Joining members using additive manufacturing

Abstract

To provide additive manufacturing using low expansion glass.SOLUTION: A method includes placing a first part proximately to a second part, disposing a sintering material in contact with both the first part and the second part, and applying energy to the sintering material to join the first part and the second part. An apparatus includes a first part, a second part, and an additively manufactured joint comprising a sintering material that joins the first part and the second part.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to additive manufacturing using, for example, low expansion glasses (e.g., for optical systems and components). [Background technology]

[0002] Conventional methods of joining glass members include adhesive bonding, frit bonding, and optical contact bonding. It has been observed that frit bonding and adhesive bonding make optical systems unstable in terms of temperature changes, changes in moisture absorption behavior, and chemical changes over time. Optical contact bonding may not fully enhance the strength of the glass structure.

[0003] Such conventional methods and systems have generally been deemed sufficient for their intended purposes. However, there remains a need in the art for improved systems and methods for bonding glass members. The present disclosure provides a solution to this need. Summary of the Invention [Means for solving the problem]

[0004] The method includes disposing a first portion proximate to a second portion, disposing a sintering material in contact with both the first and second portions, and applying energy to the sintering material to bond the first and second portions. The disposing of the sintering material and applying energy can be repeated to create successive layers of sintered material.

[0005] The sintering material comprises a titania-silica powder.The sintering material may comprise a titania-silica suspension.

[0006] The first and second portions may be made of glass.The first and second portions may be made of titania-silica glass.

[0007] The application of energy to the sintered material includes laser sintering of the sintered material. Any other suitable application of energy (e.g., electron beam welding) is contemplated herein.

[0008] The apparatus includes a first portion, a second portion, and an additively manufactured joint including a sintered material that bonds the first portion and the second portion. The additively manufactured joint can include successively sintered layers of sintered material.

[0009] The sintered material may include titania-silica (e.g., formed from a powder or suspension). The first and second parts may be made of glass (e.g., titania-silica glass). At least one of the first and / or second parts may be an optical component. The first and second parts may be separate from an original component.

[0010] These and other features of the systems and methods of the disclosed subject matter will become more readily apparent to those of ordinary skill in the art upon reading the following detailed description in conjunction with the drawings.

[0011] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] Embodiments of the devices and methods are described in detail below with reference to the drawings so that those skilled in the art to which the disclosed subject matter pertains can readily understand, without undue experimentation, how to make and use the devices and methods of the disclosed subject matter. [Brief description of the drawings]

[0012] [Figure 1] 1 is a diagram illustrating a portion of an embodiment of a method according to the present disclosure showing deposition of sintered material. [Diagram 2] 1 is a diagram illustrating a portion of an embodiment of a method according to the present disclosure showing the application of energy to a deposited sintered material. [Diagram 3] 1 is a schematic cross-sectional view illustrating an embodiment of an apparatus according to the present disclosure. [Figure 4] 1 is a schematic cross-sectional view illustrating an embodiment of an apparatus according to the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] Reference is made to the drawings, in which like reference numbers identify like structural features or aspects of the disclosed subject matter. For purposes of explanation and illustration, and not limitation, illustrative diagrams of an embodiment of the disclosed method are shown in Figures 1 and 2 and generally designated by reference number 100. Other embodiments and / or aspects of the present disclosure are shown in Figures 3 and 4. The systems and methods described herein can be used to bond two members (e.g., glass members of optical components, e.g., made of titanium silica glass).

[0014] 1 and 2, a method according to the present disclosure is diagrammatically shown. The method includes positioning a first portion 101 adjacent to a second portion 103. The first portion 101 and the second portion may be fixed in position relative to one another in any suitable manner to prevent relative movement between the first and second portions.

[0015] In some embodiments, the first portion 101 and / or the second portion 103 may be made of glass (e.g., titania-silica glass). For example, the first portion 101 and / or the second portion 103 may be made of titania-silica glass.

[0016] 1, the method includes disposing a sintering material 105 in contact with both the first portion 101 and the second portion 103. The sintering material 105 can be disposed in any suitable manner, for example, through a nozzle 107, with or without pressure.

[0017] In some embodiments (e.g., when the first portion 101 and / or the second portion 103 are made of titania-silica glass), the sintering material 105 can include titania-silica powder. In some embodiments (e.g., when the first portion 101 and / or the second portion 103 are made of titania-silica glass), the sintering material 105 can include a titania-silica suspension. For example, any other suitable material that bonds glass components is contemplated herein.

[0018] 2, the method includes applying energy to a sintering material 105 to bond a first portion 101 and a second portion 103. The application of energy to the sintering material may include laser sintering the sintering material 105 as shown. Any other suitable energy application (e.g., electron beam welding) is contemplated herein.

[0019] The deposition of sintered material 105 (e.g., as shown in FIG. 1) and application of energy (e.g., as shown in FIG. 2) can be repeated to create successive layers of sintered material as needed for a bond of appropriate strength for a desired function. The successively formed layers can be of any suitable thickness and / or shape as would be understood by one of ordinary skill in the art in light of this disclosure.

[0020] Referring to FIG. 3, the device 100 formed by the above method includes the first portion 101, the second portion 103, and an additively manufactured joint 309 including a sintered material 105 that joins the first portion 101 and the second portion 103.

[0021] The additively manufactured joint 309 can include successively sintered layers 105a of sintered material 105. As shown in Figure 3, the layers 105a may not be uniform and each layer 105a may not contact each portion 101, 103. Any suitable layering and / or shape of the additively manufactured joint 309 is contemplated herein.

[0022] In some embodiments, at least one of the first portion 101 and / or the second portion 103 may be an optical component (e.g., a mirror substrate, a lens, etc.) for any suitable use. For example, the portions 101, 103 may be portions of a glass mirror substrate that have been separated by breakage. The portions 101, 103 may be structural members that, when combined, comprise a low expansion titania silica glass mirror optical element. For example, segments of a rigid mirror core structure may be bonded to create a larger structure, or an optical faceplate may be bonded to the rigid core structure.

[0023] The first portion 101 and / or the second portion 103 may be used for any other suitable purpose. In this regard, the first portion 101 and the second portion 103 may be disposed relative to one another in any suitable manner. For example, as shown in FIG. 3, the first portion 101 may extend perpendicularly from the second portion 103 and may include a tapered end, for example, to enhance bonding via sintering.

[0024] 4, for example, device 400 can include a first portion 401, as described above, and a second portion 403, as described above, joined side-by-side via an additively manufactured joint 409 (e.g., which can be formed on both sides of portions 401, 403). As shown, joint 409 can be tapered layer-by-layer toward the top layer. As noted above, any other suitable shapes and / or numbers of layers are contemplated herein.

[0025] As described above, the titania-silica glass members can be welded using, for example, low expansion titania-silica glass powder, suspension, or drawn fibers as a filler / sintering material. The parts 101, 103 can have loosely mated surfaces that are first brought together. A low expansion titania-silica glass material can be used to fill the gap between the joining surfaces and can be melted, for example, by applying laser radiation. When the low expansion titania-silica glass material cools quickly, it fuses into the glass, for example, bonding the low expansion titania-silica glass matrices. As described above, the low expansion titania-silica glass powder, suspension, or drawn fibers can be layer-by-layer deposited around the joining surfaces, which can be fused layer-by-layer to build up glass around the joint and strengthen the welded joint.

[0026] The sintered material at the joining interface may be irradiated with a high intensity laser that can be selected to pass through one or more of the low expansion titania silica glass members. The wavelength of the laser source can be selected to transmit with minimal loss through the low expansion titania silica glass, but be absorbed by the powder or suspension at the joining interface.

[0027] The above embodiments provide improved strength, thermal stability, chemical stability, and moisture stability compared to conventional methods of bonding glass members and / or constructing glass optical elements. Additionally, the disclosed methods may enable, for example, the repair of cracked optical components (e.g., repair of glass mirror substrates) while maintaining high thermal stability and fully restoring the strength of the repaired bond. Additionally, cracked optical elements may be repaired to have the same or similar optical properties as the original components.

[0028] The methods and systems of the present disclosure provide methods and apparatus having superior properties as described above and as illustrated in the figures. Although the apparatus and methods of the disclosed subject matter have been shown and described with reference to embodiments, those skilled in the art will readily appreciate that changes and / or modifications may be made to the apparatus and methods of the disclosed subject matter without departing from the spirit and scope of the present disclosed subject matter. [Explanation of symbols]

[0029] 100 devices 101 First Part 103 Second Part 105 Sintered materials 105a Successively sintered layers 107 Nozzle 309 Additively manufactured joints 400 equipment 401 First Part 403 Second Part 409 Additively manufactured joints

Claims

1. disposing a first portion proximate to a second portion; disposing a sintered material in contact with both the first portion and the second portion; applying energy to the sintered material; combining the first portion and the second portion; A method comprising:

2. The method of claim 1 , wherein the deposition of said sintering material and the application of said energy are repeated to create successive layers of sintered material.

3. The method of claim 1 , wherein the sintered material comprises titania-silica powder.

4. The method of claim 1 , wherein the sintering material comprises a titania-silica suspension.

5. The method of claim 1 , wherein the first portion and the second portion are made of glass.

6. The method of claim 5 , wherein the first portion and the second portion are made of titania-silica glass.

7. The method of claim 1 , wherein applying energy to the sintered material comprises laser sintering the sintered material.

8. A first portion; and A second part; and an additively manufactured joint including a sintered material joining the first portion and the second portion; 13. An apparatus comprising:

9. The apparatus of claim 8 , wherein the additively manufactured joint comprises successively sintered layers of sintered material.

10. The apparatus of claim 8 , wherein the sintered material comprises titania-silica.

11. The device of claim 8 , wherein the first portion and the second portion are made of glass.

12. The apparatus of claim 8 , wherein the first portion and the second portion are made of titania-silica glass.

13. The device of claim 10 , wherein the first portion and the second portion are made of titania-silica glass.

14. The apparatus of claim 13 , wherein at least one of the first portion and / or the second portion is an optical component.

15. The apparatus of claim 8 , wherein the first portion and the second portion are originally separated from a single component.

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