discharge bow between the electrode of the first PTA torch and the material base and by connecting the second electrode torch PTA to the negative pole of a power source of chain continuous and the material feed wire metallic to the positive pole to form a circuit electric where the electrical charge is transferred by a discharge between the electrode of the second torch PTA and the wire of feeding of metallic material.
    [00023] The first and second PTA torches can advantageously have separate energy sources and means to regulate the energy supply for the respective torches. The means for regulating the energy can advantageously include means for monitoring the temperature of the deposit area of the base material and means for regulating the width and positioning of the air, such as deflection means
    Petition 870180154878, of 11/26/2018, p. 40/55
    13/20 magnetic arc. In addition, the first PTA torch used to form the melt pool in the base material can advantageously form a wide arc, such as, for example, an arc welding torch with tungsten electrode and gas protection (torch-GTAW, also indicated as TIG torch in the literature) to form a melt pool over a wider area of the base material surface.
    [00024] The term computer-aided design model ”or CAD model” as used interchangeably here means any known or conceivable virtual three-dimensional representation of the object that must be formed that can be used in the apparatus control system according to the second aspect of the invention: regulating the position and movement of the retaining substrate and operating the welding torch with an integrated wire feeder in such a way that a physical object is constructed by melting successive deposits of metallic material onto the retaining substrate in a pattern that results in the construction of a physical object according to the virtual three-dimensional model of the object. This can be achieved, for example, by forming a virtual vectorized layered model of the three-dimensional model by first dividing the virtual three-dimensional model into a set of virtual parallel layers and then dividing each of the parallel layers into a set of virtual almost one-dimensional pieces. Next, the physical object can be formed by engaging the control system to deposit and merge a series of almost one-dimensional pieces of the power supply.
    Petition 870180154878, of 11/26/2018, p. 41/55
    14/20 metallic material on the support substrate in a pattern according to the first layer of the virtual vectorized layered model of the object. Then, repeat the sequence for the second layer of the object by depositing and fusing a series of almost one-dimensional pieces of the weldable material on the previous deposited layer in a pattern according to the second layer of the virtual vectorized layered model of the object. The repetition continues the deposit and fusion process layer by layer for each successive layer of the virtual vectorized layered model of the object until the entire object is formed. However, the invention is not linked to any specific CAD model and / or computer software to run the control system of the apparatus according to the invention, nor is the invention linked to any specific type of control system. Any known or conceivable control system (CAD model, computer software, computer hardware and drivers, etc.) capable of constructing three-dimensional metallic objects by solid freeform fabrication can be employed as long as the control system is adjusted to operate separately a first PTA torch to form the melt pool and a second PTA torch to melt the metallic material feed wire in the melt pool.
    [00025] The feed rate (wire speed) and positioning of the metallic material feed wire can be advantageously controlled and regulated according to the effect of power supply to the second PTA torch to ensure that the wire is being
    Petition 870180154878, of 11/26/2018, p. 42/55
    15/20 continuously heated and melted when reaching the desired position above the melt pool in the base material. This can be achieved using a conventional gas metal arc welding torch (GMAW torch, also indicated MIG torch) as a wire feeder without forming an arc in the MIG torch. This modality of the wire feeder has the advantage of being able to electrically connect the wire to the DC power supply of the second torch PTA and also to position the wire very precisely. The metallic material feed wire can be of virtually any implementable dimension, such as 1.0 mm, 1.6 mm, 2.4 mm, etc.
    [00026] The term metallic material ”as used here means any known or conceivable metal or metal alloy that can be formed into a wire and employed in a solid free-form manufacturing process to form a three-dimensional object. Examples of suitable materials include, but are not limited to, titanium and titanium alloys, such as, for example, Ti-6Al-4V alloys.
    [00027] The effect provided to the first and second PTA torches will depend on which metallic material is being applied, the diameter of the feed wire, the heat tolerances of the base material, the deposit rate, etc. The invention is therefore not linked to any specific power supply window, but it can apply any potential difference in practical and current operation that results in an operation operation of the first and second torch PTA. A person skilled in the art will be able to find these parameters by experiment tests and
    Petition 870180154878, of 11/26/2018, p. 43/55
    16/20 error. The experiments carried out by the applicant showed that by using a 1.6 mm diameter wire made of type 5 titanium alloy, three-dimensional objects with similar mechanical properties can be constructed as conventional titanium objects at a deposit rate of 3.7 to 3.8 kg / hour when the first PTA torch is supplied with around 150 A and the second PTA torch is supplied with around 250 A. It is believed that deposit rates up to 10 kg / hour can be obtained by executing the deposit SFFF according to the first and second aspects of the invention in an atmosphere of effective protection, such as, for example, in the reaction chamber disclosed in WO 2011/0198287. This is confirmed by another experiment carried out by the applicant with a wire diameter of 2.4 mm, titanium type 5, which provided a deposit rate of 9.7 kg / h by supplying the first PTA torch with a current of around 250 A and to the second torch PTA a current of around 300 A.
    [00028] As an alternative, the invention may also include a means to create thermal pulses in the melt pool to break up growth trends of crystalline dendrites in the melt pool. This characteristic allows to form metallic objects with increased mechanical properties due to an improved grain structure. Thermal pulsation can be achieved by employing a third DC power generator that distributes a pulsed DC potential and connects the negative pole of the DC power generator to the electrode of the second torch PTA and the positive pole of the base material to form a circuit electrical where electric charge is transferred by an arc discharge
    Petition 870180154878, of 11/26/2018, p. 44/55
    17/20 pulsation between the electrode of the second torch PTA and the base material. The arc discharge between the electrode of the second torch PTA and base material will be connected and discharged according to the applied pulsation DC potential and thus form a pulsating heat flow in the melt pool in the base material. The pulse frequency can be in the range of 1 Hz to several kHz or more, that is, 10 kHz.
    List of figures [00029] Figure 1 is a copy of Figure 1 by Taminger and Hafley [1] showing a schematic view of the solid free form manufacturing principle.
    [00030] Figure 2 is a copy of Figure 1 of US 2006/0185473 showing a schematic view of the principle of manufacturing freeform solid plasma by transferred arc.
    [00031] Figure 3 is a schematic drawing showing a cross-sectional view of the apparatus according to the second aspect of the present invention.
    [00032] Figure 4 is a schematic drawing showing a cross-sectional view of a second embodiment of the invention including thermal pulsation.
    Example modalities of the invention [00033] The invention will be explained in more detail by means of example modalities. These examples should not be interpreted as limiting the general scope of the inventive idea of using two PTA torches, one to form the melt pool in the base material and one to melt the feed material.
    Petition 870180154878, of 11/26/2018, p. 45/55
    18/20
    First example embodiment [00034] The first example embodiment of the apparatus according to the second aspect of the invention is shown schematically in figure 3. The figure shows a retaining substrate 1 made of a Ti-6A1-4V bond shaped like a cuboid rectangular, on which a three-dimensional object made of the same Ti-6A1-4V alloy must be formed by solid free-form fabrication. The figure shows the initial part of the deposition process where the first Ti-6A1-4V alloy welding stripe 2 is being deposited.
    [00035] A wire 3 made of Ti-6A1-4V alloy is being continuously supplied by a wire feeder 4 that positions wire 3 such that its distal end is located above the melt pool 5 in the deposit area on the substrate holding rate 1. The wire 3 receives a speed indicated by the upper arrow in the figure that corresponds to the rate of heating and melting of the distal end in such a way that droplets 6 of molten wire are being continuously supplied to the melting pool 5.
    [00036] A first transferred arc plasma 7 is formed by a PTA torch 8 which is electrically connected to a DC power source 9 such that electrode 10 of the PTA torch becomes the cathode and the retaining substrate 1 the anode . The transferred arc plasma 7 is continuous and directed to heat and melt the base material (which at this stage of the SFFF process is the retention substrate) at the deposit point such that the melt pool 5 is obtained. The effect of the DC 9 power source is set to
    Petition 870180154878, of 11/26/2018, p. 46/55
    19/20 maintain a pool of fusion 5 with a constant size and extension by a control system (not shown). The PTA 8 torch is a gas tungsten arc welding torch (GTAW) equipped with a magnetic arc deflector (not shown) to control the size and position of the arc 8.
    [00037] A second transferred arc plasma 11 is formed by a PTA torch 12 which is electrically connected to a DC 13 power source in such a way that the electrode 14 of the PTA 12 torch becomes the cathode and the supply wire 3 o anode. The transferred arc plasma 11 is continuous and directed to heat and fuse the distal end of the wire 3. The effect of the DC 13 power phone is regulated to maintain a heating and melting rate according to the feed speed of the wire. so that droplet formation 6 is regulated to maintain a continuous dripping of molten wire into the melt pool 5. The effect provided by DC power source 13 and the feed speed of wire 3 exiting wire feeder 5 are constantly regulated and controlled by the control system in such a way that the melt pool 5 is supplied with molten wire at a rate that provides the desired deposit rate of the Ti-6A1-4V alloy. The control system is simultaneously engaged to operate and adjust the engagement of a driver (not shown) that constantly positions and moves the retaining substrate 1 such that the melt pool is located at the desired deposit point as given by the CAD model of the object that must be formed. At this stage of the SFFF process, the substrate of
    Petition 870180154878, of 11/26/2018, p. 47/55
    20/20 hold 1 is moved as indicated by the bottom arrow.
    Second example embodiment [00038] The second example embodiment of the invention is the first example embodiment given above including additional means for forming thermal pulses in the melt pool 5.
    [00039] The means for forming thermal pulses is a source of DC power 15 which is electrically connected to the second torch PTA 12 such that electrode 14 becomes the cathode and the retaining substrate 1 becomes the anode. In addition, there are means 16 for pulsating the energy distributed by the DC power source 15 such that the arc 11, in addition to heating and melting the wire 3, will enter the melting pool 5 with the same frequency as the pulsed energy supply and in this way it will provide a pulsating heat flow to the melt pool. The medium 16 can be regulated by the control system and provides a pulsating arc discharge in the melt pool with a frequency of 1 kHz.
    Reference [00040] Taminger, K.M. and Hafley, RA, Electron beam freeform fabrication for cost effective near-net shape manufacturing ”, NATO / RTOAVT - 139 Specialists' Meeting on cost effective manufacture via net shape processing (Amsterdam, Netherlands, 2006) (NATO), pages 9-25 , http://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/200800 13538_2008013396.pdf
    权利要求:
    Claims (6)
    [1]
    1. Method for making a three-dimensional object from a metallic material by solid free-form fabrication, where the object is made by melting successive deposits of the metallic material together on a retention substrate (1), the method being characterized by the fact that it comprises :
    - employ a retaining substrate (1) made of a similar metallic material as the object is to be made, and
    - each successive deposit is obtained by:
    i) employ a first transferred arc plasma (7) (PTA) to preheat and form a pool of fusion (5) in the base material in the position in which the metallic material is to be deposited, ii) feed the metallic material to be deposited in the form of a wire fed (3) of the metallic material to a position above the melt pool (5), iii) employ a second transferred arc plasma (11) (PTA) to heat and melt the fed wire (3 ) of the metallic material in such a way that the molten metallic material is dripped into the melting pool (5), and iv) moving the retaining substrate (1) in relation to the position of the first and second PTA in a predetermined pattern such that successive deposits of molten metallic material solidify and form the three-dimensional object.
    [2]
    2, characterized by the fact that the second arc plasma is used to distribute thermal pulses to the melting pool (5) by electrically connecting the electrode of the plasma torch by transferred arc (torch)
    PTA) for the negative pole of a DC power source (15) and the base material for the positive pole of the DC power source (15), and pulse the DC power (15) with a frequency in the range of 1 Hz to 10 kHz.
    6. Apparatus for a metallic material to manufacture a three-dimensional object by manufacturing solid free form, where the apparatus comprises:
    Petition 870180154878, of 11/26/2018, p. 51/55
    2/6 by an arc welding torch with tungsten electrode and gaseous protection (torch-GTAW) electrically connected to a direct current power source (9) in such a way that the electrode (10) of the GTAW torch becomes the cathode and the base material becomes the anode, and
    - the second transferred arc plasma (11) is formed by any conventional transferred arc plasma torch (PTA torch) electrically connected to a direct current power source (13) such that the electrode (14) of the PTA torch it becomes the cathode and the feed wire (3) of metallic material becomes the anode.
    2. Method, according to claim 1, characterized by the fact that
    - the first transferred arc plasma (7) is formed
    Petition 870180154878, of 11/26/2018, p. 49/55
    [3]
    3/6 (7, 11), and the activation of a wire feed system fed the feed wire (3) of metallic material, engage the control system to deposit a series of almost one-dimensional pieces of the feed wire ( 3) of metallic material on top of the base material in a pattern according to the first layer of the virtual vectorized layered model of the object, forming the second layer of the object by depositing and fusing a series of almost one-dimensional pieces of the supply wire (3 ) of metallic material on the previous deposited layer in a pattern according to the second layer of the virtual vectorized layered model of the object, and repeat the process of melting and depositing layer by layer for each successive layer of the virtual vectorized layered model of the object until entire object is formed.
    3. Method according to claim 1 or 2, characterized by the fact that the metallic material is titanium or titanium alloy.
    [4]
    4/6
    - a welding torch with an integrated wire feeder (4) which feeds a wire of the metallic material,
    - a system for positioning and moving the retaining substrate (1) in relation to the welding torch, and
    - a control system capable of reading a computer aided design (CAD) model of the object to be formed and employing the CAD model to regulate the position and movement of the system to position and move the retaining substrate (1), and operate the welding torch with an integrated wire feeder (4) in such a way that a physical object is constructed by melting successive deposits of metallic material on the retaining substrate (1), the apparatus being characterized by the fact that
    - the retaining substrate (1) is made of a metallic material similar to the object to be made,
    - the welding torch comprises
    i) a first transferred arc plasma torch (8) (PTA) electrically connected to the base material and ii) a second transferred arc plasma torch (12) (PTA) electrically connected to the metallic material feed wire,
    - the control system is capable of separately operating and regulating the first PTA torch (12) to form and maintain a pool of fusion (5) in the base material in the position in which the metallic material is to be deposited, and
    - the control system is capable of separately operating and regulating the wire feeder (4) and the second torch PTA to melt the metallic material feed in a position such that molten metallic material drips
    Petition 870180154878, of 11/26/2018, p. 52/55
    4. Method according to claim 1 or 2, characterized by the fact that the solid free-form fabrication of the object is obtained by characteristic dimensions of the object by:
    - employ a computer aided design tool (CAD) to form a virtual three-dimensional model of the object, divide the model into a set of virtual parallel layers and additionally a set of virtual almost one-dimensional pieces for each parallel layer to form a model in vectorized virtual object layers,
    - load the virtual vectorized layered model of the object in a control system capable of regulating the position and movement of the retaining substrate (1), the activation of the first and second plasma torches by transferred arc
    Petition 870180154878, of 11/26/2018, p. 50/55
    [5]
    5/6 into the melting pool (5).
    7. Apparatus, according to claim 6, characterized by the fact that
    - the first transferred arc plasma torch (
    8) is an arc welding torch with tungsten electrode and gas protection (torch-GTAW) that is electrically connected to a direct current power source (9) in such a way that the electrode (10) of the GTAW torch becomes the cathode and the base material becomes the anode, and
    - the second transferred arc plasma torch (12) is any conventional transferred arc plasma torch (torch-PTA) that is electrically connected to a direct current power source (13) such that the electrode (14) of the PTA torch becomes the cathode and the
    wire of food (3) of metallic material becomes O anode. 8. Apparatus, wake up with claim 6 or 7, characterized by fact of that the power source in
    direct current from the GTAW torch and PTA torch are two independently regulated DC power sources.
    9. Apparatus according to claim 6 or 7, characterized by the fact that
    - O wire feeder (4) is a MIG torch and - O wire of food (3 ) in metallic material is made of titanium or titanium formed per league and has one diameter of one of: 1.0, 1.6 and 2 , 4 mm.10. Females, accordingwith the claim 7,
    characterized by the fact that
    Petition 870180154878, of 11/26/2018, p. 53/55
    5. Method, according to claim
    [6]
    6/6
    - the electrode (4) of the second transferred arc plasma torch (12) is electrically connected to the negative pole of a direct current energy source (5) and the base material is electrically connected to the positive pole of the energy source of direct current ('15), and
    - the potential of the DC power source (15) is pulsed with a frequency in the range of 1 Hz to 10 kHz.
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    同族专利:
    公开号 | 公开日
    US10421142B2|2019-09-24|
    ES2564850T3|2016-03-29|
    WO2012134299A2|2012-10-04|
    EP2691197A2|2014-02-05|
    EA201391415A1|2014-03-31|
    JP2014512961A|2014-05-29|
    JP6211156B2|2017-10-11|
    US11213920B2|2022-01-04|
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    US20160318130A1|2016-11-03|
    CA2831221A1|2012-10-04|
    WO2012134299A3|2013-01-03|
    GB201105433D0|2011-05-18|
    CN103476523B|2016-04-20|
    JP2016193457A|2016-11-17|
    BR112013025043A2|2016-12-27|
    SG193965A1|2013-11-29|
    AU2012233752A1|2013-10-17|
    KR20140038958A|2014-03-31|
    US20170001253A1|2017-01-05|
    EA024135B1|2016-08-31|
    EP2691197B1|2015-12-30|
    CA2831221C|2021-01-12|
    JP5996627B2|2016-09-21|
    BR112013025043B8|2020-05-19|
    US20140061165A1|2014-03-06|
    AU2012233752B2|2017-04-06|
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    法律状态:
    2018-08-28| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|
    2019-01-29| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2019-04-02| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 30/03/2012, OBSERVADAS AS CONDICOES LEGAIS. (CO) 20 (VINTE) ANOS CONTADOS A PARTIR DE 30/03/2012, OBSERVADAS AS CONDICOES LEGAIS |
    2020-05-19| B16C| Correction of notification of the grant [chapter 16.3 patent gazette]|Free format text: REF. RPI 2517 DE 02/04/2020 QUANTO ENDERECO. |
    优先权:
    申请号 | 申请日 | 专利标题
    GB1105433.5|2011-03-31|
    GB1105433.5A|GB2489493B|2011-03-31|2011-03-31|Method and arrangement for building metallic objects by solid freeform fabrication|
    PCT/NO2012/000033|WO2012134299A2|2011-03-31|2012-03-30|Method and arrangement for building metallic objects by solid freedom fabrication|
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