Method of manufacturing metal articles
AssigneeHamilton Sundstrand Corporation
InventorsEric Karlen, William Louis Wentland
Life of this patent
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Abstract
A method for making an article is disclosed. According to the method, a digital model of the article is generated. The digital model is inputted into an additive manufacturing apparatus comprising an energy source. The additive manufacturing apparatus applies energy from the energy source to successively applied incremental quantities of a powder to fuse the powder to form the article corresponding to the digital model. The powder particles individually include a composite core including a first phase of a first metal and a second phase of a ceramic. A first shell including a second metal is disposed over the core.
Claims17
A method for making a metal-ceramic composite powder, comprising:
- fabricating a porous pre-form comprising a ceramic;
- infiltrating the porous ceramic pre-form with a liquid comprising a first metal;
- solidifying the liquid to form a solid composite structure comprising ceramic and metal;
- mechanically breaking down the solid composite structure to form composite powder particles comprising the first metal and the ceramic;
- and
- forming a first shell comprising a second metal on the powder particles,
- wherein the second metal comprises aluminum.
A method for making a metal-ceramic composite powder, comprising:
- fabricating a porous pre-form comprising a ceramic;
- infiltrating the porous ceramic pre-form with a liquid comprising a first metal;
- solidifying the liquid to form a solid composite structure comprising ceramic and metal;
- mechanically breaking down the solid composite structure to form composite powder particles comprising the first metal and the ceramic, and
- forming a first shell comprising a second metal on the powder particles,
- wherein the first shell comprises between 0.5 to 13 wt. % silicon.
A method for making a metal-ceramic composite powder, comprising:
- fabricating a porous pre-form comprising a ceramic;
- infiltrating the porous ceramic pre-form with a liquid comprising a first metal;
- solidifying the liquid to form a solid composite structure comprising ceramic and metal;
- mechanically breaking down the solid composite structure to form composite powder particles comprising the first metal and the ceramic, and
- forming a first shell comprising a second metal on the powder particles,
- forming a second shell over the first shell, the second shell having a reflectivity less than that of the first shell.
A method for making a metal-ceramic composite powder, comprising:
- fabricating a porous pre-form comprising a ceramic;
- infiltrating the porous ceramic pre-form with a liquid comprising a first metal;
- solidifying the liquid to form a solid composite structure comprising ceramic and metal;
- mechanically breaking down the solid composite structure to form composite powder particles comprising the first metal and the ceramic;
- forming a first shell comprising a second metal on the powder particles;
- and
- forming a second shell comprising 50-100 wt. % silicon over the first shell.
Dependencies are inferred from the claim text.