# US 12,109,618 B2 · Process and printed article

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- Number: US 12,109,618 B2
- Document ID: US12109618B2
- Status: Granted
- Kind: B2
- Application number: 17/197,266
- Filed: 2021-03-10
- Published: 2021-07-22
- Granted: 2024-10-08
- Earliest claimed: 2017-01-05
- Assignees: GE Infrastructure Technology LLC
- Applicants: General Electric Company
- Inventors: Ibrahim Ucok; Yan Cui; Srikanth Chandrudu Kottilingam; Surinder Singh Pabla
- Web page: https://patentgrep.com/patent/US12109618B2

## CPC

- B22F 3/15: Hot isostatic pressing
- B22F 3/24: After-treatment of workpieces or articles {(B22F3/1146 takes precedence)}
- B22F 5/009: {of turbine components other than turbine blades (of turbine blades B22F5/04)}
- B22F 5/04: of turbine blades
- B22F 10/14: by jetting of binder onto a bed of metal powder
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 10/62: by chemical means
- B22F 10/64: by thermal means (control of energy beam parameters for post heating B22F10/364)
- B23K 15/0086: {welding for purposes other than joining, e.g. build-up welding}
- B23K 15/0093: {characterised by the properties of the materials to be welded}
- B23K 26/0006: {taking account of the properties of the material involved (B23K26/32, B23K26/40 take precedence)}
- B23K 26/342: Build-up welding
- B23K 26/70: Auxiliary operations or equipment
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 15/01: all layers being exclusively metallic {(making layered metal workpieces by pressure cladding B23K20/22; making coatings with a metallic material characterised by its composition C23C30/00)}
- B33Y 10/00: Processes of additive manufacturing
- B33Y 40/20: Post-treatment, e.g. curing, coating or polishing
- B33Y 70/00: Materials specially adapted for additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- C22C 19/055: {with the maximum Cr content being at least 20% but less than 30%}
- C22C 19/056: {with the maximum Cr content being at least 10% but less than 20%}
- C22C 19/057: {with the maximum Cr content being less 10%}
- C22C 19/07: based on cobalt
- C22C 30/02: containing copper
- C22C 38/002: {containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60}
- C22C 38/02: containing silicon
- C22C 38/04: containing manganese
- C22C 38/06: containing aluminium
- C22C 38/08: containing nickel {(C22C38/105 takes precedence)}
- C22C 38/105: {containing Co and Ni}
- C22C 38/42: with copper
- C22C 38/44: with molybdenum or tungsten
- C22C 38/48: with niobium or tantalum
- C22C 38/50: with titanium or zirconium
- C22C 38/52: with cobalt
- C23C 4/08: containing only metal elements (C23C4/073 takes precedence)
- C23C 4/134: Plasma spraying
- C23C 14/16: on metallic substrates or on substrates of boron or silicon
- C23C 14/28: by wave energy or particle radiation (C23C14/32 - C23C14/48 take precedence)
- C23C 16/06: characterised by the deposition of metallic material
- C23C 16/44: characterised by the method of coating (C23C16/04 takes precedence)
- C23C 18/1637: {metallic substrate}
- C23C 18/32: Coating with nickel, cobalt or mixtures thereof with phosphorus or boron (C23C18/50 takes precedence)
- F01D 5/28: Selecting particular materials; {Particular measures relating thereto;} Measures against erosion or corrosion
- F01D 25/005: {Selecting particular materials}
- F01D 25/24: Casings (modified for heating or cooling F01D25/14); Casing parts, e.g. diaphragms, casing fastenings (casings for rotary machines or engines in general F16M {; special arrangements in stators dealing with breaking-off of part of rotor F01D21/045})
- B22F 2003/242: {Coating}
- B22F 2301/15: Nickel or cobalt
- B22F 2301/35: Iron
- B22F 2998/10: Processes characterised by the sequence of their steps
- B23K 2101/001: {Turbines}
- F05D 2300/17: Alloys
- Y02P 10/25: Process efficiency
- 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
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A process includes forming a printed article having an external surface and at least one microfeature with an internal surface by additive manufacture, coating the external surface and the internal surface of the printed article with a metallic microlayer to form a coated article, and densifying the coated article to form a component. After formation, the printed article has a porosity such that the printed article is not at full density. A densified component includes a printed article having an external surface and at least one microfeature with an internal surface and a metallic microlayer coating the external surface and the internal surface of the printed article. The printed article is formed by additive manufacture.

## Claims

### Claim 1

A densified component comprising:
a printed article having an external surface and at least one microfeature with an internal surface adjacent to the external surface, the internal surface of the at least one microfeature including a non-line-of-sight surface relative to the external surface, the at least one microfeature being an additively manufactured feature with a predetermined structure and the printed article being formed by additive manufacture with a porosity such that the printed article is not at full density, the porosity including surface-connected porosity at the external surface and at the internal surface; and
a metallic microlayer coating the external surface of the printed article and the internal surface of the at least one microfeature, including coating the non-line-of-sight surface of the at least one microfeature, to seal the surface-connected porosity of the printed article by overlaying the surface-connected porosity along the external surface and the internal surface,
wherein the metallic microlayer is formed of a material other than pure nickel.

### Claim 2 (depends on 1)

The component of claim 1, wherein the component is a gas turbine component.

### Claim 3 (depends on 1)

The component of claim 1, wherein the microfeature is a microchannel.

### Claim 4 (depends on 1)

The component of claim 1, wherein the metallic microlayer has a thickness in the range of about 5 μm to about 100 μm.

### Claim 5 (depends on 1)

The component of claim 1, wherein the metallic microlayer has a thickness in the range of about 30.5 μm to about 63.5 μm.

### Claim 6 (depends on 1)

The component of claim 1, wherein the printed article and the metallic microlayer are formed of a material independently selected from the group consisting of a nickel-based alloy and a cobalt-based alloy.

### Claim 7 (depends on 1)

The component of claim 1, wherein the printed article is iron-based and the metallic microlayer is formed of a material selected from the group consisting of a nickel-based alloy, a cobalt-based alloy, and an iron-based alloy.

### Claim 8 (depends on 1)

The component of claim 1, wherein the non-line-of-sight surface includes at least one surface-connected porosity.

### Claim 9 (depends on 8)

The component of claim 8, wherein the metallic microlayer seals the at least one surface-connected porosity.

### Claim 10 (depends on 8)

The component of claim 8, wherein the metallic microlayer covers all surface-connected porosity.

### Claim 11 (depends on 1)

The component of claim 1, wherein the component is greater than 90% of full density.

### Claim 12 (depends on 1)

The component of claim 1, wherein the printed article is formed of a superalloy including a composition, by weight, selected from the group consisting of between about 9.3% and about 9.7% tungsten (W), between about 9.0% and about 9.5% cobalt (Co), between about 8.0% and about 8.5% chromium (Cr), between about 5.4% and about 5.7% aluminum (Al), about 3.2% tantalum (Ta), about 1.4% hafnium (Hf), up to about 0.25% silicon (Si), up to about 0.1% manganese (Mn), between about 0.06% and about 0.09% carbon (C), incidental impurities, and a balance of nickel (Ni); between about 9% and about 10% Co, between about 9.3% and about 9.7% W, between about 8.0% and about 8.7% Cr, between about 5.25% and about 5.75% Al, between about 2.8% and about 3.3% Ta, between about 1.3% and about 1.7% Hf, up to about 0.9% titanium (Ti), up to about 0.6% molybdenum (Mo), up to about 0.2% iron (Fe), up to about 0.12% Si, up to about 0.1% Mn, up to about 0.1% copper (Cu), up to about 0.1% C, up to about 0.1% niobium (Nb), up to about 0.02% zirconium (Zr), up to about 0.02% boron (B), up to about 0.01% phosphorus (P), up to about 0.004% sulfur (S), incidental impurities, and a balance of Ni; about 9.75% Cr, about 7.5% Co, about 4.2% Al, about 3.5% Ti, about 4.8% Ta, about 6% W, about 1.5% Mo, up to about 0.5% Nb, up to about 0.2% Fe, up to about 0.2% Si, up to about 0.15% Hf, up to about 0.08% C, up to about 0.009% Zr, up to about 0.009% B, incidental impurities, and a balance of Ni; between about 15.7% and about 16.3% Cr, about 8.0% to about 9.0% Co, between about 3.2% and about 3.7% Ti, between about 3.2% and about 3.7% Al, between about 2.4% and about 2.8% W, between about 1.5% and about 2.0% Ta, between about 1.5% and about 2.0% Mo, between about 0.6% and about 1.1% Nb, up to about 0.5% Fe, up to about 0.3% Si, up to about 0.2% Mn, between about 0.15% and about 0.20% C, between about 0.05% and about 0.15% Zr, up to about 0.015% S, between about 0.005% and about 0.015% B, incidental impurities, and a balance of Ni; between about 13.70% and about 14.30% Cr, between about 9.0% and about 10.0% Co, between about 4.7% and about 5.1% Ti, between about 3.5% and about 4.1% W, between about 2.8% and about 3.2% Al, between about 2.4% and about 3.1% Ta, between about 1.4% and about 1.7% Mo, about 0.35% Fe, about 0.3% Si, about 0.15% Nb, between about 0.08% and about 0.12% C, about 0.1% Mn, about 0.1% Cu, about 0.04% Zr, between about 0.005% and about 0.020% B, about 0.015% P, about 0.005% S, incidental impurities, and a balance of Ni; about 12% Co, about 6.8% Cr, about 6.4% Ta, about 6.1% Al, about 4.9% W, about 2.8% rhenium (Re), about 1.5% Mo, about 1.5% Hf, about 0.12% C, about 0.02% Zr, about 0.015% B, incidental impurities, and a balance of Ni; about 13% Cr, about 7.5% Co, about 6.6% Al, about 5% Ta, about 3.8% W, about 1.6% Re, about 0.15% Hf, incidental impurities, and a balance of Ni; and about 22.5% Cr, about 19% Co, about 2% W, about 1.35% Nb, about 2.3% Ti, about 1.7% Al, about 0.1% C, incidental impurities, and a balance of Ni.

### Claim 13 (depends on 1)

The component of claim 1, wherein the printed article is formed of a superalloy including a composition, by weight, selected from the group consisting of about 29% Cr, about 10% Ni, about 7% W, about 1% Fe, about 0.7% Mn, about 0.75% Si, about 0.25% C, about 0.01% B, incidental impurities, and a balance of Co; between about 21% and about 23% Cr, between about 20% and about 24% Ni, between about 13% and about 15% W, up to about 3% Fe, up to about 1.25% Mn, between about 0.2% and about 0.5% Si, between about 0.05% and about 0.15% C, between about 0.03% and about 0.12% lanthanum (La), up to about 0.02% P, up to about 0.015% B, up to about 0.015% S, incidental impurities, and a balance of Co; between about 19% and about 21% Cr, between about 14% and about 16% W, between about 9% and about 11% Ni, up to about 3% Fe, between about 1% and about 2% Mn, between about 0.05% and about 0.15% C, up to about 0.4% Si, up to about 0.04% P, up to about 0.03% S, incidental impurities, and a balance of Co; and between about 22.5% and about 24.25% Cr, between about 9% and about 11% Ni, between about 6.5% and about 7.5% W, between about 3% and about 4% Ta, up to about 0.3% Ti, up to about 0.65% C, up to about 0.55% Zr, incidental impurities, and a balance of Co.

### Claim 14 (depends on 1)

The component of claim 1, wherein the printed article is formed of a superalloy including a composition, by weight, selected from the group consisting of about 42.5% Ni, about 12.5% Cr, about 5.75% Mo, about 2.9% Ti, up to about 1% Co, up to about 0.5% Cu, up to about 0.5% Mn, up to about 0.4% Si, up to about 0.35% Al, up to about 0.1% C, up to about 0.03% S, incidental impurities, and a balance of Fe; and between about 15% and about 17.5% Cr, between about 3% and about 5% Ni, between about 3% and about 5% Cu, up to about 1% Mn, up to about 1% Si, between about 0.15% and about 0.45% Nb plus Ta, up to about 0.07% C, up to about 0.04% P, up to about 0.03% S, incidental impurities, and a balance of Fe.

### Claim 15

A densified component comprising:
a printed article having an external surface and at least one microfeature with an internal surface, adjacent to the internal surface, the internal surface of the at least one microfeature including a non-line-of-sight surface relative to the external surface, the at least one microfeature being an additively manufactured feature with a predetermined structure and the printed article being formed of an article material selected from the group consisting of a nickel-based superalloy, a cobalt-based superalloy, and an iron-based superalloy, and being formed by additive manufacture with a porosity such that the printed article is not at full density, the porosity including surface-connected porosity at the external surface and at the internal surface; and
a metallic microlayer coating the external surface of the printed article and the internal surface of the at least one microfeature, including coating the non-line-of-sight surface of the at least one microfeature, to seal the surface-connected porosity of the printed article by overlaying the surface-connected porosity along the external surface and the internal surface,
wherein the metallic microlayer coating has a coating composition other than pure nickel and is selected from the group consisting of nickel-based, cobalt-based, and iron-based materials.

### Claim 16 (depends on 15)

The component of claim 15, wherein the component is a gas turbine component.

### Claim 17 (depends on 15)

The component of claim 15, wherein the microfeature is a microchannel.

### Claim 18 (depends on 15)

The component of claim 15, wherein the metallic microlayer has a thickness in the range of about 5 μm to about 100 μm.

### Claim 19 (depends on 1)

The component of claim 1, wherein the metallic microlayer is a braze material having a melting point temperature greater than a temperature of densification of the printed article and a portion of the braze material fills the surface-connected porosity of the non-line-of-sight surface of the inner surface.