Surface treatment of additively manufactured components

Patent metadata

Field	Value
Publication number	US-12005505-B2
Application number	US-202016901855-A
Country	US
Kind code	B2
Filing date	Jun 15, 2020
Priority date	Jun 17, 2019
Publication date	Jun 11, 2024
Grant date	Jun 11, 2024

Abstract

A method may include depositing, from a slurry, suspension, or tape, on a surface of an additively manufactured component comprising a metal or alloy, powder comprising at least one of a metal, an alloy, or a ceramic; sintering the powder to form a surface layer on the additively manufactured component; and hot isostatic pressing the additively manufactured component and the surface layer.

First claim

What is claimed is:

1. A method comprising:
additively manufacturing an additively manufactured component, the additively manufactured component comprising a sacrificial binder and a metal or alloy;
sintering, at a first time, the additively manufactured component, wherein the sacrificial binder is removed from the additively manufactured component;
applying, at a second time that is after the first time, a slurry or suspension to the additively manufactured component using dip coating, wherein the slurry or suspension includes one or more of a dispersant, a surfactant, or a pH adjustor;
depositing, at a third time that is after the second time, from the slurry or suspension, on a surface of the additively manufactured component, powder comprising at least one of a metal, an alloy, or a ceramic, wherein the powder has an average grain size that is smaller than an average grain size of the material used to form the additively manufactured component;
sintering the powder to form a surface layer on the additively manufactured component; and
hot isostatic pressing the additively manufactured component and the surface layer.

2. The method of claim 1 , wherein the additively manufactured component comprises channels between adjacent tracks of material from which the additively manufactured component is formed, and wherein an average particle size of the powder is selected to facilitate the powder filling the channel at or near the surface of the additively manufactured component.

3. The method of claim 1 , wherein the surface of the additively manufactured component comprises a stepped surface, and wherein the powder at least partially smooths the stepped surface.

4. The method of claim 3 , wherein the powder has an average particle size that is less than a step size of the stepped surface.

5. The method of claim 1 , wherein depositing the powder comprises depositing the powder from the slurry.

6. The method of claim 1 , wherein the additive manufacturing technique comprises fused deposition modeling.

7. The method of claim 1 , wherein the powder comprises a metal or alloy having a substantially similar composition to a metal or alloy of the additively manufactured component.

8. The method of claim 1 , wherein the powder comprises a mixture of a ceramic and a metal or alloy.

9. The method of claim 1 , wherein the powder comprises a ceramic.

10. The method of claim 1 , wherein a characteristic of the powder is selected to provide a selected material characteristic to the surface layer, wherein the selected material characteristic comprises at least one of fatigue performance, creep resistance, corrosion resistance, toughness, coefficient of thermal expansion, or density.

11. A method comprising:
additively manufacturing an additively manufactured component using fused deposition modeling, wherein the additively manufactured component comprises a sacrificial binder and a metal or alloy, and wherein the surface of the additively manufactured component comprises a stepped surface;
sintering, at a first time, the additively manufactured component, wherein the sacrificial binder is removed from the additively manufactured component;
applying, at a second time that is after the first time, a slurry or suspension to the additively manufactured component using dip coating, wherein the slurry or suspension includes one or more of a dispersant, a surfactant, or a pH adjustor;
depositing, at a second third time that is after the first second time, from the slurry or suspension, on a surface of the additively manufactured component, powder comprising at least one of a metal, an alloy, or a ceramic, wherein the powder has an average particle size that is less than a step size of the stepped surface and at least partially smooths the stepped surface, and wherein the average particle size of the powder is selected to facilitate the powder filling pores at or near the surface of the additively manufactured component;
sintering the powder to form a surface layer on the additively manufactured component; and
hot isostatic pressing the additively manufactured component and the surface layer.

12. The method of claim 11 , wherein the powder has a composition different from a composition of the additively manufactured component.

13. The method of claim 1 , wherein the powder has an average particle size that is less than an average particle size of the material used to form the additively manufactured component, and wherein the average particle size of the powder is selected to facilitate the powder filling pores at or near the surface of the additively manufactured component.

14. The method of claim 1 , wherein the sacrificial binder includes a polymeric material.

15. The method of claim 14 , wherein the polymeric material is a thermoplastic.

16. The method of claim 1 , wherein the metal or alloy is substantially uniformly dispersed in the sacrificial binder.

17. The method of claim 1 , wherein the sacrificial binder is formed from a curable polymer precursor.

18. The method of claim 17 , wherein the curable polymer precursor includes one or more monomers, oligomers, or non-crosslinked polymers suitable for forming the polymeric material of the sacrificial binder upon curing.

19. The method of claim 1 , wherein the additively manufactured component comprises a first metal or alloy that has a first coefficient of thermal expansion, wherein the powder comprises a second metal or alloy that has a second coefficient of thermal expansion, wherein first coefficient of thermal expansion is higher than the second coefficient of thermal expansion, and wherein the first metal or alloy contracts a greater amount than the second metal or alloy during cooling after sintering.

20. The method of claim 1 , wherein the additively manufactured component further comprises an oxide-dispersion strengthened alloy including one or more of a nickel chromium alloy, a thoria-dispersion strengthened nickel alloy, a nickel chromium alloy, a nickel aluminide alloy, an iron aluminide alloy, an iron chromium aluminide alloy, alumina, hafnia, zirconia, beryllia, magnesia, titanium oxide, silicon carbide, hafnium carbide, zirconium carbide, tungsten carbide, or titanium carbide.

21. The method of claim 20 , wherein a particle shape of the oxide-dispersion strengthened alloy is an elongated grain shape.

Assignees

• Rolls Royce Corp
• Rolls Royce High Temperature Composites Inc

Inventors

• Shuck Quinlan Yee
• Shim Sungbo

Classifications

• B22F10/64

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

• B22F10/18

  by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF] · CPC title

• B22F1/05

  Metallic powder characterised by the size or surface area of the particles · CPC title

• B22F10/60

  Treatment of workpieces or articles after build-up · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title