U.S. patent application number 17/526909 was filed with the patent office on 2022-03-10 for systems and methods for adding material to castings.
This patent application is currently assigned to CUMMINS INC.. The applicant listed for this patent is CUMMINS INC.. Invention is credited to Nikhil Doiphode, Roger D. England, Rafael Hernandez Ruiz Esparza, John A. Rupp, Howard S. Savage, Todd M. Wieland.
Application Number | 20220072616 17/526909 |
Document ID | / |
Family ID | 62146709 |
Filed Date | 2022-03-10 |
United States Patent
Application |
20220072616 |
Kind Code |
A1 |
Savage; Howard S. ; et
al. |
March 10, 2022 |
SYSTEMS AND METHODS FOR ADDING MATERIAL TO CASTINGS
Abstract
A system includes a controller, a pretreating machine, and an
additive manufacturing machine. The pretreating machine is coupled
to the controller. The pretreating machine includes a pretreater
structured to form an interface layer on a component. The additive
manufacturing machine is coupled to the controller. The additive
manufacturing machine includes a material feed and a forming beam.
The material feed is configured to selectively provide a first
amount of material on the interface layer. The forming beam is
configured to substantially melt the first amount of material,
thereby forming a first layer of a first material deposit on the
interface layer.
Inventors: |
Savage; Howard S.;
(Columbus, IN) ; England; Roger D.; (Loudon,
TN) ; Wieland; Todd M.; (Columbus, IN) ;
Esparza; Rafael Hernandez Ruiz; (Cerro de San Pedro, MX)
; Doiphode; Nikhil; (Columbus, IN) ; Rupp; John
A.; (Columbus, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CUMMINS INC. |
Columbus |
IN |
US |
|
|
Assignee: |
CUMMINS INC.
Columbus
IN
|
Family ID: |
62146709 |
Appl. No.: |
17/526909 |
Filed: |
November 15, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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16461093 |
May 15, 2019 |
11203066 |
|
|
PCT/US2017/061497 |
Nov 14, 2017 |
|
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17526909 |
|
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|
|
62422976 |
Nov 16, 2016 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B22F 7/08 20130101; B23P
6/00 20130101; Y02P 10/25 20151101; B22F 10/30 20210101; B22F 12/00
20210101; B23K 26/342 20151001; B22F 10/20 20210101; B33Y 30/00
20141201; B33Y 50/02 20141201; B33Y 10/00 20141201; B23P 6/02
20130101 |
International
Class: |
B22F 10/20 20060101
B22F010/20; B33Y 10/00 20060101 B33Y010/00; B33Y 30/00 20060101
B33Y030/00; B33Y 50/02 20060101 B33Y050/02; B23K 26/342 20060101
B23K026/342; B22F 7/08 20060101 B22F007/08 |
Claims
1-24. (canceled)
25. A method for depositing material on a component, the method
comprising: forming an excavation in a target area of the
component; applying an interface layer on the excavation by flowing
the interface layer on the excavation or by spraying a thermal
spray on the excavation; and forming a first layer of a first
material deposit on the interface layer.
26. The method of claim 25, further comprising forming a first
layer of a second material deposit on the interface layer adjacent
the first material deposit.
27. The method of claim 25, further comprising forming a second
layer of the first material deposit on the first layer of the first
material deposit.
28. The method of claim 25, further comprising: forming a first
layer of a second material deposit on the interface layer adjacent
the first material deposit; and forming a second layer of the first
material deposit on the first layer of the first material deposit
after forming the first layer of the second material deposit.
29. The method of claim 25, further comprising: forming a second
layer of the first material deposit on the first layer of the first
material deposit; and forming a first layer of a second material
deposit on the interface layer adjacent the first material deposit
after forming the second layer of the first material deposit.
30. The method of claim 25, further comprising: determining a depth
of the first layer of the first material deposit; comparing the
depth to a target depth; and forming, based on the comparison of
the depth to the target depth, a second layer of the first material
deposit on the first layer of the first material deposit.
31. The method of claim 25, further comprising: determining a depth
of the first layer of the first material deposit; comparing the
depth to a target depth; and forming, based on the comparison of
the depth to the target depth, a second layer of a second material
deposit on the interface layer adjacent the first material
deposit.
32. The method of claim 25, wherein forming the first layer of the
first material deposit on the interface layer comprises forming the
first layer of the first material deposit within the
excavation.
33. The method of claim 25, further comprising analyzing the
component to determine desired changes to the component; wherein at
least one of: the excavation is formed based on the desired
changes; the interface layer is applied based on the desired
changes; or the first layer of the first material deposit is formed
based on the desired changes.
34. The method of claim 25, further comprising performing a
finishing operation on the first material deposit.
35. The method of claim 25, wherein the component is a cast
component.
36. The method of claim 25, wherein a controller causes an
excavation machine to form the excavation in the target area.
37. The method of claim 25, wherein a controller causes a
pretreating machine to apply the interface layer on the
excavation.
38. The method of claim 25, wherein a controller causes an additive
manufacturing machine to form the first layer of the first material
deposit on the interface layer.
39. The method of claim 25, further comprising: forming a first
layer of a second material deposit on the interface layer such that
the second material deposit is separated from the first material
deposit by a portion of the interface layer; forming a second layer
of the second material deposit on the interface layer such that the
second material deposit is separated from the first material
deposit by the portion of the interface layer; and forming a second
layer of the first material deposit on the interface layer such
that the first material deposit is separated from the second
material deposit by the portion of the interface layer.
40. A system comprising: a controller; an excavation machine
coupled to the controller, the excavation machine comprising an
excavator configured to selectively remove material from a
component so as to form an excavation; a pretreating machine
coupled to the controller, the pretreating machine comprising a
pretreater configured to selectively form an interface layer on the
excavation by spraying a thermal spray on the excavation; and an
additive manufacturing machine coupled to the controller, the
additive manufacturing machine configured to selectively form a
first deposit of a first amount of material on the interface
layer.
41. The system of claim 40, wherein the additive manufacturing
machine is further configured to selectively form a second deposit
of a second amount of material on the interface layer and separated
from the first deposit by a portion of the interface layer.
42. The system of claim 40, wherein the additive manufacturing
machine is further configured to selectively form a second deposit
of a second amount of material: (i) on the first deposit or (ii) on
the interface layer adjacent the first deposit.
43. The system of claim 42, wherein the interface layer has a first
thickness and the first deposit has a second thickness, the first
thickness less than the second thickness; wherein the first amount
of material comprises a first nickel-based alloy; and wherein the
second amount of material comprises a second nickel-based alloy
different from the first nickel-based alloy.
44. The system of claim 40, wherein the additive manufacturing
machine is configured to selectively form the first deposit of the
first amount of material within the excavation.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to U.S. Provisional
Patent Application No. 62/422,976, entitled "Systems and Methods
for Adding Material to Castings" and filed Nov. 16, 2016 and the
contents of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to the field of manufacturing
systems and processes for internal combustion engines and
components thereof.
BACKGROUND
[0003] There are various situations where one may perform
structural repairs or modifications on various components of a
system such as components of an internal combustion engine. For
example, with respect to components of an internal combustion
engine, a cylinder head may crack and need repair, or the engine
may be remanufactured to modify the engine for a target
application. For cast iron components, such structural repair or
modification may be performed by arc welding. However, arc welding
requires a relatively large amount of preheating and thus, a
relatively large amount of energy. Further, arc welding is
difficult to automate and instead relies upon a skilled operator,
and arc welding does not provide an ability to tailor qualities of
added material for a target application.
SUMMARY
[0004] In a first set of embodiments, a system includes a
controller, a pretreating machine, and an additive manufacturing
machine. The pretreating machine is coupled to the controller. The
pretreating machine includes a pretreater structured to form an
interface layer on a component. The additive manufacturing machine
is coupled to the controller. The additive manufacturing machine
includes a material feed and a forming beam. The material feed is
configured to selectively provide a first amount of material on the
interface layer. The forming beam is configured to substantially
melt the first amount of material, thereby forming a first layer of
a first material deposit on the interface layer.
[0005] In a second set of embodiments, a method for depositing
material on a component includes: analyzing the component to
determine desired changes to the component; forming an excavation
in a target area of the component; applying an interface layer on
the component; and forming a first layer of a first material
deposit on the interface layer.
[0006] In a third set of embodiments, a system includes a
controller, an excavation machine, a pretreating machine, and an
additive manufacturing machine. The excavation machine is coupled
to the controller. The excavation machine includes an excavator
configured to selectively remove material from a component thereby
forming an excavation. The pretreating machine is coupled to the
controller. The pretreating machine includes a pretreater
configured to selectively form an interface layer on the
excavation. The additive manufacturing machine is coupled to the
controller. The additive manufacturing machine is configured to
selectively form a first deposit of a first amount of material on
the interface layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The details of one or more implementations are set forth in
the accompanying drawings and the description below. Other
features, aspects, and advantages of the disclosure will become
apparent from the description, the drawings, and the claims.
[0008] FIG. 1 is a block diagram of an example of a system for
forming material deposits on a component according to an
embodiment.
[0009] FIG. 2 is a cross-sectional view of material being added to
a component in an example process according to an embodiment.
[0010] FIG. 3 is a cross-sectional view of material that has been
added to a component in an example process according to an
embodiment.
[0011] FIG. 4 is a top perspective view of a material deposit that
has been formed on a component in an example process according to
an embodiment.
[0012] FIG. 5 is a top perspective view of two material deposits
that have been formed on a component in an example process
according to an embodiment.
[0013] FIG. 6 is a top perspective view of three material deposits
that have been formed on a component in an example process
according to an embodiment.
[0014] FIG. 7 is a top perspective view of material deposits that
have been formed on a component in an example process according to
an embodiment.
[0015] FIG. 8 is a detailed top perspective view of material
deposits that have been formed on a component in an example process
according to an embodiment.
[0016] FIG. 9 is a top perspective view of an excavation in a
component according to an embodiment.
[0017] FIG. 10 is a top perspective view of an excavation in a
component according to an embodiment.
[0018] FIG. 11 is a top perspective view of an excavation in a
component according to an embodiment.
[0019] FIG. 12 is a block diagram of a method for forming material
deposits on a component according to an embodiment.
[0020] It will be recognized that the figures are representations
for purposes of illustration. The figures are provided for the
purpose of illustrating one or more implementations with the
explicit understanding that they will not be used to limit the
scope or the meaning of the claims.
DETAILED DESCRIPTION
[0021] In the following detailed description, reference is made to
the accompanying drawings, which form a part thereof. In the
drawings, similar symbols identify similar components unless
otherwise specified. The illustrative embodiments described in the
detailed description, drawings, and claims are not meant to be
limiting. Other embodiments may be used, and changes may be made,
without departing from the spirit or scope of the subject matter
presented here. It will be readily understood that the aspects of
the present disclosure, as generally described herein and
illustrated in the figures, can be arranged, substituted, combined,
and designed in a wide variety of different configurations which
are made part of this disclosure.
[0022] Referring generally to the figures, systems and techniques
of the present disclosure relate to forming material deposits on
components. In some embodiments, the systems and techniques relate
to forming material deposits on cast iron components, although the
disclosure is not so limited. In some embodiments, a component
(e.g., a cast iron component) can be a component of an internal
combustion engine (e.g., a diesel engine, a gasoline engine, a
natural gas engine, a propane engine, a forced induction engine, a
naturally aspirated engine, or any other internal combustion
engine). A pretreatment includes forming an interface layer on the
component, and selectively forming material deposits on the
interface layer using an additive manufacture (AM) machine. The
interface layer thermally isolates the component from the material
deposits such that the structural integrity of the material
deposits and the component is protected. In this way, the interface
layer facilitates relatively high speed formation of material
deposits as compared, for example, to arc welding.
[0023] An advantage of the interface layer is that the interface
layer is more ductile than the component, thus the interface layer
facilitates mitigation of thermal stresses in the material deposits
that occur as the material deposits cool. Without the interface
layer, there would be no thermal isolation between the material
deposits and the cast iron component. The cast iron component can
dissipate heat relatively quickly, so that, without the interface
layer, the material deposits would cool down too quickly, which
could result in undesirable cracking in a heat affected zone (HAZ)
of the material deposits.
[0024] Additionally, the material deposits as they are formed may
cause the interface layer to at least partially melt, thus
increasing a bond strength between the interface layer and the
component.
[0025] The material deposits are formed in layers; therefore a
further advantage is that it is possible that each layer of each
material deposit may be formed from a different material or may be
formed with different properties.
[0026] The systems and techniques of the present disclosure
facilitate a reduction in remanufacturing time and prototyping
time, resulting in reduced cost. Further, the systems and
techniques of the present disclosure facilitate restoration or
modification of a component without remaking or re-machining of the
entire component, which can be time and cost prohibitive. For
example, the systems and techniques of the present disclosure
facilitate modification of geometry and/or properties of a
component without creation of modified molding, recasting, or
re-machining of a new casting with desired modifications.
[0027] FIG. 1 illustrates a system 100 for adding material deposits
on a component. The system 100 includes a controller 102, an AM
machine 104, an excavation machine 106, and a pretreating machine
107.
[0028] The term "controller" encompasses all kinds of apparatus,
devices, and machines for processing data, including by way of
example a programmable processor, a computer, a system on a chip,
or multiple ones, a portion of a programmed processor, or
combinations of the foregoing. The apparatus can include special
purpose logic circuitry, e.g., an FPGA or an ASIC. The apparatus
can also include, in addition to hardware, code that creates an
execution environment for the computer program in question, e.g.,
code that constitutes processor firmware, a protocol stack, a
database management system, an operating system, a cross-platform
runtime environment, a virtual machine, or a combination of one or
more of them. The apparatus and execution environment can realize
various different computing model infrastructures, such as
distributed computing and grid computing infrastructures.
[0029] The controller 102 includes a processing circuit 108 that
includes a processor 110, a memory 112, a component analysis module
114, a forming module 116, and an input/output module 118. The AM
machine 104 includes a forming beam 120, a material feed 122, and
sensors 124. The excavation machine 106 includes an excavator 126
and sensors 128. The pretreating machine 107 includes a pretreater
130 and sensors 132.
[0030] While not shown, it is understood that any of the AM machine
104, the excavation machine 106, and the pretreating machine 107
may include a processing circuit, a processor, a memory, and any
desired modules for locally and/or collectively controlling the AM
machine 104, the excavation machine 106, or the pretreating machine
107, respectively, or for otherwise contributing to the system
100.
[0031] The term module herein refers to circuitry for performing
the functionality described. Circuitry may include analog circuit
components, digital circuit components, or a combination of analog
and digital circuit components. Further, circuitry may include
components that implement instructions from a non-transient medium
(e.g., from a memory) to perform the functionality described, where
the instructions may be hard-coded as a physical structure or
soft-coded (e.g., software instructions stored in the memory to
configure the circuit in a specific manner). Modules may be
distributed across various hardware or computer based components.
Non-limiting examples of module implementation components include
sensors providing any value determined herein, sensors providing
any value that is a precursor to a value determined herein,
datalink and/or network hardware including communication chips,
oscillating crystals, communication links, cables, twisted pair
wiring, coaxial wiring, shielded wiring, transmitters, receivers,
and/or transceivers, logic circuits, hard-wired logic circuits,
reconfigurable logic circuits in a particular non-transient state
configured according to the module specification, any actuator
including at least an electrical, hydraulic, or pneumatic actuator,
a solenoid, an op-amp, analog control elements (springs, filters,
integrators, adders, dividers, gain elements), and/or digital
control elements.
[0032] The description herein including modules emphasizes the
structural independence of the aspects of the controller 102 and
illustrates one grouping of operations and responsibilities of the
controller 102. Other groupings that execute similar overall
operations are understood to be within the scope of the present
disclosure.
[0033] In some implementations, the controller 102 forms a portion
of a processing subsystem including one or more computing devices
having memory, processing, and communication hardware. In certain
implementations, the controller 102 is structured to perform
certain operations, such as those described herein in relation to
FIGS. 2-12. The controller 102 may be a single device or a
distributed device. The controller 102 is configured to interface
(e.g., communicate) with the AM machine 104, with the excavation
machine 106, and with the pretreating machine 107. The controller
102 cooperates with the AM machine 104, the excavation machine 106,
and the pretreating machine 107 to make desired changes to a
component. For example, the processing circuit controls the AM
machine 104, the excavation machine 106, and the pretreating
machine 107 to make the desired changes.
[0034] The processor 110 may include a microprocessor, an
application-specific integrated circuit (ASIC), a
field-programmable gate array (FPGA), another type of processing
device, discrete processing circuitry, or combinations thereof. The
memory 112 may include, but is not limited to, electronic, optical,
magnetic, or any other storage or transmission device capable of
providing program instructions to the processor 110. For example,
the memory 112 may include read only memory (ROM), electrically
erasable programmable ROM (EEPROM), erasable programmable ROM
(EPROM), flash memory, or any other suitable memory from which the
processor 110 can read instructions. The instructions may include
code generated in any suitable programming language. The processor
110 may access instructions stored in the memory 112 to perform the
functionality ascribed to the processor 110. The instructions may
represent one or more computer programs.
[0035] A computer program (also known as a program, software,
software application, script, or code) can be written in any form
of programming language, including compiled or interpreted
languages, declarative or procedural languages, and it can be
deployed in any form, including as a standalone program or as a
module, component, subroutine, object, or other unit suitable for
use in a computing environment. A computer program may, but need
not, correspond to a file in a file system. A program can be stored
in a portion of a file that holds other programs or data (e.g., one
or more scripts stored in a markup language document), in a single
file dedicated to the program in question, or in multiple
coordinated files (e.g., files that store one or more modules, sub
programs, or portions of code).
[0036] The processor 110 may use the component analysis module 114
to analyze a condition of the component prior to modification. This
analysis may provide the processor 110 with a baseline shape of the
component, relative to which the desired changes will be formed.
The component analysis module 114 may cooperate with a camera, 3D
scanner, x-ray scanner, or other imaging device to obtain
information related to the component. For example, the component
analysis module 114 may facilitate scanning of the component for
flaws. Alternatively, the component analysis module 114 may receive
or retrieve information related to the component from a digital
file. For example, the component analysis module 114 may access a
digital component archive (e.g., library, database, etc.) and
retrieve a 3D model (or set of 2D models) of the component from the
archive.
[0037] The forming module 116 determines changes to be made to the
component according to information provided from the component
analysis module 114 and information regarding a desired final
component disposition. For example, the forming module 116 may
determine where material needs to be removed, where material needs
to be added, and any desired property changes relative to the
information regarding the present status of the component from the
component analysis module 114.
[0038] The input/output module or modules 118 may facilitate
interaction of the controller 102 with the AM machine 104, with the
excavation machine 106, and with the pretreating machine 107. For
example, the input/output module 118 may translate instructions
received from the processor 110 into a format that can be read by
the AM machine 104, the excavation machine 106, or the pretreating
machine 107. Additionally, the input/output module 118 may provide
information to an operator or receive commands from an operator
through a user interface (not shown). For example, the input/output
module 118 may provide the operator with a 3D view of the component
illustrating the desired changes to be made to the component. In
another example, the input/output module 118 may receive desired
changes to the component from the operator. For example, the
operator may change dimensions, properties, and/or other
characteristics of the desired changes on a monitor and the
input/output module 118 may convey these changes to the forming
module 116. The input/output module 118 in some embodiments may
also facilitate operator selection (e.g., via a touch screen, etc.)
of a 3D model of the component within the archive for being
provided to the component analysis module 114.
[0039] Turning now to the AM machine 104, the forming beam 120 may
be a laser beam, an electron beam, or another beam configured to
controllably provide heat to a target location. The heat provided
by the forming beam 120 melts material provided by the material
feed 122. For example, the material feed 122 may provide material
at a target location and the forming beam 120 may melt the material
at the target location. The forming beam 120 has a small spot size
and quick scan speeds as compared to arc welding; thus, the forming
beam 120 may form features with increased resolution as compared to
arc welding. Additionally, use of the AM machine 104 can be
automated because the forming beam 120 is machine-controllable and
does not rely upon a skilled operator to produce desirable
results.
[0040] The material feed 122 may provide material using various
mechanisms such as via powder feed, wire feed, or other mechanism.
The material feed 122 may provide the material at a location as
instructed by the controller 102. Size, intensity, location, shape,
or other properties of the forming beam 120 may be controlled by
the controller 102. The amount of material provided, the type of
material provided, the location of the material provided, and other
properties of the material feed 122 may also be controlled by the
controller 102. The sensors 124 may provide information related to
the forming beam 120, the material feed 122, or the component to
the controller 102. For example, the sensors 124 may provide a
present shape or depth of the added materials to the controller
102, which the forming module 116 could compare to the desired
changes such that the input/output module 118 could display this
comparison to the operator.
[0041] In some cases, it may be desired to first remove material
from the component using the excavation machine 106 before adding
material to the component using the AM machine 104. In these cases,
the forming module 116 may provide instructions to the excavation
machine 106 for removing material from the component. For example,
it may be desirable to initially remove a flawed (e.g., cracked,
corroded, etc.) region from the component. The excavator 126 may
include one or more of various material removal machines such as a
mill, a water jet, a drill, a plasma torch, or other removal
machines. The sensors 128 may provide information related to the
excavator 126 to the controller 102. For example, the sensors 128
may provide a present shape of the component to the controller 102,
which the forming module 116 could compare to the instructions for
removing material such that the input/output module 118 could
display this comparison to the operator.
[0042] When the excavation machine 106 is used to create an
excavation, the AM machine 104 may form material deposits in the
excavation. For example, the AM machine 104 may form the material
deposits exclusively within the excavation created by the
excavation machine 106. Alternatively, the AM machine 104 may form
the material deposits partially within, or outside of, the
excavation created by the excavation machine 106. For some
components, the desired changes do not require the excavation
machine 106 to be used because no excavations are needed. For
example, if the desired changes are simply the addition of
material, the excavation machine 106 may not be used.
[0043] In some embodiments, the AM machine 104 may be capable of
removing material as well as adding material. For example, the
forming beam 120 may be capable of both removing material and
melting material added by the material feed 122.
[0044] The pretreating machine 107 provides an interface layer to
the component upon which the AM machine 104 forms the material
deposits. The interface layer thermally isolates the material
deposits from the component such that the structurally integrities
of the material deposits and the component are protected. If the
excavation machine 106 is used, the pretreating machine 107 may
provide the interface layer partially or completely over the
excavated portion of the component. The pretreater 130 disposes the
interface layer. For example, the pretreater 130 may be a thermal
sprayer, a nozzle, or other mechanism for providing material. The
sensors 132 may provide information related to the pretreater 130
to the controller 102. For example, the sensors 132 may provide a
present thickness or outline of the interface layer to the
controller 102, which the forming module 116 could compare to the
instructions for a desired thickness or outline of the interface
layer such that the input/output module 118 could display this
comparison to the operator.
[0045] FIGS. 2-11 illustrate, in various views and perspectives,
techniques for adding material to a component via the system 100
according to embodiments of the present disclosure. In some
embodiments, the processes are implemented by the system 100 for a
component of an internal combustion engine that is part of a
vehicular system (e.g., an automobile, a truck, a commercial
vehicle, an emergency vehicle, a construction vehicle, etc.);
however, the concepts of the present disclosure are not limited to
implementation with an internal combustion engine that is part of a
vehicular system.
[0046] FIG. 2 illustrates a process 200 for adding material
deposits 202 on a component 204 of an internal combustion engine,
as implemented by the system 100. The process 200 uses the AM
machine 104 to perform AM on the component 204. For example, the
process 200 may use the forming beam 120 to perform selective laser
sintering (SLS) or 3D printing on the component 204. The process
200 involves adding the material deposits 202 to the component 204
in a molten form and then allowing the material deposits 202 to
cool and solidify. It is to be noted that, in some embodiments, a
non-molten material may be provided by the material feed 122 and
converted to molten form, such as by the forming beam 120. The
component 204 in some embodiments is constructed from cast iron.
The component 204 may be, for example, a cylinder head, a manifold
(e.g., intake manifold, exhaust manifold, etc.), a turbocharger, or
other component of an internal combustion engine, or a component of
another system.
[0047] When the component 204 is constructed from cast iron,
several challenges exist for the process 200. Because the process
200 uses a laser, the process 200 is typically a relatively low
heat input process, due to small spot size and quick scan speeds of
the forming beam 120 as compared to arc welding. Additionally, the
component 204 can be relatively large and can dissipate heat
relatively quickly due to the metallurgical properties of the
component 204. The quick heat dissipation can result in cracking of
the material deposits 202 in a HAZ of the material deposits 202,
and the material deposits 202 can thereby be structurally
comprised. These effects can be amplified as additional layers of
material deposits 202 are formed.
[0048] To counter the heat dissipation by the component 204, the
process 200 includes pretreating the component 204 with a low heat
input process, using the pretreating machine 107, prior to
disposing the material deposits 202 on the component 204. The
pretreating machine 107 deposits an interface layer 206 on the
component 204. The pretreating machine 107 may apply the interface
layer 206 via a thermal spray to the component 204 or by flowing
the interface layer 206 onto the component 204, such as through a
brazing process. In some embodiments, the interface layer 206 is a
nickel-based alloy (e.g., cupronickel, ferronickel, etc.). The
interface layer 206 is relatively thin compared to a thickness of
the material deposits 202. When the interface layer 206 contacts
the component 204, a substrate 208 portion of the component 204 may
experience a phase transformation (e.g., from .alpha.-iron (body
centered cubic) to .gamma.-iron (face centered cubic)).
[0049] The material deposits 202 may be formed on the interface
layer 206 by the AM machine 104 through laser deposition (e.g.,
pulsed laser deposition (PLD)), laser cladding (e.g., laser hot
wire cladding), or other laser-based technique. In some
embodiments, when the AM machine 104 uses laser deposition, the
forming beam 120 melts a portion of the interface layer 206,
forming a molten pool, and powdered metal is caused to accumulate
via the material feed 122 in the molten pool, thus forming the
material deposits 202. In other embodiments, when the AM machine
104 uses laser cladding, the forming beam 120 melts a portion of
the interface layer 206 forming a molten pool, and metal wire is
fed via the material feed 122 into the molten pool where it melts,
thus forming the material deposits 202.
[0050] The interface layer 206 functions to substantially thermally
isolate the substrate 208 from the material deposits 202. Following
completion of the process 200, the material deposits 202 are formed
on the interface layer 206. Heat from the material deposits 202 and
heat from the forming beam 120 used to form the material deposits
202 can cause the interface layer 206 to at least partially melt.
This melting increases a bond strength between the interface layer
206 and the substrate 208. Subsequent formation of the material
deposits 202 further increases the bond strength between the
interface layer 206 and the substrate 208.
[0051] The heat from the material deposits 202 may create a HAZ
that is maintained in the interface layer 206. Through the use of
the interface layer 206, heat from the material deposits 202 is
maintained in the interface layer 206 long enough to avoid cracking
of the material deposits 202, thereby protecting the structural
integrity of the material deposits 202. Further, the interface
layer 206 functions to substantially thermally isolate the
substrate 208 from direct heating by the forming beam 120 used to
form the material deposits 202, thereby also protecting the
structural integrity of the substrate 208 portion of the component
204.
[0052] When the interface layer 206 is nickel-based, the interface
layer 206 has a substantially higher ductility than a substrate 208
constructed from iron. As the material deposits 202 and the
interface layer 206 cool, the interface layer 206 may stretch to
accommodate shrinkage stresses from the cooling, whereas the iron
would not stretch sufficiently to accommodate shrinkage
stresses.
[0053] In the embodiment shown in FIG. 2, each of the material
deposits 202 is constructed from a number of layers, e.g., first,
second, and third layers 211, 213, 215 (and potentially further
layers) 210 that are formed in a vertical fashion as deposited by
the material feed 122 and subsequently heated by the forming beam
120. When the material feed 122 deposits material vertically, the
process 200 does not require preheating of the component 204 or the
interface layer 206. The material deposits 202 are defined by a
height, H, and a width, W. The layers 210 (e.g., first layer 211,
second layer 213, third layer 215, etc.) have a width substantially
equal to the width W of the material deposits 202, and the layers
210 are defined by a thickness T Due to the vertical deposition by
the material feed 122, each of the layers 210 provides heat to the
already formed layers 210 beneath and to the interface layer 206.
For example, second layer 213 provides heat to first layer 211. In
this way, heat dissipation in the interface layer 206 is gradual,
and undesirable thermal stresses in the material deposits 202 and
the component 204 are minimized.
[0054] In some embodiments, the component 204 includes an
excavation 212 as formed by the excavation machine 106. The
excavation 212 is defined by a depth, D, and a length, L. The
excavation 212 may be formed by the excavation machine 106 in
various shapes and sizes such that the component 204 is tailored
for a target application or target repair procedure. In other
embodiments, the component 204 does not include the excavation 212.
In some embodiments, the AM machine 104 causes the material
deposits 202 to be located within the excavation 212 formed by the
excavation machine 106. For example, where a flaw (e.g., crack,
dent, scratch, etc.) exists in the component 204, the process 200
may remove the flaw via the excavation machine 106 and then
selectively fill the excavation 212 using the material deposits 202
via the AM machine 104. Depending on the process 200, the height,
H, of the material deposits 202, as formed by the AM machine 104,
may exceed the depth, D, of the excavation 212, as formed by the
excavation machine 106; however, the depth, D, may be equal to or
greater than the height, H.
[0055] As can be seen from the discussion above, certain features
in the component 204 may be controllably excavated and replaced via
the process 200. For example, a port in a head casting could be
controllably excavated via the process 200 and a new port
constructed by the material deposits 202. More generally, the
component 204 may be controllably remanufactured for a target
application.
[0056] FIG. 3 illustrates a number of material deposits 202, each
including a number of layers, e.g., first, second, and third layers
211, 213, 215 (and potentially further layers) 210, formed by the
AM machine 104 on the interface layer 206 which is formed on the
substrate 208 of the component 204 by the pretreating machine 107.
Because the process 200 has the capability of forming the material
deposits 202 in a layered fashion, via the AM machine 104, it is
possible for each of the layers 210 (e.g., first layer 211, second
layer 213, third layer 215, etc.) to be constructed from different
materials (e.g., by the material feed 122 depositing different
materials for each of the layers 210) or for each of the layers 210
to have different properties (e.g., by the forming beam 120 heating
each of the layers 210 differently, by the material feed 122
supplying different materials for each of the layers 210, etc.). In
this way, the material deposits 202 may have a graded composition.
In some embodiments, some or all of the material deposits 202 may
have a same material in a particular layer (e.g., a second layer of
each material deposit 202 may be of a same material). By way of
comparison, arc welding is not generally capable of tailoring each
layer of a deposit to have different properties. Therefore, arc
welding is not capable of producing deposits having graded
compositions.
[0057] As shown in FIG. 3, the material deposits 202 have a first
common layer 300, a second common layer 302, a third common layer
304, a fourth common layer 306, and a fifth common layer 308. In an
example embodiment, the first common layer 300 is constructed from
80/20 nickel/iron, the second common layer 302 is constructed from
60/40 nickel/iron, the third common layer 304 is constructed from
40/40 nickel/iron and Inconel 20, the fourth common layer 306 is
constructed from 20/20 nickel/iron and Inconel 60, and the fifth
common layer 308 is constructed from Inconel 100, such that the
material deposits 202 gradually transition from 80/20 nickel/iron
to Inconel 100 in this example.
[0058] The process 200 may be used to remove a feature in the
component 204, where the feature is constructed from one material,
and replace the feature with a same or different material (in a
same or different size and shape). For example, the layers 210
(e.g., first layer 211, second layer 213, third layer 215, etc.)
may have materials that allow the material deposits 202 to have
more advantageous properties. In this way, the process 200 may be
used to selectively remanufacture the component 204 to provide
replacement features having more advantageous properties.
[0059] In some embodiments, the process 200 may be implemented for
wrought parts where the process 200 can be used to provide adequate
properties relative to the needs of the wrought parts. For example,
the component 204 may be a wrought iron cylinder head that requires
higher strength mounting holes. Following this example, the process
200 may be implemented to form material deposits 202 of a high
strength material proximate the mounting holes.
[0060] The material deposits 202 may be formed by the AM machine
104 on the component 204 over a target length. Depending on a ratio
between the target length (e.g., length L in FIG. 2) of the
material deposits 202 combined and the width (e.g., width W of a
single material deposit 202 in FIG. 2), it may be selected to form
the material deposits 202 vertically or horizontally. For example,
if the ratio is below a target threshold it may be selected to form
the material deposits 202 horizontally. In these cases, layers 210
may be horizontally formed sequentially in a reciprocal fashion
until the material deposits 202 have attained a desired height
(e.g., height H in FIG. 2). Even when the AM machine 104 is used to
deposit material horizontally, the process 200 does not require
preheating of the component 204 or the interface layer 206. In some
embodiments, the target threshold may be related to an acceptable
range of temperatures for the interface layer 206, the substrate
208, and the layers 210. For example, the target threshold may be
selected so that the interface layer 206 maintains a desired
temperature. However, even if the ratio indicates to deposit the
layers 210 of the material deposits 202 horizontally, the
controller 102 may elect to still deposit the layers of the
material deposits 202 vertically.
[0061] In some embodiments, it may be desirable for the system 100
to group several material deposits 202 together such that the group
of material deposits 202 are formed together via the AM machine
104, and then to move on to forming another group of material
deposits 202. For example, a group of three material deposits 202
may be formed via the AM machine 104 in a sequence, such as a
circular, spiral forming sequence.
[0062] The process 200 can mitigate thermal stresses experienced in
both the material deposits 202 and the component 204 by forming the
material deposits 202 either vertically or horizontally depending
on the ratio between the target length of all of the material
deposits 202 and the width of a single material deposit 202. By
mitigating thermal stresses, the process 200 protects the
structural integrity of the material deposits 202 and the component
204. Additionally, the process 200 does not require preheating of
the substrate 208 and/or the component 204.
[0063] FIGS. 4-6 illustrate an example of the process 200 where an
initial material deposit 400, an intermediate material deposit 500,
and a terminal material deposit 600 are formed by the AM machine
104 in progressive stages. In FIG. 4, the initial material deposit
400 is formed on the interface layer 206 on the component 204,
then, as shown in FIG. 5, the intermediate material deposit 500 is
formed on the interface layer 206 adjacent the initial material
deposit 400, and then, as shown in FIG. 6, the terminal material
deposit 600 is formed on the interface layer 206 adjacent the
initial material deposit 400 and adjacent the intermediate material
deposit 500. In one example, each of the layers 210 (e.g., first
layer 211, second layer 213, third layer 215, etc.) for each of the
initial material deposit 400, the intermediate material deposit
500, and the terminal material deposit 600 is formed first before
depositing the others of the initial material deposit 400, the
intermediate material deposit 500, and the terminal material
deposit 600. In other embodiments, a first layer 211 of the initial
material deposit 400 is formed first, then a first layer 211 of the
intermediate material deposit 500 is formed, then a first layer 211
of the terminal material deposit 600 is formed, then a second layer
213 of the initial material deposit 400 is formed on the first
layer 211 of the initial material deposit 400, and so on.
[0064] FIGS. 7 and 8 illustrate material deposits 202 on a
component 204. The material deposits 202 can be added to the
component 204 by the AM machine 104 in various shapes, sizes, and
configurations such that the component 204 is remanufactured by the
system 100 for a target application. According to various
embodiments, the heat applied by the forming beam 120 in the
process 200 causes the material deposits 202 to bond with the
component 204, making the material deposits 202 structurally
coupled to the component 204. In the process 200, the material
deposits 202 undergo phase transformations (e.g., from powder to
molten to solid, etc.) due to the application of heat from the
forming beam 120 and subsequent cooling.
[0065] FIGS. 9-11 illustrate various designs of the excavation 212
as formed by the excavation machine 106 in the process 200.
According to various embodiments, the excavation 212 in the
component 204 is formed by the excavation machine 106 such that
residual stresses in subsequently formed material deposits 202 are
reduced. For example, as shown in FIG. 9, the excavation 212 may be
formed by the excavation machine 106 such that the excavation 212
has sharp angles. In another example, as shown in FIG. 10, the
excavation 212 may be formed by the excavation machine 106 such
that the excavation 212 has blended angles. In yet another example,
as shown in FIG. 11, the excavation 212 may be formed by the
excavation machine 106 such that the excavation 212 has shallow,
gradual angles. The process 200 may be implemented such that the
excavation 212 is formed by the excavation machine 106 to reduce
residual stresses in the material deposits 202 and such that the AM
machine 104 forms the material deposits 202 to selectively replace
and/or add material so that the component 204 is tailored for a
target application.
[0066] While the process 200 has been described with respect to a
component 204 of cast iron in some instances, it is to be
understood that the process 200 may be similarly implemented with
components 204 constructed of other materials such as iron alloys,
steels, and other metallic materials.
[0067] FIG. 12 illustrates a method 1200 for using the system 100
to form the material deposits 202 on the component 204. First, at
1202, the component 204 is analyzed for desired changes. This
analysis is performed by the component analysis module 114 in the
controller 102. For example, an operator may receive a cylinder
head for an internal combustion engine and may wish to alter the
cylinder head such that a different compression ratio for the
internal combustion engine may be achieved. In another example, at
1202, the component 204 may be scanned for flaws to determine
desired changes to the component to eliminate the flaws. Following
this example, the desired changes may be excavation and replacement
of flawed regions of the component 204.
[0068] Depending on the application, the system 100 may utilize the
excavation machine 106 to form an excavation 212 in a target area
of the component at 1204. For example, an excavation 212 may be
formed to selectively remove a defective area such as an area
containing a crack or blemish. Next, at 1206, the pretreating
machine 107 applies an interface layer 206 on the component. For
example, the pretreating machine 107 may apply the interface layer
206 within the excavation 212 formed by the excavation machine 106
in at 204.
[0069] Next, at 1208, the AM machine 104 forms a first layer 211 of
a material deposit 202 on the interface layer 206. For example, the
material feed 122 deposits an amount of material for the first
layer 211 on the interface layer 206 and the forming beam 120 melts
the material into the first layer 211 of the material deposit 202.
Depending on the desired changes, more layers 210 (e.g., second
layer 213, third layer 215, etc.) for the material deposit 202
and/or additional material deposits 202 may be desired. If
additional layers 210 are desired for the material deposit 202, the
AM machine 104 deposits additional layers 210, at 1210, on the
material deposit 202 in a sequential order until the material
deposit 202 has the desired number of layers 210. If additional
material deposits 202 are desired, the method 1200 loops back to
1208 for each of the additional material deposits 202. Once all of
the layers of all of the planned material deposits 202 have been
formed by the AM machine 104, the component 204 may have the
desired changes. In some applications, it is desired for the
component 204 to be subjected to finishing (e.g., polishing,
sanding, honing, reaming, buffing, painting, coating, etc.) at
1212. For example, the component 204 may be reamed by an operator
and/or by automated machinery at 1212.
[0070] While the present disclosure contains specific
implementation details, these should not be construed as
limitations on the scope of what may be claimed, but rather as
descriptions of features specific to particular implementations.
Certain features described in this specification in the context of
separate implementations can also be implemented in combination in
a single implementation. Conversely, various features described in
the context of a single implementation can also be implemented in
multiple implementations separately or in any suitable
subcombination. Moreover, although features may be described above
as acting in certain combinations and even initially claimed as
such, one or more features from a claimed combination can in some
cases be excised from the combination, and the claimed combination
may be directed to a subcombination or variation of a
subcombination.
[0071] It should be noted that references to "front," "rear,"
"upper," "top," "bottom," "base," "lower," and the like in this
description are used to identify the various components as they are
oriented in the Figures. These terms are not meant to limit the
component which they describe, as the various components may be
oriented differently in different embodiments.
[0072] Further, for purposes of this disclosure, the term "coupled"
means the joining of two members directly or indirectly to one
another. Such joining may be stationary in nature or moveable in
nature and/or such joining may allow for the flow of fluids,
electricity, electrical signals, or other types of signals or
communication between the two members. Such joining may be achieved
with the two members or the two members and any additional
intermediate members being integrally formed as a single unitary
body with one another or with the two members or the two members
and any additional intermediate members being attached to one
another. Such joining may be permanent in nature or alternatively
may be removable or releasable in nature.
[0073] It is important to note that the construction and
arrangement of the system shown in the various example
implementations are illustrative and not restrictive in character.
All changes and modifications that come within the spirit and/or
scope of the described implementations are desired to be protected.
It should be understood that some features may not be necessary and
implementations lacking the various features may be contemplated as
within the scope of the application, the scope being defined by the
claims that follow. When the language "at least a portion" and/or
"a portion" is used the item can include a portion and/or the
entire item unless specifically stated to the contrary.
* * * * *