# US 5,893,404 A · Method and apparatus for metal solid freeform fabrication utilizing partially solidified metal slurry > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 5,893,404 A - Document ID: US5893404A - Status: Granted - Kind: A - Application number: 08/717,271 - Filed: 1996-09-20 - Granted: 1999-04-13 - Earliest claimed: 1994-11-22 - Assignees: Semi-Solid Technologies Inc. - Inventors: Patricio F. Mendez; Stuart B. Brown - Web page: https://patentgrep.com/patent/US5893404A ## CPC - B22D 11/00: Continuous casting of metals, i.e. casting in indefinite lengths (metal drawing, metal extruding B21C) - B22D 11/0631: {formed by a travelling straight surface, e.g. through-like moulds, a belt} - B33Y 10/00: Processes of additive manufacturing - B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor - B33Y 80/00: Products made by additive manufacturing - Y10S 164/90: Rheo-casting - B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22) - 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 - Y10S: TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS ## Abstract Disclosed is a method and apparatus for rapidly producing a metal component from partially solidified metal slurry. A source of metal alloy slurry is provided and maintained under conditions to maintain the slurry state, for example by shearing at a temperature between a liquidus and solidus thereof. The slurry is dispensed through a source nozzle and deposited upon a substrate or upon previously dispensed slurry in a predetermined, controlled manner to produce a component of desired geometry. The substrate may be planar or contoured and may comprise an element of the component being produced. A temperature, pressure or chemical composition controlled deposition environment may be provided to facilitate producing a component having desired characteristics. ## Claims ### Claim 1 An apparatus for joining a plurality of elements utilizing partially solidified material slurry comprising: a source of partially solidified material slurry; a nozzle having an orifice with a minimum dimension of at least 250 microns attached to said source through which said slurry is dispensed; a substrate upon which said plurality of elements are mounted, said elements being oriented to form a space between which slurry is dispensed; and a controller for controlling relative movement between said nozzle and said substrate. ### Claim 2 (depends on 1) The apparatus according to claim 1 wherein: said plurality of elements are joined by a bead of said slurry. ### Claim 3 (depends on 1) The apparatus according to claim 1 wherein: said plurality of elements are joined by multiple layers of said slurry. ### Claim 4 (depends on 1) The apparatus according to claim 1 wherein: temperature of at least a portion of said plurality of elements is controlled in a predetermined manner. ### Claim 5 (depends on 4) The apparatus according to claim 4 further comprising: an environmental enclosure for preheating and controlling the temperature of said plurality of elements. ### Claim 6 An apparatus for producing a component at least in part from partially solidified material slurry comprising: a source of partially solidified material slurry; a nozzle having an orifice with a minimum dimension of at least 250 microns attached to said source through which said slurry is dispensed; a substrate; a solid phase element mounted to said substrate upon which dispensed slurry is at least partially deposited, said element being movable relative to said nozzle; and a controller for controlling relative movement between said nozzle and said element. ### Claim 7 (depends on 6) The apparatus according to claim 6 wherein: temperature of at least a portion of said element is controlled in a predetermined manner. ### Claim 8 (depends on 6) The apparatus according to claim 6 further comprising: an environmental enclosure for preheating and controlling the temperature of said element. ### Claim 9 (depends on 6) The apparatus according to claim 6 wherein: a surface of said element defines a cavity into which slurry is deposited. ### Claim 10 (depends on 6) The apparatus according to claim 6 wherein: said slurry is deposited to increase a dimension of said element. ### Claim 11 A method for joining a plurality of elements utilizing partially solidified material slurry comprising the steps of: providing a source of partially solidified material slurry; dispensing said slurry through a nozzle of said source, said nozzle having an orifice with a minimum dimension of at least 250 microns; orientating said plurality of elements to form a groove between said plurality of elements; and depositing said slurry in said groove by coordinating relative movement between said nozzle and said elements in a predetermined manner. ### Claim 12 (depends on 11) The method according to claim 11 wherein: the step of providing a source of partially solidified material slurry comprises the steps of: providing a source of molten material; and simultaneously shearing and cooling at least a portion of said molten material to a temperature between a solidus and a liquidus thereof. ### Claim 13 (depends on 11) The method according to claim 11 wherein: the step of providing a source of partially solidified material slurry comprises the steps of: providing a source of molten material; and simultaneously shearing and controlling heat flux of at least a portion of said molten material at a transition temperature thereof. ### Claim 14 (depends on 11) The method according to claim 11 further comprising the step of: providing a temperature controlled environment within which said dispensed slurry is deposited. ### Claim 15 (depends on 11) The method according to claim 11 further comprising the step of: providing temperature control of at least one of said plurality of elements. ### Claim 16 (depends on 11) The method according to claim 11 further comprising the step of: providing an environment having a predetermined chemical composition within which said dispensed slurry is deposited. ### Claim 17 A method for producing a component utilizing partially solidified material slurry comprising the steps of: providing a source of partially solidified material slurry; dispensing said slurry through a nozzle of said source, said nozzle having an orifice with a minimum dimension of at least 250 microns; providing a solid element; orientating said solid element relative to said nozzle by coordinating relative movement between said nozzle and said solid element in a predetermined manner; and depositing said slurry onto said solid element to increase a dimension thereof. ### Claim 18 (depends on 17) The method according to claim 17 further comprising the step of: repairing said solid element. ### Claim 19 (depends on 17) The method according to claim 17 further comprising the step of: filling a void in said solid element. ### Claim 20 (depends on 17) The method according to claim 17 wherein: the step of providing a source of partially solidified material slurry comprises the steps of: providing a source of molten material; and simultaneously shearing and cooling at least a portion of said molten material to a temperature between a solidus and a liquidus thereof. ### Claim 21 (depends on 17) The method according to claim 17 wherein: the step of providing a source of partially solidified material slurry comprises the steps of: providing a source of molten material; and simultaneously shearing and controlling heat flux of at least a portion of said molten material at a transition temperature thereof. ### Claim 22 (depends on 17) The method according to claim 17 further comprising the step of: providing a temperature controlled environment within which dispensed slurry is deposited. ### Claim 23 (depends on 17) The method according to claim 17 further comprising the step of: providing temperature control of at least one of said plurality of elements. ### Claim 24 (depends on 17) The method according to claim 17 further comprising the step of: providing an environment having a predetermined chemical composition within which dispensed slurry is deposited.