High-density, crack-free metallic parts

Patent metadata

Field	Value
Publication number	US-10926311-B2
Application number	US-201816123363-A
Country	US
Kind code	B2
Filing date	Sep 6, 2018
Priority date	Mar 3, 2016
Publication date	Feb 23, 2021
Grant date	Feb 23, 2021

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 molybdenum part manufactured by additive manufacturing using a molybdenum feedstock material, the part (i) comprising a plurality of molybdenum layers, (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 at least one of sodium, calcium, antimony, magnesium, phosphorous, or potassium is less than 5 ppm by weight and at least 0.001 ppm by weight.

2. The part of claim 1 , wherein the concentration within the part of each of sodium, calcium, antimony, magnesium, phosphorous, and potassium is less than 5 ppm by weight and at least 0.001 ppm by weight.

3. The part of claim 1 , wherein a concentration within the part of oxygen 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 is arc-melted.

6. The part of claim 1 , wherein the feedstock material is fabricated by a process comprising arc-melting molybdenum powder.

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

8. The part of claim 1 , wherein the concentration within the part of at least one of sodium, calcium, antimony, magnesium, or potassium is less than 5 ppm by weight and at least 0.001 ppm by weight.

9. The part of claim 1 , wherein the concentration within the part of each of sodium, calcium, antimony, magnesium, and potassium is less than 5 ppm by weight and at least 0.001 ppm by weight.

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

11. The part of claim 1 , wherein the feedstock material comprises wire fabricated by a process comprising:
compacting molybdenum powder to form a feed electrode;
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.

12. A three-dimensional part manufactured by additive manufacturing using a feedstock material comprising a metallic material comprising at least one of niobium, tantalum, rhenium, or tungsten, 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 at least one of sodium, calcium, antimony, or potassium is less than 5 ppm by weight and at least 0.001 ppm by weight.

13. The part of claim 12 , wherein the concentration within the part of each of sodium, calcium, antimony, and potassium is less than 5 ppm by weight and at least 0.001 ppm by weight.

14. The part of claim 12 , wherein a concentration within the part of oxygen is less than 5 ppm by weight and at least 0.001 ppm by weight.

15. The part of claim 12 , wherein the feedstock material comprises wire.

16. The part of claim 12 , wherein the feedstock material is arc-melted.

17. The part of claim 12 , wherein the feedstock material is fabricated by a process comprising arc-melting powder comprising the metallic material.

18. The part of claim 12 , wherein the density of the part is no less than 99% of the theoretical density of the metallic material.

19. The part of claim 12 , wherein the density of the part is no less than 99.5% of the theoretical density of the metallic material.

20. The part of claim 12 , 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.

Assignees

• Stawovy Michael Thomas
• Starck H C Inc

Inventors

• Stawovy Michael Thomas

Classifications

• B22F10/20

  Direct sintering or melting · CPC title

• B22D7/005 Primary

  from non-ferrous metals · CPC title

• B21C1/02 Primary

  Drawing metal wire or like flexible metallic material by drawing machines or apparatus in which the drawing action is effected by drums · CPC title

• B22F10/38

  to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures · CPC title

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title