Abstract: An assembly for rapid manufacturing of symmetrical objects by direct metal deposition is disclosed. A rotary stage provides rotational movement to an object supported by the stage around a central stage axis. Nozzles are spaced above the rotary stage for performing direct metal deposition for building an object supported by the stage. Each nozzle is independently moveable along a horizontal axis and independently pivotable, and combined, moveable along a vertical axis for providing symmetrical movement corresponding to a symmetrical deposition configuration of the object while the object is rotated around the central stage axis.

Abstract: An apparatus for performing direct material deposition upon a substrate for generating a three dimensional object includes a motion system for moving an head. The head includes a laser for generating a laser beam and a laser scanner for directing the laser beam at the substrate for generating a melt pool at the substrate. A nozzle delivers material into the melt pool generated by the laser beam for forming a bead of material upon the substrate. The laser scanner is cooperable with the motion system, which is moveable along a first path while the laser scanner is simultaneously moveable along a second path for progressively generating a bead of material deposited upon the substrate.

Abstract: A source of heat energy and a source of material for performing a material additive process upon the thin wall member is disclosed. A fixture is located relative to the thin wall element. The source of heat energy used for forming a joining member between the workpiece and the fixture to fixedly secure the fixture to the workpiece preventing the thin wall member from deforming when subject to the source of heat energy. A direct material additive process is upon the thin wall member adding material to the thin wall member to improve physical characteristics of the thin wall member. The joining member is mechanically removed from the workpiece after the work piece cools. A portion of the material is mechanically removed from the thin wall member to achieve desired dimensional characteristics.

Abstract: A method of forming a valve seat of an engine head formed from a first composition includes forming a groove at a predetermined valve seat location of a bore defined by the engine head. A source of directed heat energy preheats at least the valve seat location to about a temperature of the melting point of the first composition with the source of directed heat energy. The source of directed heat energy is infused with a material having a second composition generating a melt pool upon the groove by direct metal deposition with the melt pool including the second composition. The second composition includes a heat conductivity generally equal to a heat conductivity of the first composition for providing efficient transfer of heat energy from the first composition to the second composition.

Abstract: Direct metal deposition (DMD) is used to fabricate knife edges with extended service life. A metal alloy powder is deposited along a blank and melted with a laser beam so that the powder solidifies into a strip of material having a hardness and/or wear resistance greater than that of the starting material. The piece is then finished to produce a sharp edge in the solidified material. The powder may be melted while it is being deposited, or it may be melted after being deposited. A slot or groove may be formed in the blank with the metal alloy powder being deposited into the slot or groove. A hardened steel alloy powder is deposited onto a mild steel blank. For example, a tool steel or vanadium steel powder may be deposited onto a 1018 steel blank. An invention line-beam nozzle may be used for deposition and/or powder melting.

Abstract: A direct metal deposition (DMD) process is stabilized by monitoring the temperature and the shape of the melt pool during deposition, applying a recursive least square (RLS) model estimation algorithm to adaptively identify process characteristics in accordance with the temperature and the shape of the melt pool, and delivering the process characteristics to a generalized predictive controller with input constraints to control the process. The process may be controlled by adjusting laser power or by adjusting the speed of the movement of the laser. In the preferred embodiment the temperature is monitored using a two-color pyrometer, and the shape of the melt pool is monitored by detecting the edge of the melt pool with a camera and/or photodetector.

Abstract: In a direct metal deposition system which builds up a metallic overlay on a substrate by moving the substrate relative to a laser in a metallic powder feed, the laser power is adjusted for successive layers by sensing the weld pool in a plurality of selected points in each layer and adjusting the power during successive layers to maintain a weld pool that corresponds to those achieved during deposition of a lower optimal layer. This compensates for heating of the substrate resulting from the deposition which tends to increase the pool size or temperature in the higher layers.

Abstract: A direct-metal deposition (DMD) processing stage and a 5DOF (degree of freedom) dry micro-EDM (mEDM) stage are integrated to provide the submicron scale resolution necessary for the ultra-precision processing of work pieces. The DMD processing stage includes optical feedback for dimensional control utilizing a high-power, fiber-coupled diode laser with fast response time and small beam parameter product. The electrical discharge machining (EDM) stage is a dry EDM stage using an inert gas with appropriate dielectric properties to perform the surface finishing operations. The system further includes one or more surface treatment operations to obtain a desired level of surface hardness or wear resistance and/or to minimize the distortion induced in treating the surface.