Net-shape or near-net shape powder metal components and methods for producing the same

Patent metadata

Field	Value
Publication number	US-2016279708-A1
Application number	US-201514669111-A
Country	US
Kind code	A1
Filing date	Mar 26, 2015
Priority date	Mar 26, 2015
Publication date	Sep 29, 2016
Grant date	—

Abstract

The present disclosure relates to net-shape or near-net shape articles of manufacture and methods for producing the same. For example, a method for manufacturing net-shape or near-net shape metallic article includes the steps of: forming, using an additive manufacturing process, a metal can comprising a hollow interior portion, filling the hollow interior portion with a metal powder, and subjecting the metal can filled with the metal powder to a hot isostatic pressing (HIP) process to densify the metal powder. As another example, a net-shape or near-net shape metallic article of manufacture includes a metallic outer shell portion having a layer-by-layer fused microstructure that exhibits anisotropic mechanical and physical properties and a metallic inner core portion having a pressure-densified microstructure that exhibits isotropic mechanical and physical properties.

First claim

What is claimed is:

1 . A method for manufacturing net-shape or near-net shape metallic article comprising the steps of:
forming, using an additive manufacturing process, a metal can comprising a hollow interior portion; filling the hollow interior portion with a metal powder; subjecting the metal can filled with the metal powder to a hot isostatic pressing (HIP) process to densify the metal powder.

2 . The method of claim 1 , wherein the additive manufacturing process is selected from the group consisting of: direct metal laser fusion (DMLF) and electron beam melting (EBM).

3 . The method of claim 1 , further comprising the step of hermetically sealing the metal can filled with the metal powder prior to the step of HIP.

4 . The method of claim 1 , wherein the metal can and the metal powder comprise the same or different metal materials.

5 . The method of claim 1 , further comprising the step of removing the metal can from the densified metal powder, thereby leaving a densified metal powder article.

6 . The method of claim 5 , further comprising subjecting the densified metal powder article to a finishing treatment.

7 . The method of claim 1 , wherein the metal can is not removed from the densified metal powder, thereby leaving a hybrid additive manufactured/HIP-processed article.

8 . The method of claim 7 , further comprising subjecting the hybrid article to a finishing treatment.

9 . A net-shape or near-net shape metallic article of manufacture comprising:
a metallic outer shell portion having a layer-by-layer fused microstructure that exhibits anisotropic mechanical and physical properties; and a metallic inner core portion having a pressure-densified microstructure that exhibits isotropic mechanical and physical properties.

10 . The metallic article of manufacture of claim 9 , wherein the metallic outer shell portion and the metallic inner core portion comprise the same or different metal materials.

Assignees

• Honeywell Int Inc

Inventors

• Hann Brian
• Kantzos Pete

Classifications

• B22F10/66

  by mechanical means · CPC title

• B22F10/25

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

• B22F10/73

  of powder · CPC title

• B22F10/36

  of energy beam parameters · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title