Additive manufacturing utilizing metallic wire
AssigneeH.C. Starck GmbH
InventorsDavid B. Smathers, Patrick Hogan, Michael Thomas Stawovy, Maria B. Winnicka, Gary A. Rozak
Life of this patent
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Abstract
In various embodiments, additive manufacturing is utilized to fabricate three-dimensional metallic parts using metallic alloy wire as a feedstock material.
Claims20
A method of forming a three-dimensional part comprising a high-entropy alloy or a multi-principal element alloy by additive manufacturing, wherein the high-entropy alloy or multi-principal element alloy comprises four or more metallic elements selected from the group consisting of Nb, Ta, Mo, W, Ti, Hf, V, Zr, Al, and Cr, the method comprising:
- (a) providing a wire consisting essentially of the four or more metallic elements, the wire comprising an assemblage of (i) one or more first metal powders each comprising one or more of the metallic elements, wherein particles of each first metal powder are substantially spherical, and (ii) one or more second metal powders each comprising one or more of the metallic elements, wherein particles of each second metal powder are non-spherical;
- (b) translating a tip of the wire relative to a platform;
- (c) thereduring, melting a tip of the wire with an energy source to form a molten bead comprising the four or more metallic elements, whereby the bead cools to form at least a portion of a layer of a three-dimensional part;
- and
- (d) repeating steps (b) and (c) one or more times to produce the three-dimensional part,
- wherein the three-dimensional part comprises the high-entropy alloy or the multi-principal element alloy.
A method of forming a three-dimensional part comprising a high-entropy alloy or a multi-principal element alloy by additive manufacturing, wherein the high-entropy alloy or multi-principal element alloy comprises four or more metallic elements selected from the group consisting of Nb, Ta, Mo, W, Ti, Hf, V, Zr, Al, and Cr, the method comprising:
- (a) providing a wire preform consisting essentially of the four or more metallic elements, the wire preform comprising an assemblage of (i) one or more first metal powders each comprising one or more of the metallic elements, wherein particles of each first metal powder are substantially spherical, and (ii) one or more second metal powders each comprising one or more of the metallic elements, wherein particles of each second metal powder are non-spherical;
- (b) reducing a diameter of the wire preform via one or more mechanical deformation processes, thereby forming a metallic wire;
- (c) translating a tip of the wire relative to a platform;
- (d) thereduring, melting a tip of the wire with an energy source to form a molten bead comprising the four or more metallic elements, whereby the bead cools to form at least a portion of a layer of a three-dimensional part;
- and
- (e) repeating steps (c) and (d) one or more times to produce the three-dimensional part,
- wherein the three-dimensional part comprises the high-entropy alloy or the multi-principal element alloy.
Dependencies are inferred from the claim text.