ARTICLE MANUFACTURED THROUGH METAL DEPOSIT IN LAYER FIELD OF THE INVENTION The present invention generally relates to a method and apparatus for depositing a molten metal in a forming process layer by layer in a target such as for example a work space platform or well a substrate to form a three-dimensional object. BACKGROUND OF THE INVENTION Several methods have been proposed for forming three-dimensional articles by depositing layers of material on a substrate. This layered manufacturing is also known as solid-free-form manufacturing or rapid prototyping. A compiled model of a desired object is divided into slices into a limited set of layers. The layers are created sequentially, or they are joined on a previously formed layer. This placement of layers creates an object that approaches the predicted geometry of the three-dimensional object, to the extent that the layers cause a "stair effect", on the edge or in the peripheral area of an object. The stair effect is the result of the application process of the discrete layers of the material. The final appearance of the object can be improved by minimizing the thickness of the layer or by using additional processing raisings such as sandblasting and the like, which polish the surface of the object. Stereol i ography is a method for forming a three-dimensional polymeric article made from a polymeric material. In stereography and photography, a photopolymer is selectively cured using a laser beam to create each layer. The three-dimensional article is constructed on a plate of elevator type in a tank containing the liquid photopolymer. Successive layers are created by lowering the partially created objects in the photopolymer liquid and laser curing a new layer of photopolymer material on the surface of the partially constructed object. Another method comprises a fused deposit modeling process that melts and extrudes a polymeric substance through a nozzle on a target to form the three-dimensional object. Another method includes a lamination wherein layers of a paper or polymer material are cut and bonded onto the substrate, then the edges or the periphery are trimmed with a laser to correspond to a desired layer or to a desired cross section. through the article. The unwanted or waste areas of each layer are cut into a grid. These "squares" are stacked to form square prisms, truncated by the boundary of the object. The "checkered" areas are physically removed after finishing the product, leaving only the desired part.
Another method employs a lamination process in which papers or other mask type materials are used to build layers of matter). n I laser cuts the geometry of layers in the paper that is used as a mask. The material is deposited > bear in the ér > ?to. Cropped that defines a single layer of the three-dimensional article and parts of the material is spliced into the mask material. In the past, it has been difficult to form three-dimensional items made of metal by using a free-form manufacturing process or layer deposit. A method of metal fabrication involves a laser intern process that applies a layer of a metal powder material on top of partial objects and then sinterly seals using a laser beam the portion comprising the new layer . Another method of metal fabrication involves a post-sintering process where metal powder materials are bonded together with a polymer binding material. However, it is difficult to completely remove the polymer binding material from the finished three-dimensional object. The presence of binder residues subtracts from the metallic object part of its desired strength as well as other properties. further, the removal of the polymer material causes voids in the three-dimensional object in such a way that the object is relatively porous. Another metallic material (such as a metal of lower temperature) can infiltrate the three-dimensional porous object with a difference in temperature, in an attempt to fill the spaces. However, the idimensional object then has a composite structure of the "honeycomb" type with less than desirable properties and is subject to progressive deformation or warping during the sintering of the original host material. In addition, the presence of residual polymer and / or filler material act as contaminants within the three-dimensional object and consequently affect the properties of the object. The contaminants may include oxidation products, excess carbon, binder residue and the like. It will be understood that the use of fiber elements or fillers in the infiltration process is different from the use of alloy materials. In the case of infiltration, the two materials- remain distinct; on the contrary, in an alloy, the materials are homogenously mixed together to achieve a desirable combination of properties. Another concern is that when the infiltrated material imperfectly bonds with the matrix material, the microstructure has a very large number of voltage concentrators, thus reducing the strength of the object. While such ridimensioned objects "infiltrated" are sometimes called "fully dense" objects, such a term is an equivocal description of the real characteristics of the three-dimensional object since the three-dimensional object does not consist of substantially a preferred type of metal. Other manufacturing methods employ metal deposition techniques in combination with a metal removal technique such as grinding, grinding, sandblasting and the like. The effect of "staircase" and the rubosity on the edge of each layer are eliminated by machining each layer and its peripheries after depositing the layer. It is the process of machining or removal of metal that determines the real dimensional accuracy of the three-dimensional object. Currently there are several methods and devices for depositing material in fusion. For example, the North American Patent of Mertz et al. No. 5,281,769 describes a welding process and an apparatus for depositing the molten metal. A metal, in fusion, is deposited on a work surface and subsequent layers of metal are deposited there. An electrode and a welding torch can preferably be displaced as a unit in such a way that the melted metal can be deposited at selective locations on the work surface. Alternatively, the work surface can be moved while the welding torch and the collecting electrode are moved or held stationary to selectively position the deposited material on the work surface. The size of the small drop is controlled by applying additional mechanical energy to the feed wire so that the feed metal constantly vibrates. US Patent No. 5,286,573 to Prinz et al discloses a method that employs support structure for the creation of objects by means of a layer deposition process. In the deposit process, each layer is made up of two portions. A portion represents a transverse slice of a three-dimensional object that is being constructed ("the object") and consists of the desired deposit material (s). The other portion is the complement of the shape of the object of the first portion and serves as a supporting structure that supports the shape of the growing object ("the support"). The object material and support structure material are each applied in a predetermined sequence. Numerous layers are thus formed, each placed on the previous layer. In this way, a layer structure is elaborated. The layer structure contains the elaborated object of the position material surrounded by the support material. For each layer, both the support material and the object material, either the support material or the object material, or neither the support material nor the object material can be formed to produce its desired object. Preferably, the shape occurs after the application of the object material or support material and before the application of the subsequent layer. Patent document No. 5.3 < "> 1,8 > 3 by Ppnp et al describes an automated system that has numerous workstations to form objects by accumulating my. &.1 et layers.Each layer > -3S a transverse slice of a three-dimensional object which is being constructed and consists of the desired object material.In addition to the object material, each layer also contains a second portion that acts as a complement to the shape of the object of the deposit material portion and serves as a support structure. for the shape of the growing object, during the manufacture of the article, several operations are carried out on the piece, for each layer. In addition to the material deposit station, several process stations are used, each of which has at least one separate function. These functions can include any application combination of shot blasting, 3? Mp? Eza, sandblasting, heat treatment, forming, inspection, mask making and packing. U.S. Patent No. 5,3 <.;?, 415 of Ppnz et al. Describes a method for the manufacture of idimensional articles by the incremental accumulation of material of layers of material. In one embodiment, a layer of object material and support material is applied. Depending on the shape of the object, one or the other material is applied first, then it is formed until dimensional accuracy is achieved, and then the other material is deposited. The deposited layer is then machined, cleaned, shot blasting and the like are applied to it. The process is repeated until all the rails are in place. After application of the final layer, the supplementary material is removed leaving the c-shaped object formed in the deposit material. Non-Theatrical Patent No. 5,398,193 to deAngelis discloses a method and apparatus for making a three-dimensional object through the deposition layer by layer controlled and / or extraction. A representation of the three-dimensional computed model of the dimensional part is provided and the representation sliced into successive layers corresponding to the predetermined thickness layers of the part. The computer model generates sequences of the part and any contour of complementary support material corresponding to each layer. Materials for one or more contours are deposited on a work surface within a processing enclosure. Parts of the material are removed from the contours. The steps of processing by deposit and removal are repeated as necessary under the control of the computed model to finish the three-dimensional object. Additional processing includes the machining removal of a sublayer to ensure thickness tolerances or hardening and chemical surface enhancement to ensure selective adhesion of the next layer of aggregate. The steps of creating controlled layers are repeated to build the entire part surrounded by complementary materials that are then removed to obtain a fabricated part. A major disadvantage of the above methods is that it relies on a machining portion of these methods to achieve the desired dimensional accuracy of the three-dimensional object. In many situations, the objects that are being formed require several steps after manufacturing to produce an acceptable three-dimensional object or final product. An improved method is required to create solid or three-dimensional objects that employ a precise deposit of the material on a work surface or substrate. However, until the present invention, there has been no presentation or suggestion that a supply of small droplets could be precisely controlled and supplied to form a solid or three dimensional high quality article in a net form without the use of a manifold or mold . A method for forming a spray of small droplets of substantially uniform size is presented in US Pat. No. 5,26 > , 098 of Chun et al, which describes a process and an apparatus for producing and maintaining small droplets of metal of uniform size. The small drops are deposited as a mist to cover a substrate. A small droplet generator is placed inside a dew chamber. The small droplet generator consists of a container for containing and liquefying a metal charge, a device for forming small metal droplets of uniform size, and a device for loading small droplets of metal as small droplets form. The forming device is preferably either a vibration device for vibrating the melted metal in the container (or at least one jet of oscillating gas placed outside the container at the point at which the liquefied metal leaves the container). The liquefied metal is pushed from the crucible through a hole in the container to form small droplets of metal. As the liquefied metal leaves at least one hole in the form of a jet or flow, the vibrations imposed on the liquefied metal cause the jet to break into small metal droplets of uniform size. An electric charge is applied on the small drops as the small drops form. The small metal droplets can be charged either by charging the liquefied metal while it is in the container or by loading the small droplets as the small droplets form or after their formation after leaving the crucible. As each small droplet breaks from the jet or flow, the small droplet retains a portion of the charge. With this charge, the small drops are rejected between them in the duel and disperse in a cone shape as the small drops fall to a substrate. When small droplets of uniform size are charged, the small drops are oriented to form a cone configuration due to the same polarity of the small droplets and the rejection of each small droplet in relation to the small neighboring drop. The Chun et al '098 patent also claims the application of an electric field in the flow path of the small metal droplets to change their trajectories. A thesis presented by C.H. Passoi to the Department of Mechanical Engineep of the Massachusetts Institute of Technology (MIT) on May 5, 1992 describes a dew formation study using dewdrops of uniform droplets, small placement production techniques drops, and selection of small droplets and deviation where plates are placed under the load plate to deflect the small droplets charged off the side where they would be collected. The small unloaded drops can pass unimpeded.
An article written by P.J. Acquaviva et al. titled Issues ín Application of Thermo Spraying to Melt Mold Fabpcation (Application of thermal spraying for the manufacture of fusion mold) published in SBEC International, 1994, describes a process of dew and deposit of uniform small droplets that can be manipulated by the movement of a substrate at various speeds and directions. A thesis presented by God rd arl Abel to the Department of Mechanical Engineep at MIT on May 18, 1994 describes the use of a uniform small droplet dew formation process to form deposits on stationary and mobile substrates; the formation by roclo of three-dimensional parts; and, instead of allowing the small droplets to randomly disperse on the basis of an unknown disorder, the small droplets can be charged differently and after being shipped to create a more predictable mass flow distribution. U.S. Patents Nos. 5,171,360; 5,226,948; 5,259,593; and 5,340,090 to Or et al. describe methods and apparatus for forming a product in a neat manner by directing a stream of a liquid material over a manifold and the shape of the desired product. A variable disorder is applied over time to the flow to produce a stream of small liquid droplets where the small droplets settle on the collector and solidify into a unitary form. The 1995 Orme et al document filed with SFF in Austin, Texas, describes parameters ds? thermal design for the development of solid free-form manufacturing of «« .tructuralps materials with controlled small droplets. Due to the need for a better and more efficient method for the manufacture and formation of three-dimensional solid objects, and as a result of extensive research, a new method for the creation of a three-dimensional solid object has been developed by depositing a melted metal. As far as is known, there is no presentation according to which a three-dimensional solid object could be formed by supplying small metal droplets of uniform size, especially in layers, with high precision. It is therefore an object of the present invention to develop an apparatus and process for manufacturing high quality solid metal objects. The present invention further provides a process that does not involve the use of multiple processing steps to form each deposit layer, or otherwise achieve the dimensional accuracy of the three-dimensional solid object. BRIEF DESCRIPTION OF THE INVENTION The present invention provides a high precision method and apparatus for superimposing, in a crescent form, layers of small metal droplets of uniform size of a desired material (s) on a binder or platform to form a three-dimensional solid object. Objects are created quickly and directly by controlled deposition of small droplets. The deposition of the small drops in layers is controlled by the use of computer-based object geometry models. The solid object is elaborated in an increasing way using layers created from small droplets of uniform size. It is the control and application of the individual small droplets that provide the solid object with its desired characteristics. The method and apparatus of the present invention provides a "fully dense" three-dimensional solid object made of metal or a desirable alloy material. In addition, the three-dimensional solid article has a uniform density and substantially no voids and is not porous. No sintering or infiltration processes are required to form the fully dense article of the present invention. The solid object formed using the present invention has a homogeneous microstructure. In addition, the article of the present invention is substantially free of contaminants in such a way that the formed article has highly desirable physical characteristics. The article made in accordance with the present invention possesses desirable characteristics and physical properties that are substantially better than the properties found in articles formed by conventional casting processes., spray or molding. The three-dimensional solid object has dimensional tolerances, tensile strength, fatigue and compression, hardness, toughness, and characteristics and properties of desirable wear resistance. The solid object has a substantially uniform or homogeneous isotropic content of the material in the structure of the three-dimensional article. The present invention can be easily and inexpensively used very quickly and inexpensively to produce metal tools or products for the requirements of the customer's production. Furthermore, the apparatus of the present invention can be constituted of "table" size for use in applications where there is limited space availability such as submarines or offshore drilling platforms. In addition, it is possible to quickly produce a desired three-dimensional solid object in such a way that the customer does not have to have inventories that require an expensive space. In preferred embodiments, the objects are created employing a uniform droplet formation process as described in the North American Patent of Chun et al. Na 5,226,098 where the deposit material is supplied in a metal feed system having a heater to melt the metal. The melted metal is in a small droplet formation device such as a crucible having at least one orifice that allows the passage of melted metal. In a preferred embodiment, the orifice has a diameter within a range of about 50 to 500 microns. The leaking material is subjected to a pressure differential of approximately 3515.5 kg / m2 to 35155 >; sg / m2 which pushes the melted material through the hole in the form of a current. The melted metal is subjected to a certain frequency and / or amplitude in such a way that free liquefied metal. The vibration and surface tension of the metal causes the controlled breaking of the molten metal stream into small droplets of uniform size when the melted material leaves the hole. As the small droplets form, the small droplets undergo a fall, positive or negative. The similar erarga in the small individual droplets keeps the small droplets apart and prevents the small droplets from coming together in their displacement with small neighboring or adjacent droplets, and therefore allows the small droplets to maintain their uniform size. The present invention is an improvement in relation to the technology presented in the Chun et al patent. '098 where the similar charge in the small droplets causes the small droplets to spawn and deposit in the form of dew. The present invention provides a method for focusing the small droplets or aligning the small droplets in a narrow stream or in a single row after their formation instead of allowing the small droplets to be scattered in a spray. The present invention also prevents the small droplets from joining v * »rtica 1 to each other, thus maintaining a size consistency. In accordance with the present invention, the supply of small droplets is aligned or focused on a substantially narrow flow or line by passing the supply of small charged droplets adjacent to an alignment device or through said device. The alignment device adds an additional force field (electric power) that carries the m? = > I charge the small drops. The alignment device rejects the small droplets substantially uniformly inward toward an ee that extends through the alignment device. The r & ch? The small droplets inwards force the small drops to form in a thin stream. Rejecting the small drops during the trajectory of the small drops, the small drops remain focused in a single row stream or a single fine line of small drops. Accordingly, it should be further understood that the present invention comprises, in part, a method of aligning the small droplets. In several modalities, the small droplets put "in" are already - already maintaining, reducing or increasing 1 < Is the drop of the small drops as the small ot are supplied and deposited in a blank or in a partially formed three-dimensional article. In a preferred embodiment, the alignment device comprises at least one hollow axiometric rejection cylinder or in a device > I reject frus -common > which is positioned adjacent > r > well close to the white or to the partially formed article. An e e that runs through the alignment device is aligned with the nominal path > laugh the crómente of small drops. The current that emerges from molded material has an electrical charge of the same polarity as that of a small drop. In a preferred embodiment, as the jet stream is broken into small g, a charge is supplied to the small drop. When the charging device is maintained at a predetermined tension relative to the jet stream, the combination of the voltage and the > The tangent between the charging device and the jet stream carries a charge to the point of advance of the jet stream. Each small drop retains a charge that the small droplet had before freeing itself from the jet stream. The charge in the small drop causes > The small droplet rejects the small droplets adjacent to it, preventing the small droplets from coming together. In accordance with the present invention, the small charged gs. Are held in a narrow line or predetermined path by the alignment device. In preferred embodiments, the "alignment device maintains the load, applies an additional load to the small drops" riescen >Rl lenses either reduce the load on the small drop offs. The similar crankcase applied to the small droplets keeps the small droplets away from the alignment device and also away from ca > ria small drop adjacent. Therefore, when loading the device > When the alignment is large enough, the small droplets will be at a uniform distance from each other in the stream and will tend to cluster around an ee that extends through the "alignment" .The small droplets remain in a current state. The first narrow band as the small droplets pass through the alignment device or adjacent to the alignment device It should be understood that in various embodiments the alignment device may comprise an additional device for reducing the carya in the small lines. >: j > descendants providing, for example, to a stream of small positively charged droplets an electron flow which reduces the charge in the small droplets In a preferred embodiment, the small g. They supply the target in a closed system so that there is less risk of contamination or, for example, oxidation on the surface of the products. queñas drops and »3r consequent within the > rap > as > It rejects deposited materials. In a preferred embodiment, the air in the locking space is replaced by an inert beam such as argon or nitrogen. When heavy, inert lumps, such as, for example, angled, are assembled, the inert toases are preferably introduced into a lower end of the closed working space. The heavy inert gases displace the lightest air that can escape through the top part > iel space »work locked up. In another preferred embodiment, the air in the working space is replaced by a lighter inert gas with, for example, nitrogen. It will be understood, however, that the type of »inert gas depends on the type of metal that is deposited > rJ > 3. It is also necessary > ~ jue with aluminum deposit, it is preferable n ».? employ n? trogen since nitrogen and aluminum react. It is further understood that in several cases the density differences between the inert gas and the ambient air may be accentuated, for example, by the cold temperature of the argon and the heating of the nitrogen rail. In a preferred embodiment, the workspace maintains a piossive pressure such that any external movement is made and that no ambient air is created in the work space. in > rrerrado. Various containment devices to enclose the workspace include a flexible coating; For example, said coating can be made of a suitable material such as, for example, polyvinyl chloride and the like, which is mounted on a metal structure. Another device p > ara enar sk the space > The work includes a rigid transparent plastic sheet made of suitable material. These containment devices can replace the large vacuum canisters now in use such that the apparatus of the present invention can be employed in a tabletop design. A vacuum chamber can, however, be used to obtain purity levels of desired small droplets and pr »api e > ria »rJe3 > laugh three-dimensional parts as desired. In a preferred modality, the work environment has an inert atmosphere. It is understood that a controlled gas system can be used to push the melt material from > crucible rail containing the melt material at high pressures of approximately 14062 kg / m2 to 35155 t- / m2 (approximately 14i "* ~ 350 kPa) An additional controlled gas system provides a source of low pressure to approximately 703.1 lg. / m2 at 1406.2 kg / m2 to the environment »work. It will be understood that these pressures are> n manometric pressures, is to say that they are higher than the atmospheric pressure, they are not absolute pressures, and they are shown only to facilitate the illustration of the present invention. In operation, it is contemplated that if neary, the working environment could be repeatedly purged by introducing an inert gas to limit oxygen levels. It will be understood that adequate minimum oxygen levels are determined by the measurement of the properties of the final products exposed to different levels of contamination. the fine current or line >From small droplets, it is accurately poured into a blank to fine workstation to form the three-dimensional article. It will be understood that in accordance with the method of the present invention, or the supply of the current > It smears small droplets and / or the white can be washed to form the three-dimensional article. In a modality, the target can be released over a predetermined distance in response to the application of the line of small drops on the target. For example, the target may be displaced hop and / or vertically to the entity at a predetermined rate that depends, in part, on the rate of deposition of small drops. In certain preferred modes, the deposit velocity of small droplets can be monitored by a viewing system. The tridimen ion article formed in the work station is operatively connected to a system > of pusitioning. In a preferred embodiment, the positioning system comprises a table of at least 2-3 axes, and in some embodiments, a table of 3 to 5 axes, impellers for the axes, coding device for receiving and transmitting position data, and a control system to coordinate the movement along the axes. The control device may comprise a rpodalized representation of the geometry of the object supplying the > rrcr > r »deados and device to interpret the movement of the work sphere. In an alternative embodiment, the small droplet formation / delivery device may also be operatively connected to a different position device which displaces the supply of small droplets at positions between at least the X, Y and Z axes in response to a predetermined pattern. In another mode, both the work station and the supply of small droplets can be improved to form the three-dimensional article. In a preferred embodiment, a planning system, such as a suitable software program, accepts a solid model representation of the three-dimensional object. The planning system divides the geometry of the object into a finite number of slices and graphs the path of deposition required to achieve each layer, including requirements for hanging supports. tion) of the article in its entirety. The control system coordinates the planning system, the movement of the device in the form of ion / supply of small drops, and the positioning system of the work station. The monitoring system (s) also monitors all the censor inputs that pass information about the various operating parameters and maintains correct operation parameters such as pressures, temperatures, voltages. and similar. In accordance with the present invention, the parameters (such as pressure, orifice diameter, frequency and amplitude »of the vibrations of the small droplets) can be varied to change the diameter > of the small drops of uniform size. It will also be understood that the optimal diameter of the droplet drops depends, in part, on the three-dimensional articles that are being formed and the type of material being deposited. Other parameters co or for example speed »of metal feed in V5
crucible, pressure and crucible, temperature and amount of charge in the small droplets also affect size P1 and the speed of formation of the small drop of uniform size. Other parameters include the temperature of the target or the article being formed and the condition of the small drops when the small drops are deposited on the target or article that is forming. the temperature of the small droplets and / or white and the speed of falling on the white determine, in part, the binding or fusion of the small droplets in a uniform layer on the white material. In certain embodiments of the present invention, another parameter that can be varied is the "separation" distance between the ion drop shape arrangement and the work station. This change in distance affects both the size »of the impact area of the small drops and the ratio between liquid and solid of the small drops. By varying the ratio between liquid and solid, the quality of the small g ta on the substrate can be changed. It will be understood that the temperature of the reservoir material itself affects the thermal state of the small droplets. In some embodiments, the temperature of the material > of deposit can vary from a temperature jus or above the melting point, and in others? 6
embodiments said temperature may be, for example, of about 50 ° C pn \ > close to the melting point. This difference in temperature of the liquid reservoir material will obviously affect the temperature of the small droplets in relation to the distance from the orifice to the target (ie, 13"away from" 1 n "). . The small drop is supplied in a ratio between liquid and optimal solid or approximately one or two times. In several modalities, the propriore between solid and liquid > of the small drop when the small drop reaches the target is an important variable. The impact of the small droplet on the white converts the kinetic energy of the small droplet drop into thermal energy. This heat fuses again the small drop and the white at the point of impact of the small drop. This new fusion helped the process - linking the small drops on the newly formed surface. In order to achieve geometric precision, the present invention accurately aligns and focuses the stream of small droplets and carefully correlates the speed or direction of the movement of the target in relation to the placement of the flow of small droplets and the flow rate and temperature of the stream of small drops. The flow of drops is controlled for efficiency and precision. In a preferred embodiment, a suitable flow measurement system is installed such as eg a theme > of vision compute, -ado operatively connected to an optical strobe light source to estimate the velocity of the metal flow through the edging of the number of small droplets that pass in a frame at a time. The positioning system moves the target in accordance with the geometry of the object or layer of the dimensional item or support that is being created, the velocity of movement of the target along a predefined path is governed by the velocity of the target. material flow »from deposit, in accordance < The measurement of preference for a flow measurement system. The number of layers and the posiponamiento of the captures that form the article »r? Dimensional determination is determined by numerous factors »Drs. The geometry of the object dictates some points through which a layer must pass; therefore, a minimum number of layers is required in order to form the three-dimensional article. It will be understood that in various embodiments in which a support material is provided, the support material is also placed adjacent to the article > .r > partially manufactured Another factor that affects the geometry of the object is the maximum thickness of each layer. It will be understood that each layer should not be thicker than this portion of the article being formed. It will also be understood that l = >; Functional requirements of the final use of the ridiculous article dictate the surface finish of the three-dimensional article. By consict, the requirement > of a smooth surface finish or a textured finish may also limit the thickness of "rapta. It will be understood, however, that the present invention pyroporates a method for depositing small droplets * having a diameter of about 50 microns in such a manner that the formed wetted article has a desirable surface for most applications of use. final. It will further be understood that, at the edges or periphery of the article, any ladder effect depends not only on the diameter of the small droplets and consequently on the layer thickness, but also on the expansion diameter of the small > drop when the small drop comes into contact with the surface. In most embodiments, the surface adhesion of the edges or periphery of the article being formed has a highly acceptable surface finish with a minimum ladder effect suitable for most end-use requirements. It will be understood that? The actual size of the small droplets that are being deposited depends on the final use requirements of the three-dimensional article. It is the precise control of the deposit of small droplets and the size of each small droplet that allows the production of large solid items. In accordance with the method of the present invention, the deposit material and the control over the size of the small droplets is accurate within fractions > : mm. This improvement in the accuracy of position and size of the ptequenos drops allows the construction of ridiculous articles without resorting to intermediate physical models against the c > '< Do you spray metal or additional processing steps? The three-dimensional articles formed in accordance with the present invention are substantially free of aminants and can be used in industrial and commercial applications. The present invention forms small particles that are deposited in a single operation to form a three-dimensional article. The present invention includes a process of net form that rapidly produces a durable, straightforward three-dimensional article. Both the application increases as the subsequent solidification of the small droplets occurs in a controlled manner, the precision, the structure and the geometry of the article being formed are precisely controlled in such a way that no step is required. ional process to form the three-dimensional article. The small droplets are supplied with a substantially uro size at a preferred speed, and at a preferred distance from the target such that the temperature of the small droplets and the white temperature are within optically defined parameters. Paricularly, the small droplets have a preferred diameter and are deposited at a distance p > t efun in such a way that the liquid to solid ratio of the small drop is especially suitable for the link with the three-dimensional article. If the small drop is too cold, the small drop will form a material similar to dust and n »rr > will join well with the article. If the small drop is too liquid, then the liquid? it will flow and will cause surfaces 3S to shoot and not with rolables in the articulation »three-dimensional before cooling on the surface of the article t dimension l. In a preferred embodiment, the ratio between liquid and solid is approximately 30:70 and the small droplets have a substantially uniform size which varies in diameter by no more than * about ± 2% and more preferably no more than approximately ± 5X. In an especially preferred embodiment, the small droplets are formed between an apparatus that forms small drops of melted metal electrically charged uniformly. The apparatus melts a metal charge in a crucible and pushes the melted material through a small hole (45-200 μm) in diameter to form a laminar or ordinary stream of small drops. The current is broken by the imposition of vibrations (preferably from about 5 to 30 l <; Hz > to a piezoelectric path to form a stream of uniform small droplets. Each small drop is charged by a charging device, such as a high-voltage battery (approximately 300 to 400 V), to give me a small drop from the laminar jet or stream. The small droplets contained a charge of the same p:: > laridad in such a way that the small drops are rejected between them to remain separated and thus maintain its size. original rj In a preferred embodiment, the > rrris > r > It is maintained at a higher pressure than the environment of the work space to push the liquid metal D upward through the hole so that the pressure in the liquid controls the flow of the liquid through the eche. or hole. An advantage of the present invention is that it is now possible to capitalize the surface tension properties of the reservoir metal in order to build hanging portions of material. The hanging portions comprise layers of small droplets extending beyond the edge of a previous layer to form a hanging structure. Another advantage of the present invention is that the movement of the white workstation can be carried out in 3 to 5 axes. The white can be tilted in relation to the axes in addition to the linear movement along or between the e is X, Y and Z. The uiclinac i n allows the creation of hanging portions without supports in the three-dimensional article. For example, the three-dimensional article p > It must be turned 90 'to a position where the material flow continues to accumulate, but at right angles to the deposited material before, forming a positive part in the prog. pipeline completed after the return of the piarte to its original position. Another advantage of the present invention is that in some embodiments, at least two materials can be used where one material is a sacrificial support material and the other material is the desired object material. The support material is supplied adjacent to the material of the object and is used only in the support of the hanging portions of the desired object material. The soup material is removed > desp > It is the termination of the three-dimensional object by the application of thermal, oxidizing, solvent, mechanical, and other suitable devices that are not harmful to the three-dimensional article. The support material can comprise any suitable method such as pcr > Example metal with low melting point, an alloy, salt, glass, ceramic, graphite or a composite element of IO. Another advantage of the present invention is that, in some embodiments, when the distance between the small and small formation diameter and the target is large enough, a supply of small droplets proportioned from this distance will be fully requested. at the moment in which the summit of small drops reaches the target. The supply > of small droplets »rjue solidifies before reaching the target is, in essence, a supply of powdered particles that act as supports for subsequent layers of the deposit material. The dust, because it is not attached to the article that is f > If it is not indicated, it can be removed at the end of the article ri i in ion l. Still another vent of the present invention offers, in certain modalities, a device for relieving pressure in the layers of reservoir material. In certain preferred embodiments, a laser energy source is used to temper or relieve the stress on the layers of material provided to form the three-dimensional arc and to control the surface temperature of the Area. immediate to The three-dimensional metal objects formed in accordance with the present invention have desirable characteristics and are substantially equivalent to the properties of castings, or properties superior to those of the castings. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view, partly in cross section and partly as a view of the internal parts, of an apparatus for depositing material in fusion to form a dimensional article. Figure 1A is a highly enlarged perspective view, partly in section of a portion of the apparatus illustrated in the f? >; g? ra 1. Figure IB is a very enlarged sectional view of a small drop. Fig. 1C is a perspective view of another embodiment of an apparatus for depositing molten material to form a magnetical article. Figure 2 is a perspective view, partly in section and partially enlarged, of a portion of the appartment shown in Figure 1 showing a technique for depositing material and for creating hanging parts. Figure 3 is a perspective view, pia rci al mind in section, partially greatly enlarged and partially as detailed view of 3 as internal parts, a portion > of another modality of an appliance > rr > It was then used to deposit molten metal to form a three-dimensional article and to create collateral pieces. Figure 4 is a perspective view, partially in cross section, partly greatly enlarged and partly as a detailed view of the internal parts, illustrating a portion of another modality »of an apparatus for > 1eμ »: > s 11 a r material in fusion to form an item t r id i -r-nsi n 1 and create hanging parts. Figure 4A is a side elevational view, greatly enlarged, cut in section, of the plane illustrated in Figure 4 that is being formed. Figure 5 is a perspective view, partially cut away, partially enlarged and partially blunted, detailed view of the internal pits, which shows a part of another embodiment of an apparatus for poor deposit. to the merged to form a three-dimensional article and create col etes. The figure is a perspective view, partly in section, illustrating a portion of another embodiment of an apparatus for deptosing molten material to form a three-dimensional article. DESCRIPTION OF THE PREFERRED MODALITIES With reference now to the drawings, several different modalities of the process for forming an article 1 and the apparatuses for its use to carry out the process will be described in detail in detail. As shown in FIG. 1, an apparatus 10 for forming three-dimensional objects is presented in a general manner. The apparatus 10 comprises at least one apparatus 12 for the formation of uniform small droplets, and in the illustrated apparatus, comprises an additional apparatus 13. I for for »ion > : small drops. It will be understood that the appearance of uniform ion droplet form can be as described in US Pat. No. 5,266,098 and Chun t to which the training apparatuses are expressly incorporated herein by reference. of small drops um forms 12 and 13 are enclosed in a cam r-t 15 in a modal i da »J preferred. The chamber 15 comprises a sea or 8 having a suitable translucent coating 9. The bed in an inert atmosphere prevents unwanted contaminants from coming into contact with the molten material when the three-dimensional article is being formed, however, it will be understood that in vain. Other arrangements for removing contaminants from the melting metal being deposited are within the scope of the present invention, and an alternative embodiment illustrating a hemispherical chamber 15 is shown in Figure 1C. The formation of small uniform drops, in a preferred embodiment, is similar to the one in the similar to the uniform formation apparatus 13. For ease of explanation, a set of common numbers will be described. elements in each forming apparatus 12 and 13 of uniform droplets, the small ion-shaped apparatus 12 and the uniformly shaped small apparatus 13; Check each one a vibration device 16 and a crucible 18. It is understood that each crucible 18 has a heating device 19 to melt the reservoir material 14 to a desired temperature, and a displacement device 21 to displace the crucible 18 in at least one address, in some embodiments, 3 directions and / or in the e is X, Y and 7. It will be further understood that in certain embodiments the melting material 14 within the crucible 18 can be found at a desired pressure from a device pressure forming device 17. The melted material 14, in a preferred embodiment, is subjected to vibrations by means of the device 16/3 to a desired amplitude and frequency. A stream or jet 28 of material 14 is formed which leaves the crucible 18 from at least one orifice 20. The vibration of stream 28 causes the formation of a plurality of small droplets 36 >which have a uniform and uniformly substantial size and shape. According to the small droplets 36 formed, the small droplets 36 pass through a charging system 22. The charging system 22 generally comprises an arrow plate 24 having at least one opening 26 aligned with the hole 20. The system of »nar» ga 22 applies a knife on the small drops 36 as the small drops 36 are forming. As c = - »the small drop 36 will discard the current 28,» small fraction > jata 36 retains a part .8
of the load. When the small slots 36 open, the small droplets 36 pass through a focusing or alignment device 30 or adjacent to the focus or alignment device 30. In the embodiment illustrated, the The alignment position 30 may have a cylindrical shape or a conical shape, not shown, which is shown in cross section for ease of illustration The alignment device 30 comprises a carving or repellent surface 32 defining a opening 34, as can best be seen in figure 1A. The loading or repelling surface 32 is preferably made of a highly conductive material, eg copper, aluminum, steel and the like, and in the various embodiments, The aperture 34 has a diameter generally of about 10 to about 40 mm.It will be understood that in other embodiments, the length and diameter of the surface repeats a length of about 150 to about 450 mm. 32 lens depend, at least in part, »on the type of material being deposited, the size of the small drops and the final shape of the three-dimensional article. When the loading surface or repellent 32 is maintained at a desired tension above the small droplets 36 remain at a predetermined distance between them and the surface. > rt le de ca rga. or repellent 32. The repellent force is generally illustrated by means of arrows 35 to be fitted in Figure 1. According to each step, or to 36 Lia, a small droplet guide 36A is rejected, not only in a small next drop 36B, but also on the sides of the loading surface or in the back surface 32, thus avoiding small droplets of water. They should unite with each other as the entire entity is dispersed. The small droplets tend to cluster around a longitudinally insensitive device through the alignment device 30. The charge in the small droplets allows the small droplets to be supplied in a very precise fine line. Be understood that any suitable metal can be used according to the end-use application. the actual charge of each small drop > 1op > not only of the metal used but also of the diameter of the small drop and of the diameter of the opening 34 through which the small charged droplets descend and the tension between the loading plate 32 repellent and small drops 36. Lina charge in the small drops 36 / of the order of 1/1, 000,000 coulomb / gram is useful, however, it is understood that other charges are also useful and that the canals' depend on the various parameters The small droplets are at least partially diffused during the descent and are in a liquid state at the point of impact at which the small droplets at the substrate or system Positioning of work station 40. As can be seen in Figure IB, when the small g-3s 36 cool, a film 37 is formed that protects a melting portion 39. In some embodiments, when the small drop 36 comes into contact either cron the Posicumination system described in the work 40 or with small drops previously used, the film opens and the small drop flattens out. In preferred embodiments, at the point of impact, the small drop has a proportion or ima of apr-on imadate 50:50 aaq * imadamente 20:80 and preferably 30:70 between the illiquid fraction and the solid fraction of the small drop . The optimum proportion ensures an accurate deposition of small droplet drops and avoids a too important re-melting of the target or a reduction of the liquid matter at the point of impact. Referring again to FIG. 1, the position system 40 rr. Workstation assembly comprises a plurality of mobile devices for moving a station surface 42 > of work. A first mobile device 44"displaces the surface 42 of this working area in a direction Y <; ha > forward and backward) is generally "lustrated" by the arrow Y in the first positive displacement disk 44. A second mobile device 46 generally displaces the surface 2 > of work station in the X direction (horizontally or left and right) in accordance with what is generally illustrated by the arrow X illustrated in the displacement device 46. A third device »novo 48 moves the workstation in the direction Z (vertical or upper and lower) as shown generally between arrow Z on the screen 48. In some modes, a fourth device *. i 1 50 • usually moves ad? > Finally, the system 40 for positioning the work station in the X direction between at least one first position or station and a second position or station. In the embodiment illustrated in FIG. 1, the first api to a time 12 of formation of small droplets supplies a type of melting material while the second apparatus of small droplet form 13 provides a different permeation of the same. melting material. E3 workstation positioning system 40 can move between the devices 12 and 13 for forming small droplets by means of the fourth moving means 50. The system 40 of posic reaming > of the work station and the fourth moving means 50 are operatively connected through an additional moving means 52 such as, for example, a pneumatic-hydraulic device to a power source (not shown). unfair to the «provision 40» ie p »rr > 3i > Station whistle jo. The system 40 of posic lonami ento > The work e-.tar.ion and the small droplet formation apparatuses 12 and 13 are operatively connected to a control device 56 having a planning system to provide information for the displacement of the positioning system 40. of work station and / or operating instructions for devices 12 and 13 for forming small droplets. The control device 54 may have > Would you prefer a computer software program or a planning system that reads a representation in a solid model of the geometry of the object and the planning system sectioned this representation in? n Finite slice number The computer program coordinates the performance of the workstation positioning system 40 and monitors all sensor inputs such as pressure, temperature, load, feed rate, frequency, amplitude and distance. The method of the present invention results in the ability to produce, within a matter of hours, from the beginning, a new metal part having pendant portions directly from a CAD file.The three-dimensional article has the purpose of resi and the durability that can be favorably compared with their machined counterparts.In addition, while the deposit as shown here shows a single hole 20, it is understood that Use multiple orifices in the present invention according to the geometry of the article that is being formed. It is further contemplated that the chamber 15 may encompass a vacuum chamber to remove the environment or oxygen from the reservoir chamber. He also contemplated himself ». That the demi > devices that have, p »r > For example, a much smaller glass dome or you in a similar container, as illustrated in Figure 1C, can be used to evacuate the environment, oxygen or the like from the storage chamber 15 and place inside the chamber an inert gas with, for example, argon or nitrogen. The chamber may comprise a lower orifice 56, and an upper orifice 58 permitting the injection and evacuation of an inert gas and / or ambient atmosphere. In the embodiment illustrated in FIG. 1, the work station positioning system 40 can be prearranged in the three plane planes so that, when the drops 36 are deposited in a predetermined pattern, each small «Rjota 36 accumulates in small g» rr >previously deposited to form a new surface 38 of three-dimensional article 60, as illustrated in Fig. 2. The three-dimensional article 60 is generally illustrated as being formed of several small flattened 36C ribs forming the new surface 38 »As a small drop is deposited, the small droplets merge and form a vertical wall 62 in article 6? . In this mode, successive layers of small drops 36D are formed in such a way that the small droplets splice portions of the small 36C previously deposited. Subsequent small drops e, D so impacted on the previous small drops 36C in such a way that the diameter of the small drops 36D buttresses the small drops 36C. In this way, as successive rows of small drops 36E, 36F, 36G are formed, the small drops 36D, 36E, 36F and 36G form a hanging portion generally illustrated as 64. As each small drop impacts the small ones:: rj » rr > Once deposited and solidified, the hanging portion 64 is formed directly without the need for any supporting substrate. Figure 3 illustrates an example of another embodiment where a support or system 140 of work station extension that has a surface or a workstation 142 can rotate around 5 axes in such a way that the workstation 1 2? »C > It can be rotated in additional dimensions. For example, the positioning system 140 is shown rotated in the vertical direction (Y) in such a way that the small drops 36 may be deposited to form the complex dimensional structure of an article 70. It will be understood that a first portion 72 of article 70 can form r-se while flat surface 142 is in the ubstantially horizontal plane (X). Then, while the positional device is substantially in the horizontal plane, a second portion 74 is formed where the small droplets are deposited to construct the vessel by ion 7 which is understood to be an angle subst n > - I to 1 right mind err relation with the first porc i? n 72. Despiues, the device > of position 140 is rotated about an axis in a plane X-Y to allow the formatting of a third portion 76 of article 70 at an angle. As shown in Figure 3, a fourth portion 78 of Article 7? is formed by rotating the device »ie position 1 0 to a vertical direction < Y) in such a way that the small drops are deposited vertically. Referring to Figure 4, an additional three-dimensional article 80 is generally being formed in a work station positioning system 240 having a s? Profi?:? E? 2? Second work station. The positioning system 240 is of mobile preference in at least three directions between the X, Y and Z axes. In the embodiment illustrated in FIG. 4, the first device 12 for piezo formation drops > dep > > r > s? ta p? e »uer.as g» r > 82 of a first material 84 in the workstation station 242 by default. In the illustrated embodiment, the second device 13 > of fn? m = t? n > of small droplets contains a second material 90 cr »support material which deposits small droplets of the second material 90 on portions or adjacent to portions of the article 80 to act as co or a support material. As illustrated in Figure 4A, article 80 comprises a plurality of capias 80A that form a portion of article 80. Second material 90 is deposited at $ ea *? adjacent to the tank material 80. The second material 90 can then receive small additional droplets 80B held in position by the second material 90. At the end of the tridimeusian article 1 80, the second material 90 can be removed by any means, as before posed »do. Referring now to Figure 5, the small droplet formation device 12 can be moved in the X, Y and Z directions. The small-pointer device 12 is operatively connected to the device.; of displacement 21 and can move at least in a vertical direction or Z direction to raise the d? sp »3s? 11 v »t of form ión of small» g »3tas 12 in such a way that the distance between the disposition V» D of formation of small «drops 12 and a station positioning system» of work 340 that supports a The three-dimensional article 120 that is being formed can be increased. It is understood that the workstation system 340 can also be moved in a direction 7 or vertical < according to 1 »rr» illustrated in detail view of the internal parts in figure 5) to increase the distance between the small droplet forming device 12 »and the article 120 being formed. The increase in the distance between the droplet formation device 12 and the small droplet impact area allows a plurality of small droplets to solidify. It also increases before reaching the target. According to the small olives 36Z solidify, the small solidified droplets 367 form a material in powder particles 122 which is used as support material. At the end of the three-dimensional article 120, the support material or powder 122 can be removed from the three-dimensional article 320. The distance and the speed with which the small drops 36Z are deposited are monitored so that the small 36Z droplets do not form. in the article 120. In various embodiments, the dust support area 122 can not retain its desired confi guration in order to act as a suitable support for the hanging parts. In such situations, the powder support area 322 is preferably sopiortado with a wall e: < triple or internal 324 made from melt material 36. Fig. 6 further illustrates a modality > of a device 300 for relieving tension in an article 280 that is being formed. It is understood that, while the strain relief device 100 is illustrated in relation to a crucible system 290, the strain relief device 100 can be employed in all embodiments of the present invention and illustrated herein was a crucible system for facilitate ilu traci. The voltage relief device 30 may comprise a laser energy source. The strain relief device 300 has a number of steering devices 302 and 304 for directing a beam 306 of laser light or laser energy to a portion 286 / of the material being deposited. The laser beam 306 relieves the tension in the material 280 that is being deposited and simultaneously bonding on the previously deposited capias to prevent ripples, warping and other stresses from accumulating in the article 280. In addition, the laser beam 306 can be used to maintain a temperature control in the area of immediate impact as small drops 282 are deposited s »r > The three-dimensional article 280 c: ¡e is being formed. It will be understood, however, that other methods to relieve stress in each chrome layer, for example shot blasting, thermal induction or other teinplate processes, may also be employed and are useful in the present invention. Within the scope of the present invention, in another embodiment, the powder particles can be formed using two small droplet forming apparatuses; where a device is pos? i »Dna at a first distance from the workstation passivation system in such a way that the small drops form the three-dimensional article, and where the second apparatus is positioned at a second distance in relation to with the system > of posi lon of work station in such a way that the particles are formed > of dust. In accordance with the present invention, no additional processing steps are required in the finished article once the deposit process is complete. Each of the methods for forming a three-dimensional article "described here can be used to produce a three-dimensional article of any shape, size and / or chromality. While some preferred embodiments have been illustrated and described, it will be understood that the present invention is not limited to these fashion 11 but can be carried out in various ways within the scope of the following directions indicating ions.