Importance

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Abstract

A method of depositing metal onto an edge of a metallic substrate, preferably a metallic, thin-edge substrate, involves: (1) directing a high intensity light beam onto the substrate, thereby melting a portion of the substrate and forming a weld pool; (2) while directing the light beam onto the weld pool, introducing a filler wire into the weld pool, wherein exposure to the light beam and residual heat in the weld pool causes the filler wire to melt into the weld pool, the light beam providing sufficient energy to fuse the molten filler wire to the substrate; (3) feeding the filler wire into the weld pool while effecting relative motion between the filler wire and the light source relative to the substrate such that a continuous weld bead is formed from the weld pool; and (4) during steps (1)-(3), exposing the weld pool and filler wire disposed therein to a shielding gas so as to protect the weld pool and filler wire from oxidation. Preferably, the method further involves, after step (3), adjusting filler wire feed rate, light source output, weld velocity and relative movement between the substrate and the light source during deposition to compensate for variations in substrate thickness. A high aspect ratio metal deposit can be achieved by depositing several beads of metal on top of each other.

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First Claim