Metal additive manufacturing method and article

Patent metadata

Field	Value
Publication number	US-11980969-B2
Application number	US-202016849004-A
Country	US
Kind code	B2
Filing date	Apr 15, 2020
Priority date	Apr 18, 2019
Publication date	May 14, 2024
Grant date	May 14, 2024

Abstract

Disclosed herein is a method for making a metal article including repetitively depositing a layer of metal and cold working each metal layer to form the metal article. The method can be used to make a new article or repair an existing article. The metal article includes a customized local grain structure orientation which can vary by region based on design requirements.

First claim

What is claimed is:

1. A method for making a metal article comprising:
repetitively depositing a layer of metal by additive manufacturing and cold working each metal layer to form the metal article;
wherein the cold working comprises directionally cold working each metal layer;
wherein the additive manufacturing parameters are manipulated to control local average grain size and the cold working parameters are manipulated to control local grain crystallographic orientation to provide a customized local average grain size and a customized local non-random grain crystallographic orientation of the metal article; and
wherein the local non-random grain crystallographic orientation varies by region within the metal article based on design requirements;
wherein the metal article has a first physical property in a first region and a second physical property in a second region;
wherein the first region has a first physical property value of the first physical property and the second region has a second physical property value of the second physical property, the first physical property value different than the second physical property value; and
wherein the first and second regions each comprise multiple layers of deposited metal.

2. The method of claim 1 , wherein additive manufacturing method comprises a melt pool or melted metal layer.

3. The method of claim 1 , wherein additive manufacturing comprises directed energy deposition.

4. The method of claim 1 , wherein the metal layer comprises nickel, cobalt, copper, titanium, aluminum, iron, alloys including one or more of the foregoing metals, and combinations thereof.

5. The method of claim 1 , wherein the cold working directionally applies energy in the form of compressive strain.

6. The method of claim 1 , wherein cold working comprises deep rolling, deep rolling with an ultrasonic head, and high frequency electromagnetic hammer, pneumatic roller vibrator, and combinations thereof.

7. The method of claim 1 , wherein the first and second physical property is yield stress, tensile strength or tensile modulus.

8. A method for repairing a metal article comprising:
repetitively depositing a layer of metal by additive manufacturing and cold working each deposited layer,
wherein the depositing and cold working occurs over a damaged section of the metal article to form a repaired section; and
wherein the cold working comprises directionally cold working each deposited layer;
wherein the additive manufacturing parameters are manipulated to control local average grain size and the cold working parameters are manipulated to control local grain crystallographic orientation to provide a customized local average grain size and a customized local non-random grain crystallographic orientation of the metal article; and
wherein the local non-random grain crystallographic orientation varies by region within the metal article based on design requirements;
wherein the metal article has a first physical property in a first region and a second physical property in a second region;
wherein the first region has a first physical property value of the first physical property and the second region has a second physical property value of the second physical property, the first physical property value different than the second physical property value; and
wherein the first and second regions each comprise multiple layers of deposited metal.

9. The method of claim 8 , wherein additive manufacturing method comprises a melt pool or melted metal layer.

10. The method of claim 8 , wherein additive manufacturing comprises directed energy deposition.

11. The method of claim 8 , wherein the metal layer comprises nickel, cobalt, copper, titanium, aluminum, iron, alloys including one or more of the foregoing metals, and combinations thereof.

12. The method of claim 8 , wherein the cold working directionally applies energy in the form of compressive strain.

13. The method of claim 8 , wherein cold working comprises deep rolling, deep rolling with an ultrasonic head, and high frequency electromagnetic hammer, pneumatic roller vibrator, and combinations thereof.

14. The method of claim 8 , wherein the first and second physical property is yield stress, tensile strength or tensile modulus.

15. A metal article comprising:
a customized local average grain size, and having a customized local non-random grain crystallographic orientation;
wherein the local non-random grain crystallographic orientation varies by region within the article based on design requirements;
wherein the metal article has a first physical property in a first region and a second physical property in a second region;
wherein the first region has a first physical property value of the first physical property and the second region has a second physical property value of the second physical property, the first physical property value different than the second physical property value; and
wherein the first and second regions each comprise multiple layers of deposited cold worked metal.

16. The metal article of claim 15 , wherein the article comprises nickel, cobalt, copper, titanium, aluminum, iron, alloys including one or more of the foregoing metals, and combinations thereof.

17. The metal article of claim 15 , wherein the first and second physical property is yield stress, tensile strength or tensile modulus.

Assignees

• Rtx Corp

Inventors

• El-Wardany Tahany Ibrahim
• Grow Matthew
• Klecka Michael A
• Levan Gregory W
• Seabourn Daniel K

Classifications

• B23K26/342 Primary

  Build-up welding · CPC title

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title

• B33Y40/00

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

• B33Y80/00

  Products made by additive manufacturing · CPC title