Method for depositing material in a substrate

Abstract

Method for depositing materials in a substrate (12), comprising: arranging a first section of a substrate in a vertically downward direction; directing an energy beam (16) from below the first section upwards towards the first section; forming a melt pool (26) in the substrate (12) using the directed energy beam (16), wherein the melt pool (26) is formed such that it is directed vertically downwards in the first section;and directing a particle stream (20) from below the first section upwards towards the first section, wherein at least some of the particles (20A) are configured to rise in the melt pool (26) towards the substrate (12), wherein the particles (20) are made of a different material than the substrate (12), and wherein the method further comprises: solidifying the melt pool (26) after the desired quantity of particles (20) has been dispersed in the melt pool (26) and the desired particles (20A) have risen in the melt pool (26) towards the substrate (12), and forming a coating on the substrate (12) which is a metal matrix composite coating with a desired degree of porosity near the unmelted sections of the substrate (12).

Description

Cross-reference to related registrations The present application claims the effect of the preliminary US patent application No. 61 / 427729, filed on December 28, 2010, entitled SYSTEM AND METHOD FOR DEPOSITING MATERIAL IN A SUBSTRATE. Field of invention The present invention relates to material deposition and in particular to the deposition of material in a substrate. background Processes and systems that effectively deposit material, such as particles, onto a substrate remain a key area of ​​interest. Some known systems suffer from various shortcomings, deficiencies, and disadvantages with regard to specific applications. Therefore, further contributions in this technological field are needed. US 5 837 960 A and US 2004 / 0 137 259 A1 describe relevant state of the art. Brief description of the invention The present invention relates to a specific method for depositing materials in a substrate according to the features of claim 1. The embodiments, structures, features, aspects, advantages and benefits of the present application will become clear with reference to the present description and figures. Brief description of the drawings The description refers to the accompanying drawings, in which identical parts are designated by the same reference numerals in the various views, and in which: Fig. 1 schematically shows some aspects of a non-limiting example of an embodiment of a non-inventive system for adding particles to a substrate to form a matrix material; Fig. 2 schematically shows some aspects of a non-limiting example of particles deposited in a substrate to form a matrix material. Detailed description For a better understanding of the principles of the invention, reference is made below to the embodiments illustrated in the drawings, and special terms are used for their description. It is understood, however, that the scope of the invention is not to be limited by the presentation and description of specific embodiments of the invention. The drawings, particularly Fig. 1, schematically illustrate some aspects of a non-limiting example of a system 10 for adding particles to a substrate 12 to form a matrix material according to one embodiment. For example, in the case of a metal substrate 12 and particles in the form of oxides or other composite material, the system 10 forms a matrix material in the form of a metal matrix composite material. In other embodiments, the system 10 can form other matrix materials, including, for example, metal / metal matrix materials and metal / metal / composite matrix materials, wherein one of the metals is the substrate 12 and the other metal and composite material consist of particles added to the substrate 12. According to one embodiment, the system 10 is configured to provide a desired degree of porosity on the surface of the substrate 12. In one embodiment, the substrate 12 is an abrasive casing ring for a gas turbine engine. In other embodiments, the substrate 12 can be any component, such as a gas turbine engine rotor blade, a guide vane or a set of guide vanes, an abrasive casing ring for a compressor, a blower or a turbine, another gas turbine engine flow path component or any other gas turbine engine component, or any mechanical component for any machine, structure, device or system. In one embodiment, the substrate 12 is a metal component. In other embodiments, the substrate 12 can consist of one or more metal and / or non-metal materials. System 10 comprises an energy beam emission device 14 for directing an energy beam 16 onto the substrate 12. System 10 further includes a particle spray device 18 for directing one or more particle streams 20 onto the substrate 12, e.g., to and near the point of impact 22 of the energy beam 16 on the substrate 12. In one embodiment, the particles 20 are made of a different material than the substrate 12. In other embodiments, some or all of the particles 20 may be made of the same material as the substrate 12. According to one embodiment, the device 14 and the device 18 are incorporated in a single unit in the form of a combined dispensing nozzle 24, which emits both the energy beam 16 and a particle stream 20.In other embodiments, the device 14 and the device 18 can assume other configurations, including separate output devices, and can also include multiple output devices for outputting an energy beam 16 and / or a particle stream 20. In one embodiment, the device 14 is configured and operational to generate and align the energy beam 16 in the form of a laser beam. In other embodiments, the device 14 can be configured to generate other types of energy beams, including one or more electron beams and / or one or more electric arcs. The device 14 is configured and positioned to direct the energy beam 16 from below a section of the substrate 12 upwards to that section. The energy beam 16 is configured to create a melt pool 26 on the underside of the substrate 12 within that section. The energy beam 16 creates the melt pool 26 by locally melting the substrate 12, such that the melt pool 26 is directed vertically downwards, i.e., inverted. The device 18 is configured and operable to direct the particle stream 20 from below the section of substrate 12 upwards towards the section, such that at least some of the particles 20 strike and penetrate the melt pool 26. In one embodiment, some particles 20 have a different property than the other particles. For example, according to one embodiment, the particles 20 are an aggregation of different types of particles, wherein some of the particles may have a lower density than others and / or some particles may have a greater buoyancy relative to other particles in the melt pool 26. The particles with the other property are configured to rise in the melt pool 26 towards the substrate 12 (to unmelted sections of the substrate 12).Depending on the requirements of the specific embodiment, the particles 20 can be made of the same or different materials and can have the same or different sizes and shapes. According to one embodiment, the particles are composite particles, e.g., made of a ceramic composite material. In other embodiments, the particles can consist of metal particles in addition to or instead of non-metallic particles. Depending on the specific embodiment, some particles can be hollow, e.g., hollow metal and / or non-metal spheres or other shapes, while other particles can consist of solid material. In still other embodiments, the particles 20 can include reactive pore-forming agents in addition to or instead of other types of particles. In yet other embodiments, all particles 20 can be the same or substantially the same, e.g.,with regard to composition, size and shape, and can all be configured to rise in the melt pool 26 towards the substrate 12 (to unmelted sections of the substrate 12). System 10 is configured to allow particles with the desired property to rise upwards in the melt pool 26 towards unmelted sections of the substrate 12. For example, according to one embodiment, system 10 supplies sufficient energy to maintain the melt pool 26 with the particles 20 contained therein for a duration sufficient for the particles with the other property to rise in the melt pool 26. By directing the melt pool 26 downwards, the particles with the other property can rise towards the substrate 12 to, for example, create a desired degree of porosity in the substrate 12 near the unmelted sections of the substrate 12.This contrasts with other systems that form a melt pool on a top or side surface of the substrate, where the desired particles cannot migrate to unmelted sections of the substrate. System 10 also includes a positioning system 28 and a positioning system 30. According to one embodiment, system 10 further includes a housing 32 configured to enclose the substrate 12, the device 14, the device 18, the positioning system 28, and the positioning system 30. The positioning system 28 is connected to the combined dispensing nozzle 24 and is operable to move and / or rotate the combined dispensing nozzle 24 to form the melt pool 26 using the energy beam 16. According to one embodiment, the positioning system 28 is also configured to progressively or intermittently move the melt pool 26 to other sections of the substrate 12, e.g., to sections near the initial or subsequent points of the melt pool 26, which are also directed vertically downwards.In embodiments where the energy emission device 14 and the particle spray device 18 are not combined into a single head, or where multiple devices 14 and devices 18 are used, further positioning systems can be connected to each of the devices 14 and devices 18. According to one embodiment, the positioning system 28 is a multi-axis positioning system. In other embodiments, the positioning system 28 can be a single-axis positioning system. The positioning system 30 is connected to and holds the substrate 12 and is operable to move and / or rotate the substrate 12 in order to form the melt pool 26 at desired locations on the substrate 12 using the energy beam 16. According to one embodiment, the positioning system 30 is also configured to progressively or intermittently expose a second and subsequent section of the substrate 12 to the energy beam 16 and the particle stream 20, e.g., sections near the initial or subsequent positions of the melt pool 26, which are also directed vertically downwards. According to one embodiment, the positioning system 30 is configured to rotate the substrate 12 so that the desired melt pool 26 is directed downwards. According to one embodiment, the positioning system 30 is a multi-axis positioning system.In other embodiments, the positioning system 30 can be a single-axis positioning system. In various embodiments, the positioning system 28 and / or the positioning system 30 can be used to arrange the substrate 12 at the desired location to form the melt pool 26 facing downwards. In other embodiments, depending on the geometry of the substrate 12, no positioning system may be used to position the substrate 12. For example, if the substrate 12 has a relatively flat surface that can be held in place, the positioning system 30 can be replaced by a simple holding system to keep the substrate 12 in the desired orientation. Still other embodiments may not use a positioning system at all.no positioning systems are required to position the device 14 and / or the device 18, but instead a simple holding system can be used to hold the device 14 and / or the device 18 and can rely on the positioning system 30 to align the substrate 12 in the desired position. The housing 32 is configured to control the atmosphere inside the system 10 during the formation of the melt pool 26 and the spraying of the particles 20. According to one embodiment, an ambient air atmosphere is maintained inside the housing 32. In other embodiments, an inert gas or a negative pressure can be contained inside the housing 32. In the operation of system 10, a desired section of the substrate 12 is positioned vertically downwards, for example, by a positioning system 30. The energy beam 16 is directed upwards from below the section of the substrate 12 where the melt pool 26 is to be formed. In one embodiment, the energy beam 16 is directed at the section of the substrate 12 at an angle ϕ of less than 45 degrees with respect to a vertical line 34. In a particular embodiment, the energy beam 16 is directed at the section of the substrate 12 at an angle ϕ of less than approximately 15 degrees with respect to the vertical line 34. In other embodiments, larger or smaller angles can be used. The melt pool 26 is then formed by the energy beam 16, with the melt pool directed vertically downwards from the section of the substrate 12.Once the melt pool 26 has formed, a particle stream 20 is directed upwards from below the section of substrate 12 towards the section in which the melt pool 26 is formed. At least some of the particles are configured to rise within the melt pool 26 towards the substrate 12. The melt pool 26 is kept in a liquid state, for example, by the energy beam 16, while the particles rise within the melt pool towards the substrate. According to Fig. 2, in embodiments where the particles are not homogeneous, the particles 20A with the property of greater buoyancy in the melt pool and / or lower density compared to the other particles 20B are those particles that rise in the melt pool 26 towards the substrate 12. In embodiments where the particles are homogeneous, e.g., having a density and / or buoyancy with a desired value that promotes floating to the top of the inverted melt pool, similar results would be achieved near the substrate 12 at the top of the inverted melt pool. In various embodiments, a displacement and / or rotation of the substrate 12 can be provided to arrange another section of the substrate 12 vertically downwards to form a new melt pool 26 or to relocate the melt pool 26 to a new position on the substrate 12.This can be performed while the melt pool 26 is held vertically downwards, progressively moving the melt pool 26 to the next or a different section of the substrate. Similarly, the device 14 and the device 18 can be continuously or intermittently repositioned to move the melt pool 26 from one section of the substrate 12 to another section of the substrate 12. After the desired quantity of particles 20 has been dispersed in the molten pool 26 and the desired particles have risen in the molten pool 26 towards the substrate 12, the molten pool 26 solidifies and forms, for example, a coating on the substrate 12. Such a coating can be, for example, a metal matrix composite coating with a desired degree of porosity near the unmelted sections of the substrate 12. The degree of porosity is based on the selection of the particles 20. In one embodiment, the degree of porosity is configured for an abrasion resistance of the substrate 12, for example, in a casing ring component of a gas turbine engine. In other embodiments, the degree of porosity is configured to maintain lubrication, for example, to form a self-lubricating material on the substrate 12. In still other embodiments, the degree of porosity is configured to achieve a desired thermal conductivity, for example,in a turbine section component of a gas turbine engine. In other embodiments, the porosity level can be configured to achieve other desired properties. Embodiments include a method for depositing materials in a substrate, comprising the steps of: arranging a first section of a substrate in a vertically downward direction, directing an energy beam from below the first section upwards towards the first section, forming a melt pool in the substrate using the directed energy beam, wherein the melt pool in the first section is formed vertically downwards, and directing a particle stream from below the first section upwards towards the first section, wherein at least some of the particles are configured to rise in the melt pool towards the substrate. According to further training, at least some of the particles have a different property than the other particles, and the particles with the different property are at least some of the particles that rise towards the substrate in the melt pool. According to another further development, the property is a lower density than that of the other particles. According to yet another further development, the property is a greater buoyancy in the melt pool than that of the other particles. According to yet another further development, the substrate is metallic and the particles in the molten pool, in combination with the molten substrate, form a metal matrix composite material. According to yet another further education method, the particles are non-metallic. According to further training, all particles are non-metallic particles. According to further training, the particles exhibit hollow particles. According to further training, the particles contain reactive pore-forming agents. According to yet another embodiment, the method further comprises a displacement and / or rotation of the substrate to arrange a second section of the substrate in a vertically downward direction, while the melt pool is held in the vertically downward direction, with the melt pool being progressively displaced into the second section of the substrate. According to further training, the energy beam is a laser beam. According to yet another further development, the process also involves solidifying the molten pool to form a coating on the substrate. According to yet another method, the energy beam is directed at the first section at an angle of less than about 15 degrees to the vertical. According to yet another method of development, the substrate consists of a material and the melt pool is formed from the substrate material. Embodiments that do not correspond to the present invention comprise a system comprising: an energy beam emission device positioned to direct an energy beam from below a first section of a substrate upwards towards the first section, wherein the energy beam is configured to form a vertically downward-facing melt pool in the first section, and a particle spray device operable to direct a particle stream from below the melt pool upwards towards the melt pool, wherein the system is configured to allow at least some of the particles to rise upwards in the melt pool towards the substrate. According to further training, the system also has a positioning system that is connected to the substrate and can be operated to move and / or rotate the substrate in order to arrange a second section of the substrate vertically downwards, while maintaining the melt pool vertically downwards. According to another training, the positioning system is configured to progressively move the melt pool from the first section to the second section of the substrate. According to yet another further development, the system also has a positioning system that is connected to the energy beam emission device and is operable to move and / or rotate the energy beam emission device in order to form the melt pool on a second section of the substrate in a vertically downward direction. According to yet another aspect, the energy beam emission device is configured to move the molten pool progressively from the first section into the second section of the substrate. Embodiments that do not correspond to the present invention comprise a system comprising: a device for arranging a section of a substrate in a vertically downward direction, a device for forming a melt pool in the section of the substrate using a directed energy beam, wherein the melt pool is formed such that it is directed vertically downward in the section of the substrate, and a device for directing a particle stream upwards towards and into the melt pool, wherein at least some of the particles have a different property than the other particles, and wherein the particles and the melt pool, after it has solidified, form a matrix material. According to further training, the device for forming the melt pool is configured to direct the energy beam upwards towards the section of the substrate at an angle of less than approximately 15 degrees to the vertical. It is understood that, although the use of the word "preferred" in the foregoing description indicates that a feature so designated may be desirable, this feature may not be strictly necessary, so that any embodiment lacking this feature may also be considered to be included within the scope of the invention as defined by the following claims. When reading the claims, the use of words such as "a," "an," "at least a," and "at least a section" does not intend to limit the claim to only one element, unless expressly stated otherwise in the claim. Furthermore, the use of the expression "at least a section" and / or "a section" may refer to a section of an element and / or the entire element, unless expressly stated otherwise in the claim.

Claims

A method for depositing materials in a substrate (12), comprising: arranging a first section of a substrate in a vertically downward direction; directing an energy beam (16) from below the first section upwards towards the first section; forming a melt pool (26) in the substrate (12) using the directed energy beam (16), wherein the melt pool (26) is formed such that it is directed vertically downwards in the first section;and directing a particle stream (20) from below the first section upwards towards the first section, wherein at least some of the particles (20A) are configured to rise in the melt pool (26) towards the substrate (12), wherein the particles (20) are made of a different material than the substrate (12), and wherein the method further comprises: solidifying the melt pool (26) after the desired quantity of particles (20) has been dispersed in the melt pool (26) and the desired particles (20A) have risen in the melt pool (26) towards the substrate (12), and forming a coating on the substrate (12) which is a metal matrix composite coating with a desired degree of porosity near the unmelted sections of the substrate (12). The method of claim 1, wherein at least some of the particles (20A) have a different property than other particles (20B), and wherein the particles (20A) with the different property are the at least some particles (20A) that rise in the melt pool (26) towards the substrate (12). Method according to claim 2, wherein the property is a lower density than that of the other particles (20B). Method according to claim 2, wherein the property is a greater buoyancy in the melt pool than that of the other particles (20B). The method of claim 1, wherein the substrate (12) is metallic, and wherein the particles (20) in the melt pool in conjunction with the molten substrate (12) form a metal matrix composite material. Method according to claim 5, wherein the particles (20) comprise non-metallic particles. Method according to claim 5, wherein all particles (20) are non-metallic particles. Method according to claim 1, wherein the particles (20) comprise hollow particles. Method according to claim 1, wherein the particles (20) comprise reactive pore-forming agents. The method according to claim 1, further comprising a displacement and / or rotation of the substrate (12) to arrange a second section of the substrate (12) in a vertically downward direction, wherein the melt pool (26) is progressively moved into the second section of the substrate (12). Method according to claim 1, wherein the energy beam (16) is a laser. Method according to claim 1, wherein the energy beam (16) is directed at the first section at an angle (ϕ) of less than about 15 degrees with respect to the vertical (34). Method according to claim 1, wherein the substrate (12) is formed from a material, and wherein the melt pool (26) is formed from the substrate material.

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