Complex concentrated alloy and high entropy alloy additive manufacturing systems and methods

Patent metadata

Field	Value
Publication number	US-12377465-B2
Application number	US-202318329543-A
Country	US
Kind code	B2
Filing date	Jun 5, 2023
Priority date	Oct 18, 2019
Publication date	Aug 5, 2025
Grant date	Aug 5, 2025

Abstract

A complex concentrated alloy (CCA) and/or high entropy alloy (HEA) additive manufacturing nozzle can include a nozzle body defining at least four powder channels. Each powder channel can be configured to be connected to a powder supply of a plurality of powder supplies to receive a powder from the powder supply for ejecting the powder toward a build area to form an additively manufactured article having a CCA and/or an HEA.

First claim

What is claimed is:

1. An additive manufacturing system, comprising:
a complex concentrated alloy (CCA) and/or high entropy alloy (HEA) additive manufacturing nozzle, comprising:
a nozzle body defining at least four powder channels, each powder channel configured to be directly connected to a dedicated powder supply of a plurality of powder supplies to receive a powder from the powder supply for ejecting the powder toward a build area to form an additively manufactured article having a CCA and/or an HEA;

an energy applicator configured to provide energy to the powder to sinter the powder to form the additively manufactured article; and
the plurality of powder supplies connected the powder channels, wherein the plurality of powder supplies includes the same number of powder supplies as there are powder channels so that there is a one-for-one powder supply to powder channel relationship with an individual powder supply being independently dedicated to a predetermined powder channel, wherein each powder supply is different from the other powder supplies.

2. The system of claim 1 , wherein the at least four powder channels include up to eight total powder channels.

3. The system of claim 1 , wherein the at least four powder channels include eight total powder channels.

4. The system of claim 1 , wherein the nozzle further comprises an energy application channel defined through the nozzle body and configured to pass energy to the build area to allow energy application to the powder ejected toward or on the build area.

5. The system of claim 4 , wherein the energy application channel is an optical channel for passing a laser.

6. The system of claim 5 , wherein the energy application channel is surrounded by the powder channels.

7. The system of claim 6 , wherein the powder channels are disposed evenly and symmetrically around the energy application channel.

8. The system of claim 7 , wherein an axis of the powder channels intersect with an axis of the energy application channel such that powder that is ejected from the powder channels intersects with the laser.

9. The system of claim 1 , wherein the each powder channel is configured to change in flow area along a powder flow direction from a powder supply opening, through the nozzle body to an ejection opening.

10. The system of claim 1 , wherein the powder channels are angled relative to a center line of the nozzle body, wherein the powder channels converge toward the center line, wherein powder streams flowing from the powder channels intersects with a laser at a predetermined focal point.

Assignees

• Hamilton Sundstrand Corp

Inventors

• Borkowski Luke
• El-Wardany Tahany I
• Tredway William K
• Fennessy Colette O

Classifications

• B22F10/50

  Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up · CPC title

• B22F12/53

  Nozzles · CPC title

• B22F12/58

  for changing the material composition, e.g. by mixing · CPC title

• B22F10/00

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

• B33Y80/00

  Products made by additive manufacturing · CPC title