System and method for metal forming and layering using inductive heating

Patent metadata

Field	Value
Publication number	US-12390878-B2
Application number	US-202117547387-A
Country	US
Kind code	B2
Filing date	Dec 10, 2021
Priority date	Dec 10, 2021
Publication date	Aug 19, 2025
Grant date	Aug 19, 2025

Abstract

The present disclosure is directed, in certain embodiments, a system for depositing material from a metal feedstock. The system includes a feedstock guide configured to guide a metal feedstock from a material feeder to extend beyond a terminal end of the feedstock guide. The system includes a ceramic collar disposed at the terminal end of the feedstock guide and configured to guide the metal feedstock extending from the terminal end of the feedstock guide to a deposition outlet of the ceramic collar. An induction coil disposed adjacent to the ceramic collar and configured to heat a portion of the metal feedstock within the ceramic collar, such that material of the metal feedstock can be deposited on a surface from the deposition end of the ceramic collar.

First claim

What is claimed is:

1. A material deposition system, comprising:
a feedstock guide comprising a plurality of ceramic bearings, the feedstock guide configured to guide a metal feedstock from a material feeder to extend beyond a terminal end of the feedstock guide;
a ceramic collar disposed at the terminal end of the feedstock guide and configured to guide the metal feedstock extending from the terminal end of the feedstock guide to a deposition outlet of the ceramic collar; and
at least one induction coil disposed adjacent to the ceramic collar and configured to:
heat a portion of the metal feedstock surrounded by the ceramic bearings; and
allow material of the metal feedstock to be deposited on a surface from the deposition end of the ceramic collar.

2. The system of claim 1 , further comprising a drive system configured to rotate the metal feedstock when the at least one induction coil is powered.

3. The system of claim 2 , wherein the material feeder is configured to store the metal feedstock and release the metal feedstock at a controlled rate when the drive system rotates the metal feedstock.

4. The system of claim 1 , further comprising:
a movable table configured to hold a substrate on which the material of the metal feedstock is deposited; and
a control system configured to cause the movable table to move while the material of the metal feedstock is deposited.

5. The system of claim 1 , further comprising an infrared thermometer configured to measure a temperature of the heated portion of the metal feedstock.

6. The system of claim 5 , further comprising a control system configured to:
receive the temperature measured by the infrared thermometer; and
adjust power provided to the induction coil based on a comparison of the temperature and a target temperature.

7. The system of claim 1 , wherein the metal feedstock is a metal or alloy wire.

8. The system of claim 1 , wherein the material of the metal feedstock is an alloy with a softening temperature of 1500° F. or greater.

9. A material deposition system, comprising:
a feedstock guide configured to guide a metal feedstock from a material feeder to extend beyond a terminal end of the feedstock guide;
a ceramic guide comprising an integrated ceramic collar disposed around the metal feedstock extending from the terminal end of the feedstock guide and extending at least partially around a plurality of ceramic bearings configured to guide the metal feedstock extending from the terminal end of the feedstock guide to a deposition outlet of the ceramic collar; and
at least one induction coil disposed adjacent to the ceramic collar and configured to:
heat a portion of the metal feedstock surrounded by the ceramic bearings; and
allow material of the metal feedstock to be deposited on a surface from the deposition end of the ceramic collar.

10. The system of claim 9 , further comprising a drive system configured to rotate the metal feedstock when the at least one induction coil is powered.

11. The system of claim 10 , wherein the material feeder is configured to store the metal feedstock and release the metal feedstock at a controlled rate when the drive system rotates the metal feedstock.

12. The system of claim 9 , further comprising:
a movable table configured to hold a substrate on which the material of the metal feedstock is deposited; and
a control system configured to cause the movable table to move while the material of the metal feedstock is deposited.

13. The system of claim 9 , further comprising:
an infrared thermometer configured to measure a temperature of the heated portion of the metal feedstock; and
a control system configured to:
receive the temperature measured by the infrared thermometer; and
adjust the power provided to the induction coil based on a comparison of the temperature and a target temperature.

14. The system of claim 9 , wherein the metal feedstock is a metal or alloy wire.

15. The system of claim 9 , wherein the material of the metal feedstock is an alloy with a softening temperature of 1500° F. or greater.

16. A method of depositing material from a metal feedstock, the method comprising:
forcing a metal feedstock through a ceramic collar comprising a plurality of ceramic bearings;
contacting the metal feedstock extending from a deposition end of a ceramic collar to a surface;
inductively heating a portion of the metal feedstock surrounded by the ceramic bearings; and
while inductively heating the portion of the metal feedstock, rotating the metal feedstock, thereby depositing material of the metal feedstock on the surface.

17. The method of claim 16 , further comprising releasing the metal feedstock from a material feeder at a controlled rate while rotating the metal feedstock.

18. The method of claim 16 , further comprising moving a table holding the surface while the material of the metal feedstock is deposited on the surface.

19. The method of claim 16 , further comprising:
measuring a temperature of the heated portion of the metal feedstock; and
adjusting an amount of induction heating provided to the portion of the metal feedstock within the ceramic collar based on a comparison of the measured temperature and a target temperature.

20. The method of claim 16 , further comprising heating the portion of the metal feedstock within the ceramic collar by providing power to an induction coil positioned adjacent to the ceramic collar.

Assignees

• Lockheed Corp

Inventors

• Sargent Kenneth Robert
• Clark William Kenneth

Classifications

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B23K35/327 Primary

  comprising refractory compounds, e.g. carbides · CPC title