Dendrite-reinforced titanium-based metal matrix composites
AssigneeCalifornia Institute of Technology
InventorDouglas C. Hofmann
Life of this patent
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Abstract
Ti-based metal matrix composites, methods of their additive manufacture, and parts manufactured therefrom and thereby are provided. Method include layer-by-layer additive manufacturing for fabricating Ti-based metal matrix composite parts thicker than 0.5 mm, in layers with thickness between 10-1000 micrometers. The parts formed may have one or more of the following properties: a tensile strength greater than 1 GPa, a fracture toughness greater than 40 MPa m1/2, a yield strength divided by the density greater than 200 MPa cm3/g, and a total strain to failure in a tension test greater than 5%.
Claims23
A method of additively manufacturing a part comprising a metal composite material comprising:
- providing an alloy comprising Ti;
- at least one β-stabilizer, wherein a β-stabilizer is an element selected from the group consisting of Zr, Hf, Ta, Nb, V, Sn, and Mo;
- and X, wherein X represents one or more additional elements selected from the group consisting of Co, Fe, Ni, Cu, Al, B, Ag, Pd, Au, C, and Si;
- wherein the atomic % of Ti in the alloy is greater than the amount of any other element in the alloy, wherein the combined amounts of Ti and the at least one β-stabilizer comprise at least 85 atomic % of the alloy;
- and wherein the alloy does not contain Be;
- additively depositing a plurality of molten layers comprising the alloy atop one another;
- cooling each layer of the plurality of molten layers prior to depositing a layer atop thereof at a cooling rate such that upon solidification the alloy segregates phases to produce a metal matrix composite comprising a plurality of isolated crystalline dendrites characterized by a dendrite size and a dendrite density dispersed within a continuous crystalline eutectic material matrix;
- and
- repeating depositing and cooling steps to form a metal matrix composite part with a thickness of at least 0.5 mm.
A method of additively manufacturing a metal composite part comprising:
- providing a metal composite material comprising:
- an alloy comprising Ti;
- at least one β-stabilizer, wherein a β-stabilizer is an element selected from the group consisting of Zr, Hf, Ta, Nb, V, Sn, and Mo;
- and X, wherein X represents one or more additional elements selected from the group consisting of Co, Fe, Ni, Cu, Al, B, Ag, Pd, Au, C, and Si;
- wherein the atomic % of Ti in the alloy is greater than the amount of any other element in the alloy, wherein the combined amounts of Ti and the at least one β-stabilizer comprise at least 85 atomic % of the alloy;
- and wherein the alloy does not contain Be;
- wherein
- the alloy is segregated into phases comprising a plurality of isolated crystalline dendrites dispersed within a continuous crystalline eutectic material matrix
- additively depositing a plurality of layers comprising the metal composite material atop one another via a cold deposition process selected from the group consisting of:
- binder jetting, friction stir additive manufacturing, cold spraying, and ultrasonic additive manufacturing to form a metal matrix composite part with a thickness of at least 0.5 mm.
Dependencies are inferred from the claim text.