Additively manufacturing of amorphous structures

Patent metadata

Field	Value
Publication number	US-11701821-B2
Application number	US-202117566928-A
Country	US
Kind code	B2
Filing date	Dec 31, 2021
Priority date	Oct 18, 2019
Publication date	Jul 18, 2023
Grant date	Jul 18, 2023

Abstract

An additive manufacturing system configured to additively build an article can include an energy applicator, a build platform, and a powder nozzle configured to eject powder toward the build platform to be acted on by the energy applicator. The system can include a control module configured to control the energy applicator to create an amorphous structure forming at least a portion of the article.

First claim

What is claimed is:

1. A non-transitory computer readable medium comprising computer executable instructions configured to cause a computer to perform a method, the method comprising:
controlling an energy applicator of an additive manufacturing system to create an amorphous matrix forming cooling rate in a metal powder deposited on a build platform so as to form an amorphous matrix having nanocrystal grains in predetermined locations of the powder, thereby forming at least a portion of an article, wherein the energy applicator comprises a laser creating the amorphous matrix forming cooling rate and a plurality of acoustic transducers disposed on or in the build platform for inducing formation of the nanocrystal grains in the predetermined locations during said cooling.

2. The non-transitory computer readable medium of claim 1 , wherein the method includes pulsing the laser.

3. The non-transitory computer readable medium of claim 1 , wherein the amorphous matrix forming cooling rate is about 10 5 K/s or higher.

4. The non-transitory computer readable medium of claim 1 , wherein the amorphous matrix forming cooling rate is about 10 5 K/s to about 10 6 K/s.

5. The non-transitory computer readable medium of claim 1 , wherein the method further includes controlling the plurality of acoustic transducers disposed on or in the build platform to provide vibration during additive manufacturing of the article and/or a portion thereof being built.

6. The non-transitory computer readable medium of claim 5 , wherein the plurality of acoustic transducers include a plurality of ultrasonic transducers, wherein the plurality of transducers are disposed in an array on or in the build platform, and wherein the method includes controlling the plurality of transducers independently of each other to produce vibration in predetermined locations of the build platform.

7. A method, comprising:
additively manufacturing from a metal powder on a build platform to form an article that includes an amorphous structure having nanocrystal grains in at least a portion of the article; and
controlling an energy applicator of an additive manufacturing system to create an amorphous matrix forming cooling rate in the powder so as to form the amorphous matrix having nanocrystal grains in predetermined locations of the powder, thereby forming at least a portion of the article, wherein the energy applicator comprises a laser creating the amorphous matrix forming cooling rate and a plurality of acoustic transducers disposed on or in the build platform for inducing formation of the nanocrystal grains in the predetermined locations during said cooling.

8. The method of claim 7 , wherein the method includes heating the powder and allowing the heated powder to cool at an amorphous matrix forming rate.

9. The method of claim 8 , further comprising vibrating the heated powder during the heating and/or after the heating so as to form the nanocrystal grains in the amorphous matrix.

10. The method of claim 9 , wherein the vibrating includes vibrating at one or more ultrasonic frequencies.

11. The method of claim 10 , wherein the vibrating includes the vibrating an entire build area for the powder or vibrating a local portion of the powder being heated.

12. A method, comprising:
additively manufacturing an article that includes an amorphous structure having nanocrystal grains in at least a portion of the article; and
controlling a laser and one or more acoustic transducers of an energy applicator of an additive manufacturing system to create an amorphous matrix forming cooling rate in a metal powder deposited on a build platform so as to form the amorphous matrix having the nanocrystal grains in predetermined locations of the powder, thereby forming at least a portion of the article;
wherein controlling the laser includes creation of the amorphous matrix forming cooling rate; and
wherein controlling the one or more transducers includes formation of the nanocrystal grains in the predetermined locations during said cooling, the one or more transducers disposed on or in the build platform.

Assignees

• Hamilton Sundstrand Corp

Inventors

• Acharya Ranadip
• Staroselsky Alexander

Classifications

• B29C64/153 Primary

  using layers of powder being selectively joined, e.g. by selective laser sintering or melting · CPC title

• B22F10/00

  Additive manufacturing of workpieces or articles from metallic powder (apparatus or devices therefor B22F12/00) · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B22F12/43

  pulsed; frequency modulated · CPC title

• B22F12/53

  Nozzles · CPC title