Additive manufacturing processes and additively manufactured products
AssigneeThe Research Foundation for The State University of New York
InventorsScott N. Schiffres, Arad Azizi
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Abstract
A technique to additively print onto a dissimilar material, especially ceramics and glasses (e.g., semiconductors, graphite, diamond, other metals) is disclosed herein. The technique enables manufacture of heat removal devices and other deposited structures, especially on heat sensitive substrates. It also enables novel composites through additive manufacturing. The process enables rapid bonding, orders-of-magnitude faster than conventional techniques.
Claims21
A device, comprising:
- a fused layer, formed by a process comprising:
- depositing a powder on a supporting surface of a substrate, comprising particles;
- and
- locally heating a portion of the powder on the supporting surface with a focused energy beam, substantially without achieving thermal equilibrium in the substrate, to fuse the locally heated portion of the powder to form an adhesion interlayer.
A manufactured structure, comprising:
- a substrate;
- an interface layer, comprising a chemical reaction product of a surface of the substrate and a metallic composition;
- and
- a solid layer, formed over the interface layer from fused portions of the powder, in a regional pattern having at least one void region over the substrate.
An adhesive interlayer between a substrate and a fused metal alloy powder, comprising a chemical reaction product comprising at least one of a metal silicide, a metal carbide, a metal boride, and a metal nitride with a respective substrate, the chemical reaction product forming a shear resistant layer which causes the fused metal alloy powder to adhere to the substrate.
Dependencies are inferred from the claim text.