Metal additive manufacturing method and article

Patent metadata

Field	Value
Publication number	US-2020331099-A1
Application number	US-202016849004-A
Country	US
Kind code	A1
Filing date	Apr 15, 2020
Priority date	Apr 18, 2019
Publication date	Oct 22, 2020
Grant date	—

Abstract

Disclosed herein is a method for making a metal article including repetitively depositing a layer of metal and cold working each metal layer to form the metal article. The method can be used to make a new article or repair an existing article. The metal article includes a customized local grain structure orientation which can vary by region based on design requirements.

First claim

What is claimed is:

1 . A method for making a metal article comprising repetitively depositing a layer of metal by additive manufacturing and directionally cold working each metal layer to form the metal article.

2 . The method of claim 1 , wherein additive manufacturing method comprises a melt pool or melted metal layer.

3 . The method of claim 1 , wherein additive manufacturing comprises directed energy deposition.

4 . The method of claim 1 , wherein the metal layer comprises nickel, cobalt, copper, titanium, aluminum, iron, alloys including one or more of the foregoing metals, and combinations thereof.

5 . The method of claim 1 , wherein the additive manufacturing parameters are manipulated to control average grain size.

6 . The method of claim 1 , wherein the cold working directionally applies energy in the form of compressive strain.

7 . The method of claim 1 , wherein cold working comprises deep rolling, deep rolling with an ultrasonic head, and high frequency electromagnetic hammer, pneumatic roller vibrator, and combinations thereof.

8 . A method for repairing a metal article comprising repetitively depositing a layer of metal by additive manufacturing and directionally cold working each deposited layer, wherein the depositing and cold working occurs over a damaged section of the metal article to form a repaired section.

9 . The method of claim 8 , wherein additive manufacturing method comprises a melt pool or melted metal layer.

10 . The method of claim 8 , wherein additive manufacturing comprises directed energy deposition.

11 . The method of claim 8 , wherein the metal layer comprises nickel, cobalt, copper, titanium, aluminum, iron, alloys including one or more of the foregoing metals, and combinations thereof.

12 . The method of claim 8 , wherein additive manufacturing comprises directed energy deposition.

13 . The method of claim 8 , wherein the cold working directionally applies energy in the form of compressive strain.

14 . The method of claim 8 , wherein cold working comprises deep rolling, deep rolling with an ultrasonic head, and high frequency electromagnetic hammer, pneumatic roller vibrator, and combinations thereof.

15 . A metal article comprising a customized local average grain size and grain crystallographic orientation.

16 . The metal article of claim 15 , wherein the local grain crystallographic orientation varies by region within the article based on design requirements.

17 . The metal article of claim 15 , wherein the article comprises nickel, cobalt, copper, titanium, aluminum, iron, alloys including one or more of the foregoing metals, and combinations thereof.

Assignees

• United Technologies Corp

Inventors

• El-Wardany Tahany Ibrahim
• Grow Matthew
• Klecka Michael A
• Levan Gregory W
• Seabourn Daniel K

Classifications

• B22F10/64

  by thermal means (control of energy beam parameters for post heating B22F10/364) · CPC title

• B22F10/25

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

• B22F10/36

  of energy beam parameters · CPC title

• B22F2998/10

  Processes characterised by the sequence of their steps · CPC title

• Y02P10/25

  Process efficiency · CPC title