Gradient sintered metal preform

Patent metadata

Field	Value
Publication number	US-2016318104-A1
Application number	US-201415103981-A
Country	US
Kind code	A1
Filing date	Dec 5, 2014
Priority date	Dec 20, 2013
Publication date	Nov 3, 2016
Grant date	—

Abstract

A method of forming a metal component with two and three dimensional internal functionally graded alloy composition gradients includes forming the component by a powder based layer-by-layer additive manufacturing process. The areal composition distribution of each powder layer is determined by simultaneously depositing different powders and powder mixtures through a mixing valve attached to a single nozzle during powder deposition. The layers are then sintered with a directed energy source to form a forging preform. The preform is then forged to form a component.

First claim

1 . A method of forming a metal component with two and three dimensional internal alloy compositional gradients comprises:
forming the component by a powder-based layer-by-layer additive manufacturing process; controlling the areal composition of each powder layer by depositing different powders to different areas through a single powder deposition nozzle during powder deposition; and sintering the layer with a directed energy source to form the component.

2 . The method of claim 1 wherein the directed energy source is a laser.

3 . The method of claim 1 wherein the powder deposition nozzle is positioned by a computer controlled robotic support.

4 . The method of claim 1 wherein the different powders are selected with the use of a mixing valve attached to two or more powder sources.

5 . The method of claim 4 wherein the mixing valve may be controlled by manual or electronic means.

6 . The method of claim 1 wherein the two-dimensional composition gradients are radial composition gradients.

7 . The method of claim 1 wherein the metal is a nickel based, iron based, cobalt based superalloy or mixtures thereof.

8 . The method of claim 1 wherein the component is a forging preform.

9 . The method of claim 1 wherein the forging preform density is about 75 percent to about 85 percent.

10 . The method of claim 8 and further comprising forging the preform into a turbine disk.

11 . A cylindrical metal component comprising:
an outer rim section of at least a first alloy; an inner hub section of at least a second alloy; and at least one functionally graded alloy transition region between the outer rim section and the inner hub section.

12 . The component of claim 11 wherein the component is a sintered forging preform.

13 . The component of claim 11 wherein the component is formed by a powder based layer-by-layer additive manufacturing process wherein the radial composition of each layer is formed by depositing at least two powders through a single nozzle during formation of each layer.

14 . The component of claim 13 wherein the different powders are selected with the use of a mixing valve attached to two or more powder sources.

15 . The component of claim 14 wherein control of the mixing valve may be by manual or electronic means.

16 . The component of claim 13 wherein the powder deposition nozzle is positioned by a computer controlled robotic support.

17 . The component of claim 13 wherein each layer is sintered by a laser.

18 . The component of claim 12 wherein the sintered component density is about 75 percent to about 85 percent.

19 . The component of claim 11 wherein the metal is a nickel based, iron based, cobalt based superalloy or mixtures thereof.

20 . The component of claim 11 wherein the component is a turbine component.

Assignees

• United Technologies Corp

Inventors

• Ott Joe
• Twelves Jr Wendell V
• Mironets Sergey
• Kironn Lexia
• Butcher Evan
• Schirtzinger Gary A

Classifications

• B22F10/66

  by mechanical means · CPC title

• B22F5/009 Primary

  of turbine components other than turbine blades (of turbine blades B22F5/04) · CPC title

• B22F12/53

  Nozzles · CPC title

• B22F7/02 Primary

  of composite layers {(B22F7/002 takes precedence)} · CPC title

• B22F10/25

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