High-density, crack-free metallic parts
AssigneeH.C. Starck GmbH
InventorMichael Thomas Stawovy
Life of this patent
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Abstract
In various embodiments, three-dimensional layered metallic parts are substantially free of gaps between successive layers, are substantially free of cracks, and have densities no less than 97% of the theoretical density of the metallic material.
Claims19
A three-dimensional part manufactured by additive manufacturing using a feedstock material comprising molybdenum, the part (i) comprising a plurality of layers each comprising solidified molybdenum, (ii) being free of gaps between successive layers, and (iii) being free of cracks, wherein a density of the part is no less than 97% of a theoretical density of molybdenum, and wherein a concentration within the part of each of sodium, calcium, antimony, magnesium, phosphorous, and potassium is less than 1 ppm by weight and at least 0.001 ppm by weight.
A three-dimensional part manufactured by additive manufacturing using a feedstock material comprising a metallic material comprising at least one of niobium, tantalum, rhenium, tungsten, or molybdenum, the part (i) comprising a plurality of layers each comprising solidified metallic material, (ii) being free of gaps between successive layers, and (iii) being free of cracks, wherein a density of the part is no less than 97% of a theoretical density of the metallic material, and wherein a concentration within the part of each of sodium, calcium, antimony, magnesium, phosphorous, and potassium is less than 1 ppm by weight and at least 0.001 ppm by weight.
A three-dimensional part manufactured by additive manufacturing using a feedstock material comprising a metallic material comprising at least one of niobium, tantalum, rhenium, tungsten, or molybdenum, the part (i) comprising a plurality of layers each comprising solidified metallic material, (ii) being free of gaps between successive layers, and (iii) being free of cracks, wherein (a) a density of the part is no less than 97% of a theoretical density of the metallic material, (b) a concentration within the part of each of sodium, calcium, antimony, magnesium, phosphorous, and potassium is less than 1 ppm by weight and at least 0.001 ppm by weight, and (c) a concentration of oxygen within the part is less than 5 ppm by weight and at least 0.001 ppm by weight.
Dependencies are inferred from the claim text.