Systems and methods for wire deposited additive manufacturing using titanium

Patent metadata

Field	Value
Publication number	US-11819954-B2
Application number	US-202016933683-A
Country	US
Kind code	B2
Filing date	Jul 20, 2020
Priority date	Jan 28, 2019
Publication date	Nov 21, 2023
Grant date	Nov 21, 2023

Abstract

A metallic part is disclosed. The part may comprise a functionally graded monolithic structure characterized by a variation between a first material composition of a first structural element and a second material composition of at least one of a second structural element. The first material composition may comprise an alpha-beta titanium alloy. The second material composition may comprise a beta titanium alloy.

First claim

What is claimed is:

1. A method of additive manufacturing, comprising:
mixing a plurality of powdered metals comprising titanium, iron, vanadium, and aluminum to produce a powder blend;
cold isostatic pressing and sintering the powder blend to form a billet;
performing a wire forming operation on the billet to produce a worked wire, wherein the wire forming operation includes extruding the billet through a die;
heat treating the worked wire to produce a heat treated wire;
coiling the heat treated wire onto a feed spool;
loading a first structural element into an additive manufacturing machine, the first structural element having a first side, a second side, a first face, and a second face;
loading the feed spool into the additive manufacturing machine;
printing a second structural element of the heat treated wire from the feed spool, the second structural element being integral to the first structural element to form a part, wherein the second structural element is deposited over including depositing a first flange portion proximate the first side and extending perpendicular from the first face in a first direction; and
heat treating the part to generate a functionally graded monolithic structure.

2. The method of claim 1 , wherein the titanium is a titanium hydride powder and the first structural element comprises an Iron free Titanium alloy.

3. The method of claim 2 , wherein the powder blend comprises
4% to 6% by weight iron, 0.5% to 2% by weight aluminum, and 6% to 9% by weight vanadium.

4. The method of claim 3 , wherein the sintering is performed at 900° F. to 1600° F. and under a vacuum.

5. The method of claim 1 , wherein the wire forming operation includes rotary swaging via an array of swaging dies which exert force circumferentially about the billet, thereby reducing its diameter.

6. The method of claim 5 , further comprising performing a plurality of wire forming operations repeatedly or sequentially.

7. The method of claim 6 , further comprising applying an anti-oxidation coating to the billet prior to undergoing the wire forming operation.

8. The method of claim 7 , further comprising reapplying the anti-oxidation coating between successive wire forming operations.

9. The method of claim 6 , further comprising performing metal pickling treatment on the billet between wire forming operations.

10. The method of claim 1 , wherein the printing the second structural element further includes depositing a second flange portion proximate the first side and extending perpendicular from the second face in a second direction opposite the first direction.

11. The method of claim 1 , wherein the printing the second structural element further includes direction depositing a second flange portion proximate the second side and extending perpendicular from the first face in the first direction.

12. The method of claim 1 , wherein the printing the second structural element further includes depositing a second flange portion proximate the first side and extending perpendicular from the second face in a second direction opposite the first direction, depositing a third flange portion proximate the second side and extending perpendicular from the first face in the first direction, and depositing a fourth flange portion proximate the second side and extending perpendicular from the second face in the second direction.

13. The method of claim 12 , wherein the printing the second structural element integral to the first structural element forms an “I” shaped beam.

Assignees

• Goodrich Corp

Inventors

• Haynes Noel C
• Goldring Eric
• Narayan Karthik

Classifications

• B23K35/0261 Primary

  Rods, electrodes or wires · CPC title

• B22F3/24

  After-treatment of workpieces or articles {(B22F3/1146 takes precedence)} · CPC title

• B22F10/64

  by thermal means (control of energy beam parameters for post heating B22F10/364) · CPC title

• B22F10/28

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

• B22F2003/248

  Thermal after-treatment · CPC title