Pulsed directed energy deposition based fabrication of hybrid titanium/aluminum material for enhanced corrosion resistance and strength

Patent metadata

Field	Value
Publication number	US-11891684-B2
Application number	US-202117375508-A
Country	US
Kind code	B2
Filing date	Jul 14, 2021
Priority date	Feb 4, 2020
Publication date	Feb 6, 2024
Grant date	Feb 6, 2024

Abstract

A method of providing a protective titanium layer to an outer surface of an aluminum component includes providing an aluminum component and forming a first layer of titanium-based bulk metallic glass on the component, wherein formation of the bulk metallic glass layer comprises depositing a titanium alloy powder using pulsed directed energy deposition.

First claim

The invention claimed is:

1. A method of providing a protective titanium layer to an outer surface of an aluminum component, the method comprising:
providing an aluminum component;
forming a first layer of titanium-based bulk metallic glass on the component, wherein formation of the bulk metallic glass layer comprises depositing a titanium alloy powder using pulsed directed energy deposition; and
applying vibrational energy to the component during deposition of a second layer of the titanium alloy powder to introduce crystalline phases into the second layer.

2. The method of claim 1 , wherein vibrational energy is applied by an ultrasonic transducer.

3. The method of claim 1 , wherein vibrational energy is applied intermittently to form both crystalline phases and amorphous phases in the second layer.

4. The method of claim 1 , wherein crystalline phases are introduced in an amount to provide a tensile ductility of at least ten percent.

5. The method of claim 1 , and further comprising depositing a magnesium-containing powder using directed energy deposition to form an insulating layer between the component and the first layer of titanium-based bulk metallic glass.

6. The method of claim 1 , wherein forming the first layer of titanium-based bulk metallic glass further comprises simultaneously depositing a magnesium-containing powder using pulsed directed energy deposition.

7. The method of claim 6 , wherein the first layer of titanium-based bulk metallic glass comprises a plurality of sub-layers and wherein depositing the magnesium-containing powder comprises depositing an amount of magnesium-containing powder that decreases with successive sub-layers.

8. The method of claim 1 , and further comprising forming a third layer of titanium-based bulk metallic glass on the component, wherein the second layer is formed between the first layer and the third layer.

9. The method of claim 1 , and further comprising:
modeling a target microstructure for each of a plurality of titanium alloy layers; and
devising a deposition process based on the microstructure model, wherein devising the deposition process comprises determining a schedule for applying vibrational energy.

10. The method of claim 1 , wherein the titanium alloy powder has a melting point not exceeding 250 K greater than a melting point of the aluminum component.

11. The method of claim 1 , wherein the component is an airfoil and the titanium-based bulk metallic glass layer is formed on a leading edge of the airfoil.

12. A method of providing a protective titanium layer to an aluminum component, the method comprising:
forming a first titanium-based layer on the component, wherein the first titanium-based layer is a bulk metallic glass characterized by an amorphous microstructure, and wherein forming the first titanium-based layer comprises:
depositing titanium alloy powder on an outer surface of the aluminum component; and
pulsing energy directly to titanium alloy powder to melt the titanium alloy powder;

forming a second titanium-based layer on the component, wherein forming the second titanium-based layer comprises:
depositing titanium alloy powder;
pulsing energy directly to titanium alloy powder to melt the titanium alloy powder; and
applying vibrational energy to the component to introduce crystalline phases into the second titanium-based layer.

13. The method of claim 12 , wherein crystalline phases are introduced in an amount to provide a tensile ductility of at least ten percent.

14. The method of claim 12 , wherein vibrational energy is applied intermittently to form both crystalline phases and amorphous phases in the second titanium-based layer.

15. The method of claim 12 , and further comprising depositing a magnesium-containing powder using directed energy deposition to form an insulating layer between the component and the first titanium-based layer.

16. The method of claim 12 , wherein forming the first titanium-based layer further comprises simultaneously depositing a magnesium-containing powder using pulsed directed energy deposition.

17. The method of claim 12 , wherein forming the first titanium-based layer comprises solidifying the melted titanium alloy powder by cooling at a rate of 10 5 - 10 6 K/s.

Assignees

• Hamilton Sundstrand Corp

Inventors

• El-Wardany Tahany Ibrahim
• Acharya Ranadip
• Fennessy Colette Opsahl
• Pess Matthew

Classifications

• C23C14/16 Primary

  on metallic substrates or on substrates of boron or silicon · CPC title

• B23K15/0086

  welding for purposes other than joining, e.g. build-up welding · CPC title

• C23C14/025

  Metallic sublayers · CPC title

• C23C14/28

  by wave energy or particle radiation (C23C14/32 - C23C14/48 take precedence) · CPC title

• Y10T428/12736

  Al-base component · CPC title