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US 12,005,505 B2Granted
Surface treatment of additively manufactured components
AssigneesROLLS-ROYCE plc, Rolls-Royce High Temperature Composites Inc.
InventorsQuinlan Yee Shuck, Sungbo Shim
Life of this patent
Estimating the term…
Abstract
A method may include depositing, from a slurry, suspension, or tape, on a surface of an additively manufactured component comprising a metal or alloy, powder comprising at least one of a metal, an alloy, or a ceramic; sintering the powder to form a surface layer on the additively manufactured component; and hot isostatic pressing the additively manufactured component and the surface layer.
Claims21
A method comprising:
- additively manufacturing an additively manufactured component, the additively manufactured component comprising a sacrificial binder and a metal or alloy;
- sintering, at a first time, the additively manufactured component, wherein the sacrificial binder is removed from the additively manufactured component;
- applying, at a second time that is after the first time, a slurry or suspension to the additively manufactured component using dip coating, wherein the slurry or suspension includes one or more of a dispersant, a surfactant, or a pH adjustor;
- depositing, at a third time that is after the second time, from the slurry or suspension, on a surface of the additively manufactured component, powder comprising at least one of a metal, an alloy, or a ceramic, wherein the powder has an average grain size that is smaller than an average grain size of the material used to form the additively manufactured component;
- sintering the powder to form a surface layer on the additively manufactured component;
- and
- hot isostatic pressing the additively manufactured component and the surface layer.
4 more elements
A method comprising:
- additively manufacturing an additively manufactured component using fused deposition modeling, wherein the additively manufactured component comprises a sacrificial binder and a metal or alloy, and wherein the surface of the additively manufactured component comprises a stepped surface;
- sintering, at a first time, the additively manufactured component, wherein the sacrificial binder is removed from the additively manufactured component;
- applying, at a second time that is after the first time, a slurry or suspension to the additively manufactured component using dip coating, wherein the slurry or suspension includes one or more of a dispersant, a surfactant, or a pH adjustor;
- depositing, at a second third time that is after the first second time, from the slurry or suspension, on a surface of the additively manufactured component, powder comprising at least one of a metal, an alloy, or a ceramic, wherein the powder has an average particle size that is less than a step size of the stepped surface and at least partially smooths the stepped surface, and wherein the average particle size of the powder is selected to facilitate the powder filling pores at or near the surface of the additively manufactured component;
- sintering the powder to form a surface layer on the additively manufactured component;
- and
- hot isostatic pressing the additively manufactured component and the surface layer.
4 more elements
Dependencies are inferred from the claim text.