Additive manufactured alloy components

Patent metadata

Field	Value
Publication number	US-11426798-B2
Application number	US-201916394691-A
Country	US
Kind code	B2
Filing date	Apr 25, 2019
Priority date	May 15, 2018
Publication date	Aug 30, 2022
Grant date	Aug 30, 2022

Abstract

An additive manufacturing technique may include forming, on a surface of a substrate, a layer of material using an additive manufacturing technique. The material may include a sacrificial binder and a powder comprising an oxide-dispersion strengthened alloy dispersed in the binder. The technique may include forming, on the layer of material, at least one additional layer of material to form an additively manufactured component. The binder may be selectively sacrificed to leave the powder, for example, to form a component including an alloy.

First claim

What is claimed is:

1. A method comprising:
depositing, from a filament delivery device, a softened or melted filament onto a surface of a substrate to form a first layer of material on the surface of the substrate, wherein the filament comprises a sacrificial binder and a powder comprising an oxide-dispersion strengthened alloy dispersed in the binder;
depositing, from the filament delivery device, the softened or melted filament on the first layer of material to form at least one additional layer of material on the first layer of material, wherein the first layer of material and the at least one additional layer of material, in combination, form an additively manufactured component;
selectively sacrificing the sacrificial binder of the deposited filament to leave the powder in the material; and
sintering the powder of the additively manufactured component to form a sintered additively manufactured component.

2. The method of claim 1 , wherein the sacrificial binder comprises a curable polymer precursor, the method further comprising directing an energy source at the deposited softened or melted filament to selectively cure the curable polymer precursor to form the layer of material.

3. The method of claim 1 , wherein the sacrificial binder in the first layer of material comprises a polymer formed by curing of the curable polymer precursor.

4. The method of claim 1 , wherein selectively sacrificing the binder comprises alternating selectively sacrificing the binder with the deposition of the softened or melted filament by the filament delivery device to form respective layers of the additively manufactured component.

5. The method of claim 1 , wherein selectively sacrificing the binder comprises selectively thermally or chemically sacrificing the binder after forming the additively manufactured component to remove the sacrificial binder from the additively manufactured component.

6. The method of claim 1 , wherein the filament comprises more than about 80% by volume of the powder dispersed in the sacrificial binder and less than 20% by volume of the sacrificial binder.

7. The method of claim 1 , wherein the filament comprises more than about 80% by volume of the oxide-dispersion strengthened alloy.

8. The method of claim 1 , wherein the sacrificial binder comprises a curable polymer precursor, the method further comprising heating the filament with the filament delivery device to soften or melt the filament for deposition onto the surface of the substrate, and wherein the heating of the filament with the filament delivery device initiates curing of the curable polymer precursor.

9. The method of claim 1 , wherein the oxide-dispersion strengthened alloy comprises at least one of a superalloy or a particle-dispersion strengthened alloy.

10. The method of claim 1 , wherein the filament includes at least one shrink-resistant agent.

11. The method of claim 1 , wherein the filament comprises the sacrificial binder in a concentration configured to cause the material to shrink by less than about 20% of an initial volume of the deposited filament in response to selectively sacrificing the binder.

12. The method of claim 2 , wherein the energy source includes a laser.

13. The method of claim 1 , wherein depositing, from the filament delivery device, the softened or melted filament onto the surface of the substrate to form the first layer of material on the surface of the substrate comprises depositing the softened or melted filament onto the surface of the substrate to form a plurality of roads adjacent to each other, the plurality of roads combining to form the first layer of the material on the surface of the substrate.

14. The method of claim 1 , wherein selectively sacrificing the sacrificial binder of the deposited filament to leave the powder in the material comprises sacrificing the sacrificial binder of the deposited filament in the first layer of material prior to depositing the softened or melted filament on the first layer of material to form at least one additional layer of material on the first layer of material, and subsequently sacrificing the sacrificial binder of the deposited filament in the at least one additional layers.

15. The method of claim 1 , wherein the sacrificial binder comprises a thermoplastic.

16. The method of claim 15 , wherein the thermoplastic includes at least one of a polyvinyl alcohol, a polyolefin, a polystyrene, an acrylonitrile butadiene styrene, a polylactic acid, a thermoplastic polyurethane, or an aliphatic polyamides.

17. The method of claim 1 , wherein depositing, from the filament delivery device, the softened or melted filament onto the surface of the substrate to form the first layer of material on the surface of the substrate comprises extruding, from a nozzle of the filament delivery device, the softened or melted filament onto the surface of the substrate to form the first layer of material on the surface of the substrate.

18. The method of claim 1 , wherein selectively sacrificing the sacrificial binder of the deposited filament to leave the powder in the material comprises chemically dissolving the sacrificial binder to leave the powder.

Assignees

• Rolls Royce Corp

Inventors

• Shuck Quinlan Yee

Classifications

• B22F10/32

  of the atmosphere, e.g. composition or pressure in a building chamber · CPC title

• B22F1/10

  Metallic powder containing lubricating or binding agents; Metallic powder containing organic material · CPC title

• B22F10/18

  by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF] · CPC title

• B22F12/41

  characterised by the type, e.g. laser or electron beam · CPC title

• C22C32/0026

  Matrix based on Ni, Co, Cr or alloys thereof · CPC title