Metal additive manufacturing using gas mixture including oxygen

Patent metadata

Field	Value
Publication number	US-10583532-B2
Application number	US-201514981321-A
Country	US
Kind code	B2
Filing date	Dec 28, 2015
Priority date	Dec 28, 2015
Publication date	Mar 10, 2020
Grant date	Mar 10, 2020

Abstract

A metal powder additive manufacturing system and method are disclosed that use increased trace amounts of oxygen to improve physical attributes of an object. The system may include: a processing chamber; a metal powder bed within the processing chamber; a melting element configured to sequentially melt layers of metal powder on the metal powder bed to generate an object; and a control system configured to control a flow of a gas mixture within the processing chamber from a source of inert gas and a source of an oxygen containing material, the gas mixture including the inert gas and oxygen from the oxygen containing material.

First claim

What is claimed is:

1. A metal powder additive manufacturing system, the system comprising:
a processing chamber;
a metal powder bed within the processing chamber;
a melting element configured to create a melt pool and sequentially melt layers of metal powder on the metal powder bed to generate an object;
a source of inert gas in fluid communication with the processing chamber;
a source of oxygen containing material in fluid communication with the processing chamber; and
a control system in communication with the source of inert gas and the source of oxygen containing material, the control system configured to:
control a flow of a gas mixture provided to the processing chamber, the gas mixture including:
inert gas from the source of inert gas and
oxygen from the source of oxygen containing material, and

maintain the amount of the oxygen provided to the processing chamber to change the melt pool characteristics of the object.

2. The system of claim 1 , wherein the oxygen containing material includes an oxygen containing gas.

3. The system of claim 2 , wherein the oxygen containing gas includes air.

4. The system of claim 2 , wherein the oxygen containing gas includes pure oxygen.

5. The system of claim 1 , wherein the oxygen containing material includes water.

6. The system of claim 1 , wherein a volume percentage of oxygen in the gas mixture is between approximately 0.5% to approximately 1%.

7. The system of claim 1 , wherein the metal powder includes a metal powder non-reactive to the gas mixture.

8. The system of claim 1 , wherein the metal powder include cobalt chromium molybdenum (CoCrMo).

9. The system of claim 1 , wherein the inert gas is chosen from the group consisting of: argon and nitrogen.

10. The system of claim 1 , wherein the control system controls at least one of: a flow valve system coupled to the source of inert gas, a flow valve system coupled to the source of oxygen containing material and a pump coupled to the source of inert gas and the source of oxygen containing material.

11. The system of claim 1 , wherein the control system changes the amount of oxygen in the gas mixture during operation to maintain the amount of oxygen provided to the processing chamber.

12. A metal powder additive manufacturing method, the method comprising:
providing a metal powder bed within a processing chamber;
creating a melt pool;
sequentially melting layers of metal powder on the metal powder bed to generate an object;
supplying inert gas to the processing chamber from a source of inert gas in fluid communication with the processing chamber;
supplying oxygen to the processing chamber from a source of oxygen containing material in fluid communication with the processing chamber;
controlling a flow of a gas mixture provided to the processing chamber from the source of inert gas and the source of an oxygen containing material, the gas mixture including the inert gas from the source of inert gas and oxygen from the source of oxygen containing material; and
maintaining the amount of the oxygen provided to the processing chamber to change the melt pool characteristics of the object.

13. The method of claim 12 , wherein the oxygen containing material includes an oxygen containing gas.

14. The method of claim 13 , wherein the oxygen containing gas includes air.

15. The method of claim 13 , wherein the oxygen containing gas includes pure oxygen.

16. The method of claim 12 , wherein the oxygen containing material includes water.

17. The method of claim 12 , wherein a volume percentage of oxygen in the gas mixture is between approximately 0.5% to approximately 1%.

18. The method of claim 12 , wherein the metal powder includes a metal powder non-reactive to the gas mixture.

19. The method of claim 12 , wherein the metal powder include cobalt chromium molybdenum (CoCrMo).

20. The method of claim 12 , wherein the inert gas is chosen from the group consisting of: argon and nitrogen.

Assignees

• Gen Electric

Inventors

• Crear Donnell Eugene
• Dulkiewicz Chad Joseph
• Swanner Jr Archie Lee

Classifications

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title