Rapid manufacturing process of ferrous and non-ferrous parts using plasma electron beam

Patent metadata

Field	Value
Publication number	US-10279420-B2
Application number	US-201615333539-A
Country	US
Kind code	B2
Filing date	Oct 25, 2016
Priority date	Oct 28, 2015
Publication date	May 7, 2019
Grant date	May 7, 2019

Abstract

Provided is a rapid manufacturing process of ferrous and non-ferrous parts using a plasma electron beam in which the plasma electron beam is workable even in a low vacuum pressure environment and has a relatively large radiation range, productivity of the process is improved as a high-power beam can be emitted to a ferrous and non-ferrous powder, and production costs are reduced due to low maintenance and manufacturing costs.

First claim

What is claimed is:

1. A rapid manufacturing process of ferrous and non-ferrous parts using a plasma electron beam, the process comprising:
a first supply step of supplying a ferrous and non-ferrous powder onto a laminated plate;
a first preheating step of preheating, by a plasma electron beam, the ferrous and non-ferrous powder supplied onto the laminated plate;
a first melting and laminating step of melting and laminating the ferrous and non-ferrous powder by emitting a plasma electron beam to a part of the preheated ferrous and non-ferrous powder so that a ferrous and non-ferrous layer is formed on the laminated plate when the first preheating step is completed; and
a multi-layer laminating step of laminating a plurality of ferrous and non-ferrous layers so that parts having a predetermined shape are formed by repeating steps of supplying, preheating, and melting and laminating the ferrous and non-ferrous powder on the ferrous and non-ferrous layer,
wherein the multi-layer laminating step includes:
a second supply step of supplying the ferrous and non-ferrous powder onto the ferrous and non-ferrous layer so that a powder layer made of the ferrous and non-ferrous powder is formed on the ferrous and non-ferrous layer;
a second preheating step of preheating the powder layer when the second supply step is completed;
a second melting and laminating step of melting a part of the powder layer by emitting the plasma electron beam to the part of the powder layer so that another ferrous and non-ferrous layer is formed on the ferrous and non-ferrous layer when the second preheating step is completed; and
a repeating step of repeating the second supply step, the second preheating step, and the second melting and laminating step so that the parts having the predetermined shape are formed on the laminated plate when the second melting and laminating step is completed; and
a remelting step of remelting the ferrous and non-ferrous layers by emitting the plasma electron beam to the ferrous and non-ferrous layers so that thicknesses of the ferrous and non-ferrous layers are uniform and a surface roughness, density, corrosion property, and hardness are improved when the second melting and laminating step of the multi-layer laminating step is completed or the repeating step is completed.

2. A rapid manufacturing process of ferrous and non-ferrous parts using a plasma electron beam, the process comprising:
a first supply step of supplying a ferrous and non-ferrous powder onto a laminated plate;
a first preheating step of preheating, by a plasma electron beam, the ferrous and non-ferrous powder supplied onto the laminated plate;
a first melting and laminating step of melting and laminating the ferrous and non-ferrous powder by emitting a plasma electron beam to a part of the preheated ferrous and non-ferrous powder so that a ferrous and non-ferrous layer is formed on the laminated plate when the first preheating step is completed; and
a multi-layer laminating step of laminating a plurality of ferrous and non-ferrous layers so that parts having a predetermined shape are formed by repeating steps of supplying, preheating, and melting and laminating the ferrous and non-ferrous powder on the ferrous and non-ferrous layer,
wherein the multi-layer laminating step includes:
a second supply step of supplying the ferrous and non-ferrous powder onto the ferrous and non-ferrous layer so that a powder layer made of the ferrous and non-ferrous powder is formed on the ferrous and non-ferrous layer;
a second preheating step of preheating the powder layer when the second supply step is completed;
a second melting and laminating step of melting a part of the powder layer by emitting the plasma electron beam to the part of the powder layer so that another ferrous and non-ferrous layer is formed on the ferrous and non-ferrous layer when the second preheating step is completed; and
a repeating step of repeating the second supply step, the second preheating step, and the second melting and laminating step so that the parts having the predetermined shape are formed on the laminated plate when the second melting and laminating step is completed
wherein, in the second preheating step, a plasma electron beam having lower power and a wider width than power and a width of the plasma electron beam emitted to the powder layer in the second melting and laminating step is emitted to the powder layer.

3. The process of claim 1 , further comprising a checking step of checking a surface quality of the ferrous and non-ferrous layers before the remelting step, performing the remelting step when the surface quality of the ferrous and non-ferrous layers is a predetermined reference or more, and repeating the second supply step, the second preheating step, and the second melting and laminating step when the surface quality of the ferrous and non-ferrous layers is less than the predetermined reference.

4. The process of claim 1 , the repeating step further includes an additional melting step of remelting the ferrous and non-ferrous layers laminated in multiple stages by selectively emitting the plasma electron beam to the laminated ferrous and non-ferrous layers.

5. The process of claim 1 , wherein, in the second preheating step, a plasma electron beam having lower power and a wider width than power and a width of the plasma electron beam emitted to the powder layer in the second melting and laminating step is emitted to the powder layer.

Assignees

• Univ Chosun Iacf

Inventors

• Ahn Dong Gyu
• Lee Ho Jin

Classifications

• B22F12/52

  Hoppers · CPC title

• B22F10/364

  for post-heating, e.g. remelting · CPC title

• B22F10/362

  for preheating · CPC title

• B22F1/142

  Thermal or thermo-mechanical treatment · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title