Producing ultra-fine-grained materials using additive manufacturing

Patent metadata

Field	Value
Publication number	US-2023249255-A1
Application number	US-202218086944-A
Country	US
Kind code	A1
Filing date	Dec 22, 2022
Priority date	Feb 4, 2022
Publication date	Aug 10, 2023
Grant date	—

Abstract

A method is provided for producing ultra-fine-grained materials using additive manufacturing. The method includes commanding, by a controller, a laser device to produce a plurality of optical pulses to a base material to add an additive material to the base material. The method further includes commanding, by the controller, a vibration mechanism to vibrate the base material as the plurality of optical pulses are being applied to the base material forming fine equiaxed grains with random crystallographic texture in the base material.

First claim

What is claimed is:

1 . A method for producing ultra-fine-grained materials using additive manufacturing, the method comprising:
commanding, by a controller, a laser device to produce a plurality of optical pulses to a base material to add an additive material to the base material; and commanding, by the controller, a vibration mechanism to vibrate the base material as the plurality of optical pulses are being applied to the base material forming fine equiaxed grains with random crystallographic texture in the base material.

2 . The method of claim 1 , wherein the laser device is a pulsed laser.

3 . The method of claim 1 , wherein the vibration mechanism is an array of ultrasonic transducers and wherein the controller commands the array of ultrasonic transducers to vibrate the base material in a first direction.

4 . The method of claim 3 , wherein the first direction is a vertical direction.

5 . The method of claim 1 , wherein the vibration mechanism is a table vibrator and wherein the controller commands the table vibrator to vibrate the base material in at least one of a second direction or a third direction.

6 . The method of claim 5 , wherein the second direction is a lateral direction.

7 . The method of claim 5 , wherein the third direction is a longitudinal direction.

8 . The method of claim 1 , further comprising:
commanding, by the controller, an additive powder feeder to preheat the additive material prior to being added to the base material.

9 . The method of claim 1 , further comprising:
commanding, by the controller, an ultrasonic pulsed laser that follows a pulsed laser that is applying the plurality of optical pulses to apply ultrasonic vibrations to the base material.

10 . A system for producing ultra-fine-grained materials using additive manufacturing, the system comprising:
a pulsed laser configured to apply a plurality of optical pulses to a base material to add an additive material to the base material; and a vibration mechanism configured to vibrate the base material as the plurality of optical pulses are being applied to the base material forming fine equiaxed grains with random crystallographic texture in the base material.

11 . The system of claim 10 , wherein the vibration mechanism is configured to vibrate the base material in a first direction.

12 . The system of claim 11 , wherein the vibration mechanism is an array of ultrasonic transducers and wherein the first direction is a vertical direction.

13 . The system of claim 10 , wherein the vibration mechanism is configured to vibrate the base material in at least one of a second direction or a third direction.

14 . The system of claim 13 , wherein the vibration mechanism is a table vibrator and wherein the second direction is a lateral direction.

15 . The system of claim 13 , wherein the vibration mechanism is a table vibrator and wherein the third direction is a longitudinal direction.

16 . The system of claim 10 , further comprising:
an additive powder feeder configured to preheat the additive material prior to being added to the base material.

17 . The system of claim 10 , further comprising:
an ultrasonic pulsed laser configured to apply ultrasonic vibrations to the base material, wherein the ultrasonic vibrations follow the pulsed laser applying the plurality of optical pulses.

18 . A control system for producing ultra-fine-grained materials using additive manufacturing, the control system comprising:
a pulsed laser; an array of ultrasonic transducers; a controller; and a tangible, non-transitory memory configured to communicate with the controller, the tangible, non-transitory memory having instructions stored thereon that, in response to execution by the controller, cause the controller to perform operations comprising:
applying, by the pulsed laser, a plurality of optical pulses to a base material to add an additive material to the base material; and
vibrating, by the array of ultrasonic transducers, the base material as the plurality of optical pulses are being applied to the base material to form fine equiaxed grains with random crystallographic texture in the base material.

19 . The control system of claim 18 , wherein the vibrating of the base material is in a first direction and wherein the first direction is a vertical direction.

20 . The control system of claim 18 , further comprising:
a table vibrator, and wherein the operations further comprise:
vibrating, by the table vibrator, the base material in at least one of a second direction or a third direction, wherein the second direction is a lateral direction, and wherein the third direction is a longitudinal direction.

Assignees

• Goodrich Corp

Inventors

• Borkowski Luke B
• Staroselsky Alexander
• Acharya Ranadip
• Mironets Sergey

Classifications

• B22F10/50 Primary

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

• B22F12/13

  to preheat the material · CPC title

• B22F12/30

  Platforms or substrates · CPC title

• B22F12/43

  pulsed; frequency modulated · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title