Additive manufacturing of articles comprising beryllium

Patent metadata

Field	Value
Publication number	US-2016167133-A1
Application number	US-201514965572-A
Country	US
Kind code	A1
Filing date	Dec 10, 2015
Priority date	Dec 12, 2014
Publication date	Jun 16, 2016
Grant date	—

Abstract

A method of making an article includes depositing a plurality of layers to form a three-dimensional preform, sintering the preform to form a sintered preform, and infiltrating the preform with at least one metal to form the article. At least one layer of the plurality of layers is formed from a beryllium-containing composition including beryllium powder. The infiltrating metal can be selected from aluminum and magnesium.

First claim

1 . A method of making an article, comprising:
depositing a plurality of layers to form a three-dimensional preform; sintering the preform to form a sintered preform; and infiltrating the sintered preform with at least one metal to form the article; wherein at least one layer of the plurality of layers is formed from a beryllium-containing composition comprising beryllium powder.

2 . The method of claim 1 , wherein the at least one metal is selected from the group consisting of aluminum, magnesium, and lithium.

3 . The method of claim 1 , wherein the beryllium-containing composition further comprises a binder.

4 . The method of claim 3 , wherein the binder is selected from the group consisting of polyethylene, polypropylene, polyvinyl alcohol, collodion, and silicates.

5 . The method of claim 3 , wherein the beryllium-containing composition comprises from 0.1 wt % to 99.9 wt % of the binder and from 0.1 wt % to 99.9 wt % of the beryllium powder.

6 . The method of claim 1 , wherein the beryllium powder comprises beryllium particles coated with nickel.

7 . The method of claim 6 , wherein the beryllium powder comprises from about 92 wt % to less than 100 wt % beryllium and from greater than zero wt % to about 8 wt % nickel.

8 . The method of claim 1 , wherein the article comprises from 0 to about 5 wt % nickel, from about 58 to about 65 wt % beryllium, and from about 30 to about 42 wt % aluminum.

9 . The method of claim 1 , wherein the depositing is performed at about room temperature.

10 . The method of claim 1 , further comprising curing the plurality of layers prior to sintering the preform.

11 . The method of claim 10 , further comprising removing undesired material prior to sintering and after curing.

12 . The method of claim 1 , further comprising annealing the article.

13 . The method of claim 12 , further comprising finishing the annealed article.

14 . The method of claim 13 , wherein the finishing comprises at least one action selected from the group consisting of polishing and plating.

15 . The article formed by the method of claim 1 .

16 . The article of claim 15 , having a density of about 1.5 g/cc to about 2.5 g/cc.

17 . The article of claim 15 , having a coefficient of thermal expansion at 25° C. of from about 5 ppm/° C. to about 25 ppm/° C.

18 . The article of claim 15 , having an elastic modulus of about 100 GPa to about 300 GPa.

19 . The article of claim 15 , having a yield strength of about 150 to about 900 MPa.

20 . The article of claim 15 , having an ultimate tensile strength of from about 170 MPa to about 1000 MPa.

Assignees

• Materion Corp

Inventors

• Yurko James Andrew

Classifications

• B22F3/26

  Impregnating {(making ferrous alloys by impregnation C22C33/0242)} · CPC title

• B22F2998/10

  Processes characterised by the sequence of their steps · CPC title

• B22F1/105

  containing inorganic lubricating or binding agents, e.g. metal salts · CPC title

• B22F1/102

  Metallic powder coated with organic material · CPC title

• B22F10/66

  by mechanical means · CPC title