Build materials having a powder mixture comprising graphene, methods of producing articles therefrom, and articles produced therewith

Patent metadata

Field	Value
Publication number	US-2024058862-A1
Application number	US-202217937813-A
Country	US
Kind code	A1
Filing date	Oct 4, 2022
Priority date	Aug 17, 2022
Publication date	Feb 22, 2024
Grant date	—

Abstract

Methods and build materials are provided for producing articles with additive manufacturing processes. The methods comprise providing a build material comprising a powder mixture of about 95.0 wt. % to about 99.95 wt. % metallic powder and about 0.05 wt. % to about 5.0 wt. % graphene powder and performing an additive manufacturing process to produce the article from the build material. The graphene powder comprises nanoplatelets having between 1 and 30 layers of graphene.

First claim

What is claimed is:

1 . A method of producing an article, the method comprising:
providing a build material comprising a powder mixture of about 95.0 wt. % to about 99.95 wt. % metallic powder and about 0.05 wt. % to about 5.0 wt. % graphene powder, wherein the graphene powder comprises nanoplatelets having between 1 and 30 layers of graphene; and performing an additive manufacturing process to produce the article from the build material.

2 . The method of claim 1 , further comprising preparing the build material by:
mixing the metallic powder, the graphene powder, and a dispersing agent to form a powder mixture; and drying the powder mixture to form the build material.

3 . The method of claim 1 , wherein the nanoplatelets have between 1 and 20 layers of graphene.

4 . The method of claim 1 , wherein the metallic powder comprises nickel, aluminum, iron, or alloys thereof.

5 . The method of claim 1 , wherein the graphene powder has a composition comprising about 92 wt. % to about 100 wt. % carbon.

6 . The method of claim 1 , wherein the graphene powder has a composition consisting essentially of:
about 92 wt. % to about 100 wt. % carbon; up to about 8.0 wt. % oxygen; up to about 0.2 wt. % sulfur; up to about 0.2 wt. % nitrogen; up to about 0.2 wt. % silicon; and the balance incidental impurities.

7 . The method of claim 1 , wherein the build material has a substantially uniform distribution of the graphene powder therein.

8 . The method of claim 1 , wherein a majority of the nanoplatelets have more than one layer of graphene.

9 . The method of claim 1 , wherein a hot isostatic pressing process is not performed on the article.

10 . The method of claim 1 , wherein the additive manufacturing process is a powder bed fusion process.

11 . The method of claim 1 , wherein the article is configured to be installed as a component in a gas turbine engine as a component thereof.

12 . The method of claim 11 , wherein the component is a turbine vane, turbine blade, or a turbine nozzle.

13 . An article produced by a method comprising the steps of providing a build material comprising a powder mixture of about 95.0 wt. % to about 99.95 wt. % metallic powder and about 0.05 wt. % to about 5.0 wt. % graphene powder, wherein the graphene powder comprises nanoplatelets having between 1 and 30 layers of graphene, and performing an additive manufacturing process to produce the article from the build material.

14 . The article of claim 13 , wherein the article has a fatigue life and a rupture life greater than a comparable article consisting of the metallic alloy and produced by a metalworking process or an additive manufacturing process that includes a subsequent hot isostatic pressing process.

15 . The article of claim 13 , wherein the article has a fatigue life and a rupture life greater than a comparable article consisting of the metallic alloy and produced by a forging process.

16 . The article of claim 13 , wherein the metallic powder comprises nickel, aluminum, iron, or alloys thereof, the graphene powder has a composition comprising about 92 wt. % to about 100 wt. % carbon, and the build material has a substantially uniform distribution of the graphene powder therein.

17 . The article of claim 16 , wherein the graphene powder has a composition consisting essentially of:
about 92 wt. % to about 100 wt. % carbon; up to about 8.0 wt. % oxygen; up to about 0.2 wt. % sulfur; up to about 0.2 wt. % nitrogen; up to about 0.2 wt. % silicon; and the balance incidental impurities.

18 . A build material for use in an additive manufacturing process, the build material comprising a powder mixture of about 95.0 wt. % to about 99.95 wt. % metallic powder and about 0.05 wt. % to about 5.0 wt. % graphene powder, wherein the graphene powder comprises nanoplatelets having between 1 and 30 layers.

19 . The build material of claim 18 , wherein the metallic powder comprises nickel, aluminum, iron, or alloys thereof, the graphene powder has a composition comprising about 92 wt. % to about 100 wt. % carbon, and the build material has a substantially uniform distribution of the graphene powder therein.

20 . The build material of claim 19 , wherein the graphene powder has a composition consisting essentially of:
about 92 wt. % to about 100 wt. % carbon; up to about 8.0 wt. % oxygen; up to about 0.2 wt. % sulfur; up to about 0.2 wt. % nitrogen; up to about 0.2 wt. % silicon; and the balance incidental impurities.

Assignees

• Honeywell Int Inc

Inventors

• Dilip Vasisht
• Sharma Kedar
• Kurlgeri Riyazahmmad
• Gollakota Venkata Sai Manohar
• Chikkala Eswara Naidu
• Baughman Brian
• Kington Harry
• Mcdonald Robert

Classifications

• C22C33/02

  by powder metallurgy · CPC title

• C22C1/0433

  Nickel- or cobalt-based alloys · CPC title

• C22C1/0416

  Aluminium-based alloys · CPC title

• B22F5/04

  of turbine blades · CPC title

• B22F5/009 Primary

  of turbine components other than turbine blades (of turbine blades B22F5/04) · CPC title