US 10,850,346 B2Granted

Composition and method for fusion processing aluminum alloy

AssigneeRaytheon Company

InventorsNorman Dana Nelson, Ralph P. Mason, Mark J. Pistorino

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Abstract

An aluminum alloy precursor composition and method for fusion processing is provided which reduces hot cracking, improves compositional control, reduces porosity, and/or enhances the mechanical properties of the fusion processed article. The precursor material and fusion process using the same may be utilized for forming an article that meets compositional specifications for aluminum 6061 alloy, while minimizing defects and meeting desired strength and ductility requirements. The fusion process may include a leading energy beam for liquefying the precursor material to form a melt pool, and a trailing energy beam directed toward a trailing region of the melt pool. The trailing energy beam may be configured to enhance agitation and/or redistribution of liquid in the melt pool to prevent hot cracking, reduce porosity, or improve other characteristics of the solidified part. The method also may improve processing parameters, such as adjusting vacuum level to prevent volatilization of alloying elements.

Claims23

Dependent claims

A method of forming an aluminum alloy article by fusion processing, comprising:

obtaining an aluminum alloy precursor material in solid state form, the aluminum alloy precursor material having a chemical composition, in weight % of the aluminum alloy precursor material, comprising:
Al from 50% or greater;
Si from 0.40% to 0.80%;
Cu from 0.15% to 0.40%;
Mg from 2.5% to 5.0%;
Cr from 0.04% to 0.35%;
Ti from 0.0% to 0.15%;
Fe from 0.0% to 0.7%;
Mn from 0.0% to 0.15%;
and
Zn from 0.0% to 0.005%;
exposing the aluminum alloy precursor material to at least one direct energy source sufficient to heat and liquefy the precursor material;
forming a melt pool with the liquefied precursor material on a substrate, wherein the forming the melt pool with the liquefied precursor material is performed as at least one of the at least one direct energy source or the substrate move relative to each other in a travel direction;
solidifying the melt pool to form the aluminum alloy article, the aluminum alloy article having a chemical composition, in weight % of the aluminum alloy forming the article, comprising:
Al from 50% or greater;
Si from 0.40% to 0.80%;
Cu from 0.15% to 0.40%;
Mg from 0.8% to 1.2%;
Cr from 0.04% to 0.35%;
Ti from 0.0% to 0.15%;
Fe from 0.0% to 0.7%;
Mn from 0.0% to 0.15%;
and
Zn from 0.0% to 0.005%;
wherein the fusion processing is an electron beam additive manufacturing process,
wherein the method further comprises:
(i) providing the aluminum alloy precursor material as a wire;
(ii) feeding the wire of aluminum alloy precursor material to a feed region;
and
(iii) exposing the wire of aluminum alloy precursor material to the at least one direct energy source at the feed region to thereby heat and liquefy the wire, wherein the at least one direct energy source is an electron beam;
wherein the solidifying the melt pool includes forming a re-solidified layer that trails the melt pool;
wherein the method further includes building the aluminum alloy article as a three-dimensional structure re-solidified layer by re-solidified layer;
wherein the melt pool has a leading region and a trailing region, the leading region being characterized by a liquid phase, and the trailing region being characterized by a solid-liquid phase between a liquid interface and a solid interface of the melt pool;
and
the method further comprising:
exposing the trailing region of the melt pool to a trailing energy beam that is configured to redistribute liquid constituents in the trailing region to thereby disrupt formation of a dendritic microstructure and reduce hot cracking when the melt pool solidifies.

33 more elements

A method of forming an aluminum alloy article by fusion processing, comprising:

obtaining an aluminum alloy precursor material in solid state form, the aluminum alloy precursor material having a chemical composition, in weight % of the aluminum alloy precursor material, comprising:
Al from 50% or greater;
Si from 0.40% to 0.80%;
Cu from 0.15% to 0.40%;
Mg from greater than 1.2% to 5.0% or less;
Cr from 0.04% to 0.35%;
Ti from 0.0% to 0.15%;
Fe from0.0% to 0.7%;
Mn from 0.0% to 0.15%;
and
Zn from 0.0% to 0.005%;
exposing the aluminum alloy precursor material to at least one direct energy source sufficient to heat and liquefy the precursor material;
forming a melt pool with the liquefied precursor material on a substrate, wherein the forming the melt pool with the liquefied precursor material is performed as at least one of the at least one direct energy source or the substrate move relative to each other in a travel direction;
solidifying the melt pool to form the aluminum alloy article, the aluminum alloy article having a chemical composition, in weight % of the aluminum alloy forming the article, comprising:
Al from 50% or greater;
Si from 0.40% to 0.80%;
Cu from 0.15% to 0.40%;
Mg from 0.8% to 1.2%;
Cr from 0.04% to 0.35%;
Ti from 0.0% to 0.15%;
Fe from 0.0% to 0.7%;
Mn from 0.0% to 0.15%;
and
Zn from 0.0% to 0.005%;
wherein the at least one direct energy source is a leading energy beam, and wherein the melt pool has a leading region and a trailing region;
wherein the leading region of the melt pool is proximal to the leading energy beam as at least one of the leading energy beam or the substrate move in the travel direction;
and
wherein the trailing region of the melt pool trails the leading region as at least one of the leading energy beam or the substrate move in the travel direction;
the method further comprising:
exposing the trailing region of the melt pool to a trailing energy beam;
wherein the leading region of the melt pool is a liquid-phase region, and wherein the trailing region of the melt pool is a transitional solid-liquid phase region between a liquid interface and a solid interface of the melt pool;
and
wherein the trailing energy beam is configured to redistribute liquid constituents in the trailing region to thereby reduce hot cracking when the melt pool solidifies.

30 more elements

A method of forming an aluminum alloy article by fusion processing, comprising:

obtaining an aluminum alloy precursor material in solid state form, the aluminum alloy precursor material having a chemical composition, in weight % of the aluminum alloy precursor material, comprising:
Al from 50% or greater;
Si from 0.40% to 0.80%;
Cu from 0.15% to 0.40%;
Mg from greater than 1.2% to 5.0% or less;
Cr from 0.04% to 0.35%;
Ti from 0.0% to 0.15%;
Fe from 0.0% to 0.7%;
Mn from 0.0% to 0.15%;
and
Zn from 0.0% to 0.005%;
exposing the aluminum alloy precursor material to at least one direct energy source sufficient to heat and liquefy the precursor material;
forming a melt pool with the liquefied precursor material on a substrate, wherein the forming the melt pool with the liquefied precursor material is performed as at least one of the at least one direct energy source or the substrate move relative to each other in a travel direction;
solidifying the melt pool to form the aluminum alloy article, the aluminum alloy article having a chemical composition, in weight % of the aluminum alloy forming the article, comprising:
Al from 50% or greater;
Si from 0.40% to 0.80%;
Cu from 0.15% to 0.40%;
Mg from 0.8% to 1.2%;
Cr from 0.04% to 0.35%;
Ti from 0.0% to 0.15%;
Fe from 0.0% to 0.7%;
Mn from 0.0% to 0.15%;
and
Zn from 0.0% to 0.005%;
wherein the at least one direct energy source is a leading energy beam, and wherein the melt pool has a leading region and a trailing region;
wherein the leading region of the melt pool is proximal to the leading energy beam as at least one of the leading energy beam or the substrate move in the travel direction;
and
wherein the trailing region of the melt pool trails the leading region as at least one of the leading energy beam or the substrate move in the travel direction;
the method further comprising:
exposing the trailing region of the melt pool to a trailing energy beam;
and
wherein the trailing energy beam is configured in a concave pattern that opens toward the leading region of the melt pool.

29 more elements

A method of forming an aluminum alloy article by fusion processing, comprising:

obtaining an aluminum alloy article by fusion processing, comprising:
obtaining an aluminum alloy precursor material in solid state form, the aluminum alloy precursor material having a chemical composition, in weight % of the aluminum alloy precursor material, comprising:
Al from 50% or greater;
Si from 0.40% to 0.80%;
Cu from 0.15% to 0.40%;
Mg from greater than 1.2% to 5.0% or less;
Cr from 0.04% to 0.35%;
Ti from 0.0% to 0.15%;
Fe from 0.0% to 0.7%;
Mn from 0.0% to 0.15%;
and
Zn from 0.0% to 0.005%;
exposing the aluminum alloy precursor material to at least one direct energy source sufficient to heat and liquefy the precursor material;
forming a melt pool with the liquefied precursor material on a substrate, wherein the forming the melt pool with the liquefied precursor material is performed as at least one of the at least one direct energy source or the substrate move relative to each other in a travel direction;
solidifying the melt pool to form the aluminum alloy article, the aluminum alloy article having a chemical composition, in weight % of the aluminum alloy forming the article, comprising:
Al from 50% or greater;
Si from 0.40% to 0.80%;
Cu from 0.15% to 0.40%;
Mg from 0.8% to 1.2%;
Cr from 0.04% to 0.35%;
Ti from 0.0% to 0.15%;
Fe from 0.0% to 0.7%;
Mn from 0.0% to 0.15%;
and
Zn from 0.0% to 0.005%;
wherein the at least one direct energy source is a leading energy beam, and wherein the melt pool has a leading region and a trailing region;
wherein the leading region of the melt pool is proximal to the leading energy beam as at least one of the leading energy beam or the substrate move in the travel direction;
and
wherein the trailing region of the melt pool trails the leading region as at least one of the leading energy beam or the substrate move in the travel direction;
the method further comprising:
exposing the trailing region of the melt pool to a trailing energy beam;
and
wherein the trailing energy beam is spaced apart from the leading energy beam at varying distances as the leading energy beam moves in a travel direction.

30 more elements

Dependencies are inferred from the claim text.

Facts

Application: 15/457,312Filed 13 Mar 2017 · continuation in part
Priority: 4 Dec 2015
Published: US 2017/0182595 A129 Jun 2017
Granted: 1 Dec 2020
Term ends: Not estimatedThe source records don’t support an estimate.

Classification35 codes

B23K 15/0086
Welding: welding for purposes other than joining, e.g. build-up welding
B22F 10/25
Direct sintering or melting: direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
B22F 10/364
Of energy beam parameters: for post-heating, e.g. remelting
B22F 10/38
Process control: to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures