High-density, crack-free metallic parts

Patent metadata

Field	Value
Publication number	US-10099267-B2
Application number	US-201715446491-A
Country	US
Kind code	B2
Filing date	Mar 1, 2017
Priority date	Mar 3, 2016
Publication date	Oct 16, 2018
Grant date	Oct 16, 2018

Abstract

In various embodiments, three-dimensional layered metallic parts are substantially free of gaps between successive layers, are substantially free of cracks, and have densities no less than 97% of the theoretical density of the metallic material.

First claim

What is claimed is:

1. A three-dimensional part manufactured by additive manufacturing using a feedstock material comprising molybdenum, the part (i) comprising a plurality of layers each comprising solidified molybdenum, (ii) being free of gaps between successive layers, and (iii) being free of cracks, wherein a density of the part is no less than 97% of a theoretical density of molybdenum, and wherein a concentration within the part of each of sodium, calcium, antimony, magnesium, phosphorous, and potassium is less than 1 ppm by weight and at least 0.001 ppm by weight.

2. The part of claim 1 , wherein the density of the part is no less than 99% of the theoretical density of molybdenum.

3. The part of claim 1 , wherein a concentration of oxygen within the part is less than 5 ppm by weight and at least 0.001 ppm by weight.

4. The part of claim 1 , wherein the feedstock material comprises wire.

5. The part of claim 1 , wherein the feedstock material comprises arc-melted wire.

6. The part of claim 1 , wherein the feedstock material comprises wire fabricated by a process comprising:
compacting powder to form a feed electrode, the powder comprising molybdenum;
arc-melting the feed electrode in a processing ambient comprising a vacuum or one or more inert gases, thereby forming a billet; and
mechanically deforming the billet into wire having a diameter less than a diameter of the billet.

7. The part of claim 1 , wherein the density of the part is no less than 99.5% of the theoretical density of molybdenum.

8. A three-dimensional part manufactured by additive manufacturing using a feedstock material comprising a metallic material comprising at least one of niobium, tantalum, rhenium, tungsten, or molybdenum, the part (i) comprising a plurality of layers each comprising solidified metallic material, (ii) being free of gaps between successive layers, and (iii) being free of cracks, wherein a density of the part is no less than 97% of a theoretical density of the metallic material, and wherein a concentration within the part of each of sodium, calcium, antimony, magnesium, phosphorous, and potassium is less than 1 ppm by weight and at least 0.001 ppm by weight.

9. The part of claim 8 , wherein the density of the part is no less than 99% of the theoretical density of the metallic material.

10. The part of claim 8 , wherein the feedstock material comprises wire.

11. The part of claim 8 , wherein the feedstock material comprises arc-melted wire.

12. The part of claim 8 , wherein the feedstock material comprises wire fabricated by a process comprising:
compacting powder to form a feed electrode, the powder comprising the metallic material;
arc-melting the feed electrode in a processing ambient comprising a vacuum or one or more inert gases, thereby forming a billet; and
mechanically deforming the billet into wire having a diameter less than a diameter of the billet.

13. The part of claim 8 , wherein the density of the part is no less than 99.5% of the theoretical density of the metallic material.

14. A three-dimensional part manufactured by additive manufacturing using a feedstock material comprising a metallic material comprising at least one of niobium, tantalum, rhenium, tungsten, or molybdenum, the part (i) comprising a plurality of layers each comprising solidified metallic material, (ii) being free of gaps between successive layers, and (iii) being free of cracks, wherein (a) a density of the part is no less than 97% of a theoretical density of the metallic material, (b) a concentration within the part of each of sodium, calcium, antimony, magnesium, phosphorous, and potassium is less than 1 ppm by weight and at least 0.001 ppm by weight, and (c) a concentration of oxygen within the part is less than 5 ppm by weight and at least 0.001 ppm by weight.

15. The part of claim 14 , wherein the density of the part is no less than 99% of the theoretical density of the metallic material.

16. The part of claim 14 , wherein the feedstock material comprises wire.

17. The part of claim 14 , wherein the feedstock material comprises arc-melted wire.

18. The part of claim 14 , wherein the feedstock material comprises wire fabricated by a process comprising:
compacting powder to form a feed electrode, the powder comprising the metallic material;
arc-melting the feed electrode in a processing ambient comprising a vacuum or one or more inert gases, thereby forming a billet; and
mechanically deforming the billet into wire having a diameter less than a diameter of the billet.

19. The part of claim 14 , wherein the density of the part is no less than 99.5% of the theoretical density of the metallic material.

Assignees

• Stawovy Michael Thomas
• Starck H C Inc

Inventors

• Stawovy Michael Thomas

Classifications

• B22F10/20

  Direct sintering or melting · CPC title

• B23K2103/08

  Non-ferrous metals or alloys · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• C22C27/04

  Alloys based on tungsten or molybdenum · CPC title

• B22F3/24

  After-treatment of workpieces or articles {(B22F3/1146 takes precedence)} · CPC title