Granted Patent B2

US 7,977,599 · App. 11/947,252 · Granted Jul 12, 2011

Abstract

Claims (23)

1. An erosion resistant torch for use in a solid free form fabrication system for manufacturing a component from successive layers of metal feedstock material, the erosion resistant torch comprising:

a torch structure including an outer wall and a torch nozzle, the torch nozzle comprised of copper and having an exterior surface and an interior surface, the exterior surface and the outer wall defining a coaxial channel, the interior surface defining a gas flow channel and an orifice, the orifice having an inner diameter less than an inner diameter of the gas flow channel and the coaxial channel, and at least a portion of the coaxial channel surrounding the gas flow channel;

an arc electrode disposed within the gas flow channel and configured to emit energy via the orifice as a high velocity constricted energy stream; and

rhenium disposed on at least a portion of the interior surface of the torch nozzle.

2. The erosion resistant torch of claim 1 , wherein the rhenium is a coating layer disposed on the interior surface of the torch nozzle.

3. The erosion resistant torch of claim 1 , wherein the rhenium is a coating layer disposed on an intermediate bonding layer, the intermediate bonding layer disposed on the interior surface of the torch nozzle.

4. The erosion resistant torch of claim 1 , wherein the rhenium is an insert positioned within the orifice defined in the torch nozzle.

5. An erosion resistant torch for use in an ion fusion fabrication system for manufacturing a component from successive layers of metal feedstock material, the erosion resistant torch comprising:

a torch structure including an outer wall and a torch nozzle, the torch nozzle comprised of copper and having an exterior surface and an interior surface, the exterior surface and the outer wall defining a coaxial channel, the interior surface defining a gas flow channel and an orifice, the orifice having an inner diameter less than an inner diameter of the gas flow channel and the coaxial channel, and at least a portion of the coaxial channel surrounding the gas flow channel;

an arc electrode disposed within the gas flow channel and configured to emit energy via the orifice as a high velocity constricted energy stream;

rhenium disposed on at least a portion of the interior surface of the torch nozzle; and

a bonding material disposed between the rhenium and the torch nozzle to bond the rhenium to the torch nozzle.

6. The erosion resistant torch of claim 5 , wherein the rhenium is a coating disposed on the bonding material, the bonding material disposed as a coating on the interior surface of the torch nozzle.

7. The erosion resistant torch of claim 5 , wherein the rhenium is an insert positioned within the orifice defined in the torch nozzle.

8. A solid free form fabrication system for manufacturing a component from successive layers of a metal feedstock material, the system comprising:

an erosion resistant torch positioned to emit an energy stream in an energy path;

a feedstock feed mechanism operable to feed the metal feedstock material into the energy path and deposit the metal feedstock material into a predetermined region to form the successive layers of the metal feedstock material;

a positioning arm coupled to the energy stream and the feedstock feed mechanism to form a deposition head, whereby the positioning arm is positionable to align the deposition head with a targeted region to fabricate a three-dimensional structure by transferring the metal feedstock material from the feedstock feed mechanism to the targeted region in a controlled manner by melting the metal feedstock material at a deposition point and allowing it to re-solidify at the targeted region; and

a control platform coupled to the positioning arm, the control platform including a plurality of control components, whereby a plurality of customizable control parameters are input into the plurality of control components and provide positioning and repositioning of the positioning arm and operation of the deposition head;

wherein the erosion resistant torch comprises:

a torch structure including an outer wall and a torch nozzle, the torch nozzle comprised of copper and having an exterior surface and an interior surface, the exterior surface and the outer wall defining a coaxial channel, the interior surface defining a gas flow channel and an orifice, the orifice having an inner diameter less than an inner diameter of the gas flow channel and the coaxial channel, and at least a portion of the coaxial channel surrounding the gas flow channel;

an arc electrode disposed within the gas flow channel and configured to emit energy via the orifice as a high velocity constricted energy stream; and

rhenium disposed on at least a portion of the interior surface of the torch nozzle.

Assignments (9)