Structured powder particles for feedstock improvement for laser based additive manufacturing

Patent metadata

Field	Value
Publication number	US-2017368603-A1
Application number	US-201615189244-A
Country	US
Kind code	A1
Filing date	Jun 22, 2016
Priority date	Jun 22, 2016
Publication date	Dec 28, 2017
Grant date	—

Abstract

A process comprising providing a metallic first powder having a plurality of first particles. The process includes adding a second material to the first powder, the second material having a plurality of second particles. The process includes combining the first powder with the second material to form a modified powder including modified powder particles having an interior portion containing an interior composition, and an outer surface portion with an outer composition different from the interior composition.

First claim

What is claimed is:

1 . A process comprising:
providing a metallic first powder having a plurality of first particles; adding a second material to the first powder, the second material having a plurality of second particles; combining the first powder with the second material to form a modified powder including modified powder particles having an interior portion containing an interior composition, and an outer surface portion with an outer composition different from the interior composition.

2 . The process according to claim 1 , wherein said outer surface portion includes properties selected from the group consisting of low flammability, low reflectivity, low melting point and low moisture/contamination pick up.

3 . The process according to claim 2 wherein said low reflectivity outer surface portion is selected from the group consisting of Mg, W, Fe, Mo, Cr, and Si.

4 . The process according to claim 2 wherein said low flammability outer surface portion is selected from the group consisting of Zr, Ti, Si, Cr, Mn, Sn, Zn, Pb, Mo, Co, W, Cu, and Ni.

5 . The process according to claim 1 , wherein said outer surface portion comprises a continuous coating.

6 . The process according to claim 1 , wherein said outer surface portion comprises a discontinuous coating.

7 . The process according to claim 1 , further comprising:
forming an additional layer, said additional layer having a composition different from the interior composition.

8 . The process according to claim 7 , wherein said internal portion composition is selected from the group consisting of a major constituent of an end alloy.

9 . The process according to claim 1 , further comprising:
melting said modified powder during an additive build, dissolving said outer composition into a melt pool; mixing said outer composition into said interior composition.

10 . A modified powder composition comprising:
an interior portion containing an interior composition; and an outer surface portion with an outer composition different from the interior composition coupled to said interior portion, wherein said outer surface portion includes properties selected from the group consisting of low flammability, low reflectivity, low melting point and low moisture/contamination pick up.

11 . The modified powder composition according to claim 10 , further comprising:
an additional layer, said additional layer having a composition different from the interior composition.

12 . The modified powder composition according to claim 10 , wherein interior portion composition is selected from the group consisting of a major constituent of an end alloy.

13 . The modified powder composition according to claim 10 , wherein said outer surface portion comprises a continuous coating.

14 . The modified powder composition according to claim 10 , wherein said outer surface portion comprises a discontinuous coating.

15 . The modified powder composition according to claim 10 , wherein said low flammability outer surface portion is selected from the group consisting of Zr, Ti, Si, Cr, Mn, Sn, Zn, Pb, Mo, Co, W, Cu, and Ni.

16 . The modified powder composition according to claim 10 , wherein said low reflectivity outer surface portion is selected from the group consisting of Mg, W, Fe, Mo, Cr, and Si.

Assignees

• United Technologies Corp

Inventors

• Beals James T
• She Ying
• Jagdale Vijay
• Sharon John A

Classifications

• B22F12/70

  Gas flow means · CPC title

• B22F12/44

  characterised by the configuration of the radiation means · CPC title

• B22F10/25

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

• B22F1/17

  Metallic particles coated with metal · CPC title

• B22F12/90

  Means for process control, e.g. cameras or sensors · CPC title