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US 12,259,185 B2Granted
Powder feeder system and method for recycling metal powder
AssigneeContinuum Powders Corporation
InventorsPaul Meese, Matthew Charles, Sonia Zacher, Daniel Mendez
Life of this patent
Estimating the term…
Abstract
A powder feeder system for a foundry system having a mixing hearth includes a housing assembly, and a feeder assembly in the housing assembly having a moveable barrel feeder for feeding a pre-weighed charge of metal powder into the mixing hearth of the foundry system during operation thereof. A method for recycling metal powder includes the steps of melting a content of the mixing hearth completely; and then feeding the metal powder into the mixing hearth while the contents of the mixing hearth are still molten using the powder feeder system.
Claims20
A powder feeder system for a foundry system having a mixing hearth configured to form a molten metal comprising:
- a housing assembly comprising a plurality of tubular members configured to provide a sealed flow path for an additive manufacturing metal powder to the mixing hearth, the tubular members including a discharge conduit configured to discharge the additive manufacturing metal powder into the mixing hearth;
- and
- a feeder assembly in the housing assembly comprising a moveable barrel feeder in flow communication with the discharge conduit configured to feed a pre-weighed charge of the additive manufacturing metal powder on demand through the discharge conduit into the mixing hearth of the foundry system during operation thereof, such that the additive manufacturing metal powder penetrates a surface of the molten metal in the mixing hearth.
A powder feeder system for a foundry system having a mixing hearth configured to form a molten metal comprising:
- a housing assembly comprising a plurality of tubular members configured to provide a sealed flow path for an additive manufacturing metal powder to the mixing hearth, the tubular members including a discharge conduit configured to discharge the additive manufacturing metal powder into the mixing hearth;
- and
- a feeder assembly in the housing assembly configured to feed the additive manufacturing metal powder into the mixing hearth of the foundry system during operation thereof, the feeder assembly comprising a moveable barrel feeder in flow communication with the discharge conduit, and a drive assembly configured to position the barrel feeder in a loading position in which a pre-weighed charge of the additive manufacturing metal powder is loaded into the barrel feeder, or a feeding position in which the pre-weighed charge of the metal powder is directed through the discharge conduit into the mixing hearth such that the additive manufacturing metal powder penetrates a surface of the molten metal in the mixing hearth, the barrel feeder comprising a hollow cylindrical member having sidewalls, sealed end plates, an internal chamber for the additive manufacturing metal powder, and a feeder port opening extending through the sidewalls into the internal chamber thereof.
A powder feeder system for a foundry system having a mixing hearth comprising:
- a housing assembly comprising a plurality of tubular members configured to provide a sealed flow path for a metal powder to the mixing hearth, the tubular members including a discharge conduit in proximity to the mixing hearth;
- and
- a feeder assembly in the housing assembly configured to feed a metal powder into the mixing hearth of the foundry system during operation thereof, the feeder assembly comprising a moveable barrel feeder in flow communication with the discharge conduit, and a drive assembly configured to position the barrel feeder in a loading position in which a pre-weighed charge of the metal powder is loaded into the barrel feeder, or a feeding position in which the metal powder is inserted into the mixing hearth, the barrel feeder comprising a hollow cylindrical member having sidewalls, sealed end plates, an internal chamber for the metal powder, and a feeder port opening extending through the sidewalls into the internal chamber thereof,
- wherein the housing assembly comprises a cross fitting wherein the barrel feeder of the feeder assembly is mounted for rotation.
1 more element
A powder feeder system for a foundry system having a mixing hearth comprising:
- a housing assembly comprising a plurality of tubular members configured to provide a sealed flow path for a metal powder to the mixing hearth, the tubular members including a discharge conduit in proximity to the mixing hearth;
- and
- a feeder assembly in the housing assembly configured to feed a metal powder into the mixing hearth of the foundry system during operation thereof, the feeder assembly comprising a moveable barrel feeder in flow communication with the discharge conduit, and a drive assembly configured to position the barrel feeder in a loading position in which a pre-weighed charge of the metal powder is loaded into the barrel feeder, or a feeding position in which the metal powder is inserted into the mixing hearth, the barrel feeder comprising a hollow cylindrical member having sidewalls, sealed end plates, an internal chamber for the metal powder, and a feeder port opening extending through the sidewalls into the internal chamber thereof,
- wherein the drive assembly comprises a bell crank having a support plate, a hydraulic cylinder attached to the support plate, and at least one linkage attached to a shaft on the barrel feeder.
1 more element
A powder feeder system for a foundry system having a mixing hearth comprising:
- a housing assembly comprising a plurality of tubular members configured to provide a sealed flow path for a metal powder to the mixing hearth, the tubular members including a discharge conduit in proximity to the mixing hearth;
- and
- a feeder assembly in the housing assembly configured to feed a metal powder into the mixing hearth of the foundry system during operation thereof, the feeder assembly comprising a moveable barrel feeder in flow communication with the discharge conduit, and a drive assembly configured to position the barrel feeder in a loading position in which a pre-weighed charge of the metal powder is loaded into the barrel feeder, or a feeding position in which the metal powder is inserted into the mixing hearth, the barrel feeder comprising a hollow cylindrical member having sidewalls, sealed end plates, an internal chamber for the metal powder, and a feeder port opening extending through the sidewalls into the internal chamber thereof,
- wherein the foundry system comprises a view port and the housing assembly is mounted to the view port.
1 more element
A method for recycling an additive manufacturing metal powder comprising:
- providing a foundry system comprising a heat source and a mixing hearth contained in a sealed reaction chamber;
- providing a powder feeder system for the foundry system comprising a housing assembly comprising a plurality of tubular members configured to provide a sealed flow path for the additive manufacturing metal powder to the mixing hearth, and a feeder assembly having a moveable barrel feeder in the housing assembly for feeding a pre-weighed charge of the additive manufacturing metal powder into the mixing hearth of the foundry system during operation thereof;
- melting a content of the mixing hearth to form a pool of molten metal;
- and
- feeding the pre-weighed charge of the additive manufacturing metal powder into the mixing hearth, such that the additive manufacturing metal powder penetrates a surface of the molten metal in the mixing hearth.
2 more elements
Dependencies are inferred from the claim text.