Method of reinforcement for additive manufacturing
AssigneeThe Boeing Company
InventorsBrett Ian Lyons, Christopher S. Huskamp
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Abstract
Materials and methods are presented for manufacturing fiber reinforced parts. A powder material comprising a matrix material of a particular particle size distribution comprising substantially oriented fiber of a predetermined length distribution and diameter (L/D). A manufactured part that has substantially randomly oriented fiber is provided using an energy delivery system and the powder material.
Claims37
A method for manufacturing parts, the method comprising:
- introducing directed energy to powder particles having a predetermined particle size distribution, the powder particles comprising a plurality of anisotropically aligned reinforcing fibers with a first average fiber orientation within the powder particles;
- and
- providing a manufactured part from the powder particles, the manufactured part having a second average fiber orientation that is substantially isotropic compared to the first average fiber orientation within the manufactured part
- wherein the powder particles have a Gaussian particle size distribution and/or have a substantially spherical shape.
A powder for additive manufacturing, the powder comprising:
- a matrix material that is metal or comprised of a polymer that is semi-crystalline, is capable of entering a liquid state and a crystalline state within an overlapping range of temperatures, has having a particle size distribution capable of allowing particles to flow through openings formed by larger particles in the particle size distribution;
- a plurality of fibers within the matrix material, the plurality of fibers having a calculated main fiber direction vector, wherein the main direction vector correlates with an average fiber orientation within the matrix material;
- and
- wherein the average fiber orientation is of an angle less than 30 degrees of that of the calculated main fiber direction vector, whereby the plurality of fibers in the particle are completely anisotropically aligned when the average fiber orientation angle is zero degrees, and the powder is free-flowing.
A manufactured part comprising a matrix material having a substantially isotropic arrangement of reinforcing fibers of a predetermined fiber aspect ratio (length/diameter), the part made by the process of additive manufacturing a powder of a predetermined particle size distribution comprising the matrix material having a substantially anisotropic arrangement of the reinforcing fibers with the predetermined fiber aspect ratio wherein the fibers of the manufactured part have an average fiber length of between about 10 microns to about 150 microns and an average fiber diameter of between about 3 microns to about 8 microns.
A powder for additive manufacturing, the powder comprising:
- particles formed of a plurality of fibers disposed within a matrix material, wherein the particles have a particle size distribution selected such that relatively smaller particles within the particle distribution are capable of flowing through openings that are defined by relatively larger particles within the particle distribution when such larger particles are in a packed relationship so as to render the powder free flowing;
- wherein the plurality of fibers disposed within the matrix material have a calculated main fiber direction vector, wherein the main direction vector correlates with an average fiber orientation within each particle;
- and
- wherein the average fiber orientation is of an angle less than 30 degrees of that of the calculated main fiber direction vector, whereby the plurality of fibers in the particle are anisotropically aligned when the average fiber orientation angle is zero degrees;
- and
- wherein the plurality of fibers within the matrix material subjected to additive manufacturing provides for an average fiber orientation that is substantially more random than the average fiber orientation of the particles;
- wherein the plurality of fibers have an average fiber length of between about 25 microns to about 75 microns and an average fiber diameter of between about 4 microns to about 6 microns.
A powder for additive manufacturing of a part, comprising:
- particles formed of matrix material containing a plurality of reinforcing fibers, and wherein the plurality of fibers are in a substantially anisotropic orientation in each particle, wherein the plurality of fibers have an average fiber length of between about 10 microns to about 250 microns and an average fiber diameter of between about 3 microns to about 8 microns;
- where each particle has a calculated main fiber direction vector, wherein the main direction vector correlates with an average fiber orientation within the particles;
- and
- wherein the average fiber orientation is of an angle less than 30 degrees of that of the calculated main fiber direction vector, whereby the plurality of fibers in the particle are anisotropically aligned when the average fiber orientation angle is zero degrees;
- providing for free flowing particles that allow the fibers therein to assume a substantially isotropic orientation in a subsequently laser sintered manufactured part.
Dependencies are inferred from the claim text.