Three-dimensional (3D) printing

Patent metadata

Field	Value
Publication number	US-11633782-B2
Application number	US-201616073173-A
Country	US
Kind code	B2
Filing date	Apr 19, 2016
Priority date	Apr 19, 2016
Publication date	Apr 25, 2023
Grant date	Apr 25, 2023

Abstract

In a three-dimensional printing method example, a liquid functional agent is selectively applied. The liquid functional agent includes an alloying agent. A metallic build material is applied. The liquid functional agent is selectively applied before the metallic build material, after the metallic build material, or both before and after the metallic build material. The liquid functional agent patterns the metallic build material to form a composite layer. At least some of the metallic build material is exposed to energy to melt the at least some of the metallic build material to form a layer. Upon contact or after energy exposure, the alloying agent and the build material alter a composition of the composite layer.

First claim

What is claimed is:

1. A three-dimensional (3D) printing method, comprising:
selectively applying a liquid functional agent including a liquid vehicle and an alloying agent selected from the group consisting of an alloying element that interacts with a metallic build material to form an alloy, a metal oxide that reduces to form the alloying element, a thermally decomposing precursor that liberates the alloying element, wherein the thermally decomposing precursor is selected from the group consisting of sucrose, a metal carbonyl, an organometallic compound of a transition metal, a dispersion of alloying metal oxide particles, and a metal salt that is to produce the metal oxide that reduces to form the alloying element;
applying the metallic build material, wherein the metallic build material is selected from the group consisting of steel, stainless steel, titanium, aluminum, nickel, cobalt, iron, nickel cobalt alloys, gold, silver, platinum, and copper;
wherein the liquid functional agent is selectively applied after the metallic build material, and wherein the liquid functional agent patterns the metallic build material to form a composite layer; and
exposing at least some of the metallic build material to energy from a tightly focused energy source sufficient to elevate a temperature of the at least some of the metallic build material above its melting point, thereby melting the at least some of the metallic build material to form a layer, wherein the tightly focused energy source is selected from the group consisting of a laser, an electron beam, and a microwave tip emitter;
wherein the build material alter a composition of the composite layer through energy-induced alloying.

2. The method as defined in claim 1 wherein the at least some of the metallic build material includes the composite layer and unpatterned metallic build material.

3. The method as defined in claim 1 , further comprising:
liberating the alloying element from the alloying agent; and
reacting the alloying element with the build material in the composite layer to form the alloy.

4. The method as defined in claim 3 wherein the alloying agent is the metal oxide and wherein the alloying element is an elemental metal produced from the metal oxide by reducing the metal oxide.

5. The method as defined in claim 4 wherein the reducing of the metal oxide is accomplished by:
heating the metal oxide in an environment containing a reducing gas selected from the group consisting of hydrogen gas and carbon monoxide gas, or an inert gas in combination with the reducing gas; or
activating a reducing species in the liquid functional agent during the energy exposure, the reducing species being selected from the group consisting of a sugar and an aldehyde.

6. The method as defined in claim 4 , further comprising selectively applying a second liquid functional agent including a reducing species selected from the group consisting of a sugar and an aldehyde to the composite layer, and wherein the reducing of the metal oxide is accomplished by activating the reducing species in the second liquid functional agent during the energy exposure.

7. The method as defined in claim 1 wherein the thermally decomposing precursor is the metal salt, and wherein the alloying element is an elemental metal liberated from the metal salt by:
thermal decomposition of the metal salt to form the metal oxide; and
reducing the metal oxide.

8. The method as defined in claim 7 wherein the reducing of the metal oxide is accomplished by:
heating the metal oxide in an environment containing a reducing gas selected from the group consisting of hydrogen gas and carbon monoxide gas, or an inert gas in combination with the reducing gas; or
activating a reducing species in the liquid functional agent during the energy exposure, the reducing species being selected from the group consisting of a sugar and an aldehyde.

9. The method as defined in claim 7 , further comprising selectively applying a second liquid functional agent including a reducing species selected from the group consisting of a sugar and an aldehyde to the composite layer, and wherein the reducing of the metal oxide is accomplished by activating the reducing species in the second liquid functional agent during the energy exposure.

10. The method as defined in claim 1 wherein the thermally decomposing precursor is the sucrose, the metal carbonyl, or the organometallic compound of the transition metal, and wherein the thermal decomposition of the thermally decomposing precursor is accomplished by heating the thermally decomposing precursor in an environment containing an inert gas or a reducing gas.

11. The method as defined in claim 1 wherein:
the alloying agent is the alloying element that interacts with the metallic build material to form the alloy; and
the alloying element is selected from the group consisting of ruthenium, rhodium, palladium, osmium, iridium, platinum, copper, silver, gold, carbon, boron, sulfur, silicon, nickel, tin, and indium.

12. The method as defined in claim 5 wherein:
the metal oxide is selected from the group consisting of iron (II) oxide, iron (III) oxide, iron (II, III) oxide, magnesium oxide, chromium (II) oxide, chromium (III) oxide, chromium dioxide, chromium trioxide, chromium (IV) oxide, zinc oxide, cadmium oxide, cobalt (I) oxide, cobalt (II) oxide, cobalt (II, III) oxide, copper (I) oxide, copper (II) oxide, copper peroxide, copper (III) oxide, mercury (I) oxide, mercury (II) oxide, molybdenum dioxide, molybdenum trioxide, nickel (II) oxide, nickel (III) oxide, titanium monoxide, titanium dioxide, dititanium trioxide, aluminum oxide, bismuth (III) oxide, gallium (III) oxide, indium (III) oxide, lead (II) oxide, lead dioxide, lead (II, IV) oxide, tin (II) oxide, tin (IV) oxide, zirconium dioxide, vanadium (II) oxide, vanadium (III) oxide, vanadium (IV) oxide, vanadium (V) oxide, phosphorous (III) oxide, and phosphorous (V) oxide.

13. The method as defined in claim 10 , wherein the thermally decomposing precursor is
the metal carbonyl, and the metal carbonyl is selected from the group consisting of Ni(CO 4 ), Fe(CO 5 ), and Cr(CO) 6 .

14. The method as defined in claim 10 , wherein the thermally decomposing precursor is the organometallic compound of the transition metal, and the organometallic compound of the transition metal is a cyclopentadienyl complex of a transition metal selected from the group consisting of Co, Fe, Ni, Rh, Zr, and Ti.

Assignees

• Hewlett Packard Development Co

Inventors

• Shaarawi Mohammed S
• Mckinnell James
• Kasperchik Vladek
• Champion David A
• Long Greg Scott

Classifications

• B22F10/32

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

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B29C67/00

  Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 · CPC title

• B22F12/63

  Rollers · CPC title

• B33Y40/00 Primary

  Auxiliary operations or equipment, e.g. for material handling · CPC title