Multi-material functional parts using additive manufacturing

Patent metadata

Field	Value
Publication number	US-2018133803-A1
Application number	US-201715815816-A
Country	US
Kind code	A1
Filing date	Nov 17, 2017
Priority date	Nov 17, 2016
Publication date	May 17, 2018
Grant date	—

Abstract

A method of forming a component includes depositing successive layers of a binder and first particles of a first material using a layering device to build a first green segment, depositing successive layers of the binder and second particles of a second material different than the first material using the layering device to build a second green segment, assembling the first green segment and the second green segment together to form a green component, and infiltrating the green component with a metallic infiltrant to form the component.

First claim

What is claimed is:

1 . A method, comprising:
depositing successive layers of a first binder and first particles comprising a first material using a layering device to build a first green segment; depositing successive layers of a second binder and second particles comprising a second material different than the first material using the layering device to build a second green segment; assembling the first green segment and the second green segment together to form a green component; and infiltrating the green component with a metallic infiltrant to form a component.

2 . The method of claim 1 , further comprising:
placing the green component into a vacuum furnace; and heating the green component to burn out the first binder and second binder.

3 . The method of claim 1 , wherein depositing the first binder and first particles comprises:
providing a layer of the first particles in powder form; and dispensing the first binder selectively over the layer of powder.

4 . The method of claim 1 , wherein the volume ratio of the first binder to the first material within the first green segment varies among different layers.

5 . The method of claim 1 , wherein a first volume ratio of the first binder to the first material within the first green segment is different than a second volume ratio of the second binder to the second material within the second green segment.

6 . The method of claim 1 , further comprising:
designing a microstructure of the component, the microstructure having varying volume ratios of metallic infiltrant to the first material and to the second material; and depositing greater amounts of first binder and second binder in areas to have greater volume ratios of metallic infiltrant to the first material and to the second material.

7 . The method of claim 1 , wherein the first segment and the second segment have interlocking features.

8 . The method of claim 1 , wherein the metallic infiltrant is selected from at least one of a bronze alloy, a copper alloy, a nickel alloy, and a cobalt alloy.

9 . The method of claim 1 , wherein the first material has a greater erosion resistance and a lower toughness than the second material, or wherein the first binder and the second binder have the same material composition.

10 . The method of claim 1 , where the first binder and second binder have the same material composition.

11 . A method, comprising:
designing a component using a computer aided design program, the component comprising at least two segments; depositing a binder and matrix material layer by layer using a layering device to build each segment separately; assembling the at least two segments together to form a green component; and infiltrating the green component with a metallic infiltrant to form the component.

12 . The method of claim 11 , further comprising hot isostatic pressing the component.

13 . The method of claim 11 , further comprising:
placing at least one insert in the green component prior to infiltrating, the at least one insert comprising a material having a melting temperature greater than the metallic infiltrant.

14 . A component for downhole operation equipment, comprising:
a microstructure comprising a metallic infiltrant dispersed in a matrix of at least two types of matrix material particles, wherein each type of matrix material particle is in a separate region of the component; and an interlocking interface between two of the separate regions.

15 . The component of claim 14 , wherein the separate regions of the component comprise a wear resistant region and a tough region, and wherein a first type of matrix material particles forming the wear resistant region has greater wear resistance than a second type of matrix material particles forming the tough region.

16 . The component of claim 14 , wherein the interlocking interface comprises mating castellations.

17 . The component of claim 14 , wherein the mean free path between matrix material particles is different in two of the separate regions.

18 . The component of claim 14 , wherein a volume ratio of the metallic infiltrant to the matrix material particles varies through one of the separate regions.

19 . The component of claim 14 , where the component is an axial pulse generator comprising:
a first region comprising the metallic infiltrant and a first type of matrix material particles; a second region positioned adjacent to the first region, the second region comprising the metallic infiltrant and a second type of matrix material particles; and a third region positioned adjacent to the second region, the third region comprising the metallic infiltrant and a third type of matrix material particles; wherein the third type of matrix material particles have a greater toughness than the first and second types of matrix material particles; and wherein the first type of matrix material particles has a greater erosion resistance than the second and third types of matrix material particles.

20 . The component of claim 14 , wherein the component is a rotor, comprising:
a body comprising the metallic infiltrant and a first type of matrix material particles; and a plurality of blades extending from the body, the blades comprising the metallic infiltrant and a second type of matrix material particles.

Assignees

• Schlumberger Technology Corp

Inventors

• Karuppoor Srinand Sreedharan

Classifications

• B22F10/14

  by jetting of binder onto a bed of metal powder · CPC title

• B22F7/04 Primary

  with one or more layers not made from powder, e.g. made from solid metal · CPC title

• B22F2007/045

  accompanied by fusion or impregnation · CPC title

• F01D5/02

  Blade-carrying members, e.g. rotors (rotors of non-bladed type F01D1/34; stators F01D9/00 {; selecting particular materials F01D5/28}) · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title