# US 10,483,037 B2 · Method of manufacturing a magnetically graded material

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- Number: US 10,483,037 B2
- Document ID: US10483037B2
- Status: Granted
- Kind: B2
- Application number: 15/347,953
- Filed: 2016-11-10
- Published: 2017-06-15
- Granted: 2019-11-19
- Earliest claimed: 2015-12-10
- Assignees: ROLLS-ROYCE plc
- Applicants: ROLLS-ROYCE plc
- Inventors: Alexis Lambourne; Iain Todd
- Web page: https://patentgrep.com/patent/US10483037B2

## CPC

- C22C 38/00: Ferrous alloys, e.g. steel alloys (cast-iron alloys C22C37/00)
- B22F 5/10: of articles with cavities or holes, not otherwise provided for in the preceding subgroups
- B22F 10/32: of the atmosphere, e.g. composition or pressure in a building chamber
- B23K 35/0255: {for use in welding (B23K35/0205 takes precedence)}
- B23K 35/3086: {containing Ni or Mn}
- B23K 35/383: {mainly containing noble gases or nitrogen}
- B33Y 10/00: Processes of additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- C22C 33/0285: {with Cr, Co, or Ni having a minimum content higher than 5%}
- C22C 38/001: {containing N}
- C22C 38/38: with more than 1.5% by weight of manganese
- C22C 38/40: with nickel
- H01F 1/0306: {Metals or alloys, e.g. LAVES phase alloys of the MgCu2-type (H01F1/0304 takes precedence)}
- H01F 41/02: for manufacturing cores, coils, or magnets (H01F41/14 takes precedence; for dynamo-electric machines H02K15/00)
- H01F 41/16: the magnetic material being applied in the form of particles, e.g. by serigraphy {, to form thick magnetic films or precursors therefor} (H01F41/18 {-H01F41/24} take precedence)
- H02K 1/02: characterised by the magnetic material
- H02K 1/246: {Variable reluctance rotors}
- H02K 1/27: Rotor cores with permanent magnets
- H02K 15/02: of stator or rotor bodies
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 12/53: Nozzles
- B22F 12/70: Gas flow means
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- 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
- H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53})
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A method of manufacturing a magnetically graded material, including depositing a steel filler material to a substrate, and applying a directed energy source to first and second regions of the filler material to thereby join the filler material to form a joined material. The energy source is directed to the first region while the first region is provided with an inert shield gas such that the material of the first regions includes a magnetic phase, and the energy source is directed to the second region while the second region is provided with a nitrogen containing shield gas to thereby impart an non-magnetic phase to the joined material.

## Claims

### Claim 1

A method of manufacturing a magnetically graded material, the method comprising:
in an additive layer manufacture process:
depositing a powder or wire material to a substrate; and
applying a directed energy source comprising one of a laser and an electron beam to first and second regions of the powder or wire material to thereby join the first and second regions to form a joined material; wherein
the energy source is directed to the first region while the first region is provided with a shield gas comprising an inert shield gas such that the material of the first region comprises a magnetic phase,
the shield gas is changed to comprise a nitrogen containing shield gas when the energy source is directed to the second region such that the second region is provided with the nitrogen containing shield gas to thereby impart an non-magnetic phase to the second region, and the inert shield gas is substantially free of nitrogen.

### Claim 2 (depends on 1)

The method according to claim 1, wherein the magnetic phase comprises a ferromagnetic phase.

### Claim 3 (depends on 2)

The method according to claim 2, wherein the magnetic phase comprises a body centred cubic ferritic microstructure comprising at least one of a martensite microstructure, a cementite microstructure, and a bainite microstructure.

### Claim 4 (depends on 1)

The method according to claim 1, wherein the non-magnetic phase comprises a paramagnetic phase.

### Claim 5 (depends on 4)

The method according to claim 4, wherein the non-magnetic phase comprises a face centered cubic phase microstructure comprising an austenitic microstructure.

### Claim 6 (depends on 1)

The method according to claim 1, wherein the inert shield gas comprises one or more of argon, hydrogen, helium, carbon dioxide, xenon, neon, or mixtures thereof.

### Claim 7 (depends on 1)

The method according to claim 1, wherein the steel filler material may comprise less than approximately 0.05% weight of carbon.

### Claim 8 (depends on 7)

The method according to claim 7, wherein the steel filler material comprises 20% weight of chromium, 5% weight of manganese, less than 0.05% weight of carbon, the remainder consisting of iron and incidental impurities.

### Claim 9 (depends on 1)

The method according to claim 1, wherein the steel filler material comprises an alloy having a nickel equivalent weight percent of less than 20%.

### Claim 10 (depends on 1)

The method according to claim 1, wherein the steel filler material comprises an alloy having a chromium equivalent weight percent greater than 10%.

### Claim 11 (depends on 1)

The method according to claim 1, wherein the step of applying the energy source to the second region comprises applying the energy source such that the second region contains greater than 0.1% weight of nitrogen.

### Claim 12 (depends on 11)

The method according to claim 11, wherein the step of applying the energy source to the second region comprises applying the energy source such that the second region contains between 0.1 and 0.4% weight of nitrogen.