Structured material alloy component fabrication

Patent metadata

Field	Value
Publication number	US-10626974-B2
Application number	US-201314763896-A
Country	US
Kind code	B2
Filing date	Jan 28, 2013
Priority date	Jan 28, 2013
Publication date	Apr 21, 2020
Grant date	Apr 21, 2020

Abstract

A novel manufacturing method for functionally graded component includes a cold sprayed additive manufactured core material and a cold sprayed additive manufactured set of teeth around said core made from another material.

First claim

What is claimed is:

1. A method of manufacturing a component comprising:
spraying a first powdered metal onto a substrate to form an additive manufactured core;
spraying a second powdered metal to form an additive manufactured set of teeth around the additive manufactured core, the second powdered metal different than the first powdered metal; and
removing the substrate, wherein the step of spraying a first powdered metal onto the substrate comprising cold spraying the first powdered metal onto the substrate having a mandrel shape center to form a gear shaft inner diameter upon removal of the substrate.

2. The method as recited in claim 1 , further comprising removing the substrate subsequent to a heat treating.

3. The method as recited in claim 1 , further comprising spraying the second powdered metal to plastically deform the first powdered metal.

4. The method as recited in claim 3 , further comprising generating high strain rate plasticity.

5. The method as recited in claim 1 , further comprising spraying the first and second powdered metal via a cold spray system.

6. The method as recited in claim 1 , further comprising heat-treating the additive manufactured set of teeth.

7. The method as recited in claim 1 , further comprising final machining the additive manufactured set of teeth.

8. The method as recited in claim 1 , wherein spraying the second powdered metal comprises spraying a tool steel alloy powdered metal.

9. The method as recited in claim 1 , further comprising removing the substrate via melting, subsequent to the heat treating.

Assignees

• United Technologies Corp

Inventors

• El-Wardany Tahany I
• Nardi Aaron T
• Viens Daniel V
• Gu Wenjiong
• Amis Eric J
• Reeve Hayden M

Classifications

• C23C28/021

  including at least one metal alloy layer · CPC title

• B22F3/02

  Compacting only · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• Y10T74/19949

  Teeth · CPC title

• F16H55/17

  Toothed wheels (worm wheels F16H55/22; chain wheels F16H55/30) · CPC title