Methods for Modifying and Enhancing Material Properties of Additive Manufactured Metallic Parts

Patent metadata

Field	Value
Publication number	US-2016355904-A1
Application number	US-201615171619-A
Country	US
Kind code	A1
Filing date	Jun 2, 2016
Priority date	Jun 2, 2015
Publication date	Dec 8, 2016
Grant date	—

Abstract

A device for additive manufacturing of an object. The device includes: a first probe configured to form the object; and a work-hardening second probe, where the work-hardening second probe is an ultrasonic probe, and further where the second probe is configured to emit ultrasonic energy to modify a substructure of the object during manufacture; wherein the first probe is configured to increase a temperature of at least a portion of a first layer of the object facing the first probe, to a first depth; and wherein the second probe is configured to work-harden the at least a portion of the first layer of the object facing the first probe, to a second depth, the second depth being greater than the first depth.

First claim

What is claimed is:

1 . A device for additive manufacturing of an object, the device comprising:
a first probe configured to form the object; and a work-hardening second probe.

2 . The device of claim 1 , wherein the work-hardening second probe is an ultrasonic probe, and further wherein the second probe is configured to emit ultrasonic energy to modify a substructure of the object during manufacture.

3 . The device of claim 1 , wherein the work-hardening second probe comprises a laser, and further wherein the second probe is configured to emit laser energy to modify a substructure of the object during manufacture.

4 . The device of claim 1 , wherein the first probe is configured to form the object through sintering or melting with the aid of a laser beam or electron beam.

5 . The device of claim 4 , wherein the second probe is configured to work-harden the at least a portion of the first layer of the object facing the first probe, to a second depth, wherein the second depth is equal to or greater than the first depth.

6 . The device of claim 1 , wherein the work-hardening enhances multi-material bonding of the object.

7 . The device of claim 1 , wherein the work-hardening enhances bonding between deposited layers of the object.

8 . The device of claim 1 , wherein the work-hardening reduces distortion, porosity, and cracking of the object.

9 . A device for additive manufacturing of an object, the device comprising:
a first probe configured to form the object; and a work-hardening second probe, wherein the work-hardening second probe is an ultrasonic probe, and further wherein the second probe is configured to emit ultrasonic energy to modify a substructure of the object during manufacture; wherein the first probe is configured to sinter or melt a portion of a first layer of the object facing the first probe, to a first depth; and wherein the second probe is configured to work-harden the at least a portion of the first layer of the object facing the first probe, to a second depth, wherein the second depth is equal to or greater than the first depth.

10 . A method for additive manufacturing of an object, the method comprising the steps of:
providing a dual-probe additive manufacturing device, the device comprising a first probe configured to form the object and a work-hardening second probe; adding, with the first probe, a layer of the object; and work-hardening, with the second probe, the added layer of the object.

11 . The method of claim 10 , wherein the work-hardening step is performed concurrently with the adding step.

12 . The method of claim 10 , wherein the work-hardening second probe is an ultrasonic probe, and further wherein the second probe is configured to emit ultrasonic energy to build a substructure in the object by work hardening in the form of patterns during manufacture.

13 . The method of claim 10 , wherein the work-hardening second probe comprises a laser, and further wherein the second probe is configured to emit laser energy to modify a substructure of the object during manufacture.

14 . The method of claim 10 , wherein the first probe is configured to form the object through sintering or melting with the aid of a laser beam or electron beam.

15 . The method of claim 10 , wherein the second probe is configured to work-harden the at least a portion of the first layer of the object facing the first probe, to a second depth, wherein the second depth is equal to or greater than the first depth.

16 . The method of claim 10 , wherein the work-hardening enhances multi-material bonding of the object.

17 . The method of claim 10 , wherein the work-hardening enhances bonding between deposited layers of the object.

18 . The method of claim 10 , wherein the work-hardening reduces distortion, porosity and cracking of the object.

Assignees

• Achuthan Ajit
• Gale Joshua D
• Univ Clarkson

Inventors

• Achuthan Ajit
• Gale Joshua D

Classifications

• B22F10/50

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

• B22F10/25

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

• B23K26/0093

  combined with mechanical machining or metal-working covered by other subclasses than B23K · CPC title

• B23K15/0086

  welding for purposes other than joining, e.g. build-up welding · CPC title

• B23K2103/05

  Stainless steel · CPC title