# US 12,214,445 B2 · Inclined structure and method of manufacturing same

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- Number: US 12,214,445 B2
- Document ID: US12214445B2
- Status: Granted
- Kind: B2
- Application number: 17/288,846
- Filed: 2019-10-17
- Published: 2022-01-06
- Granted: 2025-02-04
- Earliest claimed: 2018-10-26
- Assignees: Kawasaki Jukogyo Kabushiki Kaisha
- Applicants: Kawasaki Jukogyo Kabushiki Kaisha
- Inventors: Kentaro Watanabe; Ryo Morihashi; Hiroka Fujita; Yoshikatsu Sato; Hayato Iwasaki
- Web page: https://patentgrep.com/patent/US12214445B2

## CPC

- B23K 9/042: {Built-up welding on planar surfaces}
- B23K 26/342: Build-up welding
- B22F 10/22: Direct deposition of molten metal
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 10/38: to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
- B33Y 10/00: Processes of additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- Y02P 10/25: Process efficiency
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A method of manufacturing an inclined structure extending in an oblique direction from a surface of a base metal includes: forming a base portion by stacking a plurality of build-up layers on the surface of the base metal, each of the plurality of build-up layers being formed by a plurality of beads, the base portion including a reference surface inclined at an opposite side of the oblique direction across a perpendicular line of the surface of the base metal; and forming a projecting portion by stacking a plurality of build-up layers on the reference surface of the base portion, each of the plurality of build-up layers being formed by a plurality of beads, the projecting portion extending in the oblique direction from the base portion.

## Claims

### Claim 1

A method of manufacturing an inclined structure extending in an oblique direction from a surface of a base metal, the method comprising:
forming a base portion by stacking a plurality of build-up layers on the surface of the base metal, each of the plurality of build-up layers being formed by a plurality of beads, the base portion including a reference surface inclined at an opposite side of the oblique direction across a perpendicular line of the surface of the base metal; and
forming a projecting portion by stacking a plurality of build-up layers on the reference surface of the base portion, each of the plurality of build-up layers being formed by a plurality of beads, the projecting portion extending in the oblique direction from the base portion.

### Claim 2 (depends on 1)

The method according to claim 1, wherein the inclined structure has an annular shape which increases or decreases in diameter in a direction away from the base metal.

### Claim 3 (depends on 1)

The method according to claim 1, wherein stacking of the plurality of build-up layers on the surface of the base metal and stacking of the plurality of build-up layers on the reference surface of the base portion are performed by laser metal deposition.

### Claim 4 (depends on 3)

The method according to claim 3, wherein:
powder is used as a welding material in the laser metal deposition; and
when stacking the plurality of build-up layers on the reference surface, each of the build-up layers is formed such that the beads are arranged in order from a side close to the base metal.

### Claim 5 (depends on 1)

The method according to claim 1, wherein when stacking the plurality of build-up layers on the surface of the base metal, each of the build-up layers is formed such that the beads are arranged in order from a side close to the reference surface.

### Claim 6 (depends on 2)

The method according to claim 2, wherein stacking of the plurality of build-up layers on the surface of the base metal and stacking of the plurality of build-up layers on the reference surface of the base portion are performed by laser metal deposition.

### Claim 7 (depends on 6)

The method according to claim 6, wherein:
powder is used as a welding material in the laser metal deposition; and
when stacking the plurality of build-up layers on the reference surface, each of the build-up layers is formed such that the beads are arranged in order from a side close to the base metal.

### Claim 8 (depends on 2)

The method according to claim 2, wherein when stacking the plurality of build-up layers on the surface of the base metal, each of the build-up layers is formed such that the beads are arranged in order from a side close to the reference surface.

### Claim 9 (depends on 3)

The method according to claim 3, wherein when stacking the plurality of build-up layers on the surface of the base metal, each of the build-up layers is formed such that the beads are arranged in order from a side close to the reference surface.

### Claim 10 (depends on 4)

The method according to claim 4, wherein when stacking the plurality of build-up layers on the surface of the base metal, each of the build-up layers is formed such that the beads are arranged in order from a side close to the reference surface.

### Claim 11 (depends on 6)

The method according to claim 6, wherein when stacking the plurality of build-up layers on the surface of the base metal, each of the build-up layers is formed such that the beads are arranged in order from a side close to the reference surface.

### Claim 12 (depends on 7)

The method according to claim 7, wherein when stacking the plurality of build-up layers on the surface of the base metal, each of the build-up layers is formed such that the beads are arranged in order from a side close to the reference surface.