Precision laser welding or sintering producing three-dimensional objects, first forms an envelope, then fills it e.g. with foamed metal, for rapid manufacture of extremely diverse complex shapes including clad turbine blades in ceramic

摘要

An envelope is constructed from a material in layers, using the cited techniques. It is filled by the same, or one or more different materials. An Independent claim is included for equipment carrying out the method, consisting essentially of a power laser moved freely, relative to a construction platform. Preferred features: During or after filling, a solid core is formed inside. The filling is a melt introduced under pressure, setting afterwards. The core is a foam. Filling is melted-on by induction or resistance heating. It is alternatively sintered or polymerized. The intervening space of a double-walled envelope is filled. With the material in the cavity, the molding is formed by polymerization, sintering or melt setting. The double walled body is made in at least two parts. On the inner wall, laser beam precision weld-coating produces bridging sections. The envelope is made from a powder or powder mixture by laser beam precision weld coating. The powder or powder mixture is selected for its influence on mechanical, thermal, electrical, magnetic or physiological characteristics. Its composition is varied to permits local modification of these characteristics. An organic compound causing degassification on heating is included in the core. The envelope surrounds a higher-melting supportive material. The laser is similarly used to construct a supportive structure inside. Filling and/or deaeration openings of the envelope are closed using the same welding technique. During layered construction, local mechanical operations are carried out. The envelope is a metal or alloy optionally containing hard material, or a ceramic. The envelope minimum thickness is 0.1 mm. The laser beam passes through a head with integral gas and powder supply, the latter having a powder layer thickness dosing unit. A mobile cutting and/or erosive unit is employed.