Other

Westaim Technologies

Stephen F Corbin

Prasad Shrikrishna Apte

Amir Khajepour

Ehsan Toyserkani

Douglas J McIsaac

Christine E Third

Xin Qiao

A system is disclosed for monitoring and controlling laser cladding process by powder injection in real-time. The invention combines laser cladding technique along with automated direct feedback control to achieve a good quality clad in terms of dimensional and metallurgical characteristics. The system uses optical CCD-based detectors as the feedback system. The optical CCD-based detectors along with a pattern recognition algorithm is used to determine the clad characteristics in real-time. These characteristics are clad's dimensions, solidification rate, and roughness that are fed into a closed loop control system to adjust the laser power and table velocity to produce desired clad quality.

System and method for closed-loop control of laser cladding by powder injection

Variable melting point solders and brazes having compositions comprising a metal or metal alloy powder having a low melting point with a metal powder having a higher melting point. Upon heating, in-situ alloying occurs between the low and high melting point powders such that solidification occurs at the solder or braze temperature thus creating a new, higher solidus (or melting) temperature with little or no intermetallic formation. A solder comprising Sn powder mixed with a Sn&mdash;Bi eutectic powder having a composition of 63 wt % Sn:57 wt % Bi such that the bulk composition of the mixture is 3 wt % Bi has an initial melting point of 140&deg; C. and a re-melt temperature of 220&deg; C. after heating due to in-situ alloying. A composition of Pb powder mixed with a Pb&mdash;Sn eutectic powder having a composition of 62 wt % Sn:58 wt % Pb such that the bulk composition of the mixture is 15 wt % Sn has an initial melting point of 183&deg; C. and a re-melt temperature of 250&deg; C.

Variable melting point solders and brazes

Novel processes are provided for the production of porous ceramic preforms, metal activated porous ceramic preforms and intermetallic/ceramic/metal composites. These products are all manufactured using processes which are based on tape casting techniques.

Method of manufacturing intermetallic/ceramic/metal composites

A process is provided for the manufacture of porous metal components. The process involves preparing a colloidal suspension comprising a metal-containing powder in admixture with a binder system, and a plasticizer in an organic solvent. Optionally, a particulate pore forming agent may be added to the suspension. The suspension is cast into a thin sheet and air dried to thereby form a tape. The tapes are layered and formed by compacting at predetermined pressures to laminate the tapes, thus forming a green body. Optionally, a second pore-forming agent may be introduced between, or associated with, the tape layers. The green body is heated at a controlled rate to form a brown body, and finally sintered under controlled conditions to produce the finished component.

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Kitchener, Canada

Stephen F Corbin