# US 10,480,051 B2 · Fcc materials of aluminum, cobalt, iron and nickel, and products made therefrom

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- Number: US 10,480,051 B2
- Document ID: US10480051B2
- Status: Granted
- Kind: B2
- Application number: 16/268,350
- Filed: 2019-02-05
- Published: 2019-06-06
- Granted: 2019-11-19
- Earliest claimed: 2016-04-20
- Assignees: Arconic Inc.
- Applicants: Arconic Inc.
- Inventors: Jen Lin; Xinyan Yan
- Web page: https://patentgrep.com/patent/US10480051B2

## CPC

- C22C 30/00: Alloys containing less than 50% by weight of each constituent
- B22F 1/00: Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F 3/15: Hot isostatic pressing
- B22F 3/17: by forging
- B22F 3/18: by using pressure rollers
- B22F 3/20: by extruding
- B22F 5/009: {of turbine components other than turbine blades (of turbine blades B22F5/04)}
- B22F 5/04: of turbine blades
- B22F 7/06: of composite workpieces or articles from parts, e.g. to form tipped tools {(B22F7/002 takes precedence)}
- B23K 10/027: {Welding for purposes other than joining, e.g. build-up welding}
- B23K 15/0086: {welding for purposes other than joining, e.g. build-up welding}
- B23K 15/0093: {characterised by the properties of the materials to be welded}
- B23K 26/0006: {taking account of the properties of the material involved (B23K26/32, B23K26/40 take precedence)}
- B23K 26/342: Build-up welding
- B23K 35/0261: {Rods, electrodes or wires}
- B23K 35/3033: {Ni as the principal constituent}
- B33Y 10/00: Processes of additive manufacturing
- B33Y 70/00: Materials specially adapted for additive manufacturing
- C22C 19/03: based on nickel
- C22F 1/002: {by rapid cooling or quenching; cooling agents used therefor}
- C22F 1/10: of nickel or cobalt or alloys based thereon
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 2998/10: Processes characterised by the sequence of their steps
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- B23K 2103/08: Non-ferrous metals or alloys
- B23K 2103/26: {Alloys of Nickel and Cobalt and Chromium}
- Y02P 10/25: Process efficiency
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- C22F: CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS (surface treatment of metallic material involving at least one process provided for in class C23 and at least one process covered by this subclass, C23F17/00)
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

The present disclosure relates to new materials comprising Al, Co, Fe, and Ni. The new materials may realize a single phase field of a face-centered cubic (fcc) solid solution structure immediately below the solidus temperature of the material. The new materials may include at least one precipitate phase and have a solvus temperature of at least 1000° C. The new materials may include 4.4-11.4 wt. % Al, 4.9-42.2 wt. % Co, 4.6-28.9 wt. % Fe, and 44.1-86.1 wt. % Ni. In one embodiment, the precipitate is selected from the group consisting of the L12 phase, the B2 phase, and combinations thereof. The new alloys may realize improved high temperature properties.

## Claims

### Claim 1

A method comprising:
(a) using a feedstock in an additive manufacturing apparatus, wherein the feedstock comprises:
4.4-11.4 wt. % Al;
4.9-42.2 wt. % Co;
4.6-28.9 wt. % Fe; and
44.1-86.1 wt. % Ni;
(b) producing a metal product in the additive manufacturing apparatus using the feedstock.

### Claim 2 (depends on 1)

The method of claim 1, wherein the feedstock comprises a powder feedstock, wherein the method comprises:
(a) dispersing a metal powder of the powder feedstock in a bed and/or spraying a metal powder of the powder feedstock towards or on a substrate;
(b) selectively heating a portion of the metal powder above its liquidus temperature, thereby forming a molten pool;
(c) cooling the molten pool, thereby forming a portion of the metal product, wherein the cooling comprises cooling at a cooling rate of at least 100° C. per second; and
(d) repeating steps (a)-(c) until the metal product is completed, wherein the metal product comprises a metal matrix, wherein the Al, Co, Fe, and Ni make-up the matrix.

### Claim 3 (depends on 1)

The method of claim 1, wherein the feedstock comprises a wire feedstock, wherein the method comprises:
(a) using a radiation source to heat the wire feedstock above its liquidus point, thereby creating a molten pool, wherein the molten pool comprises Al, Co, Fe, and Ni;
(b) cooling the molten pool at a cooling rate of at least 1000° C. per second; and
(c) repeating steps (a)-(b) until the metal product is completed, wherein the metal product comprises a metal matrix, wherein the Al, Co, Fe, and Ni make-up the matrix.

### Claim 4 (depends on 1)

The method of claim 1, comprising: cooling at a rate sufficient to form at least one precipitate phase.

### Claim 5 (depends on 4)

The method of claim 4, wherein the at least one precipitate phase comprises at least one of L12 and B2.

### Claim 6 (depends on 5)

The method of claim 5, wherein the metal product comprises at least 0.5 vol. % of the precipitate phase.

### Claim 7 (depends on 1)

The method of claim 1, comprising:
working the metal product.

### Claim 8 (depends on 7)

The method of claim 7, wherein the producing step comprises:
first producing a portion of the metal product using the feedstock;
second producing another portion of the metal product using the feedstock;
wherein the working occurs at least after the first or second producing steps.

### Claim 9 (depends on 8)

The method of claim 8, wherein the working occurs between the first producing step and the second producing step.

### Claim 10 (depends on 8)

The method of claim 8, wherein the working comprises one or more of rolling, forging, extrusion and hot isostatic pressing.