# US 2020/0399744 A1 · Additively manufactured oxide dispersion strengthened medium entropy alloys for high temperature applications

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 2020/0399744 A1
- Document ID: US20200399744A1
- Status: Published application
- Kind: A1
- Application number: 16/906,319
- Filed: 2020-06-19
- Published: 2020-12-24
- Earliest claimed: 2019-06-21
- Assignees: United States of America as represented by the Administrator of NASA
- Applicants: United States of America as represented by the Administrator of NASA
- Inventors: Timothy M. Smith; Robert W. Carter; Christopher A. Kantzos; Michael J. Kulis
- Web page: https://patentgrep.com/patent/US20200399744A1

## CPC

- C22C 30/00: Alloys containing less than 50% by weight of each constituent
- B22F 1/05: Metallic powder characterised by the size or surface area of the particles
- B22F 1/07: Metallic powder characterised by particles having a nanoscale microstructure (nanosized particles B22F1/054)
- B22F 1/16: Metallic particles coated with a non-metal (coated with lubricating or binding agents or with organic material B22F1/10)
- B33Y 70/10: Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 2302/25: Oxide
- B22F 2304/10: Micron size particles, i.e. above 1 micrometer up to 500 micrometer
- B33Y 10/00: Processes of additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- Y02P 10/25: Process efficiency
- Y10T 428/12014: having metal particles
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- 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
- 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
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

An additive manufacturing powdered composite material includes metal particles coated with a coating of ceramic particles. The metal particles may include a ternary NiCoCr alloy, with select additions of minor amounts of other elements. The ceramic particles may include yttrium oxide or other oxides. The composite material is suitable for additive manufacturing (AM) into a component for high temperature (>1000° C.) applications. The AM component includes a metal matrix formed from the alloy, with the ceramic particles dispersed in the matrix.

## Claims

### Claim 1

An additive manufacturing powdered composite material comprising metal particles coated with a coating of ceramic particles, wherein:
the metal particles comprise an alloy including:
30-35 wt % cobalt,
26-31 wt % chromium,
0-3.0 wt % rhenium,
0-1.0 wt % aluminum,
0.01-0.1 wt % carbon,
0-1.0 wt % titanium, and
nickel making up a balance of a weight of the alloy,
the ceramic particles comprise yttrium oxide, hafnium oxide, zirconium oxide, aluminum oxide, thorium oxide, or combinations thereof.

### Claim 2 (depends on 1)

The composite material according to claim 1, wherein the alloy comprises:
30-35 wt % cobalt,
26-31 wt % chromium,
0.01-0.1 wt % carbon, and
at least one of:
a) 0.1-3.0 wt % rhenium,
b) 0.1-1.0 wt % aluminum, and
c) 0.1-1.0 wt % titanium, and
nickel making up a balance of the weight of the alloy.

### Claim 3 (depends on 1)

The composite material according to claim 1, wherein the alloy comprises:
30-35 wt % cobalt,
26-31 wt % chromium,
0.01-0.1 wt % carbon,
0.25-1.5 wt % niobium,
1.5-4.5 wt % tungsten, and
at least one of:
a) 0.1-3.0 wt % rhenium,
b) 0.1-1.0 wt % aluminum, and
c) 0.1-1.0 wt % titanium, and
nickel making up a balance of the weight of the alloy.

### Claim 4 (depends on 3)

The composite material according to claim 3, wherein the alloy is a solid solution and has a freezing range of less than or equal to 80° C.

### Claim 5 (depends on 1)

The composite material according to claim 1, wherein the metal particles are included at 95.0-99.5 wt % of the composition.

### Claim 6 (depends on 5)

The composite material according to claim 5, wherein the ceramic particles are included at 0.9-1.1 wt % of the composition and consist of yttrium oxide.

### Claim 7 (depends on 1)

The composite material according to claim 1, wherein the metal particles are micron sized.

### Claim 8 (depends on 7)

The composite material according to claim 7, wherein the metal particles have a rounded shape and an average particle size of 10-45 μm.

### Claim 9 (depends on 7)

The composite material according to claim 7, wherein the ceramic particles are nano-sized.

### Claim 10 (depends on 9)

The composite material according to claim 9, wherein the ceramic particles have an average particle size of 100-200 nm.

### Claim 11 (depends on 10)

The composite material according to claim 10, wherein the coating completely covers the metal particles and has an average coating thickness of 100-500 nm.

### Claim 12

An additively manufactured component comprising ceramic particles dispersed in a metal matrix, wherein:
the metal matrix comprises an alloy including:
30-35 wt % cobalt,
26-31 wt % chromium,
0-3.0 wt % rhenium,
0-1.0 wt % aluminum,
0.01-0.1 wt % carbon,
0-1.0 wt % titanium, and
nickel making up a balance of a weight of the alloy,
the ceramic particles comprise yttrium oxide, hafnium oxide, zirconium oxide, aluminum oxide, thorium oxide, or combinations thereof.

### Claim 13 (depends on 12)

The component according to claim 12, wherein the alloy comprises:
30-35 wt % cobalt,
26-31 wt % chromium,
0.01-0.1 wt % carbon, and
at least one of:
a) 0.1-3.0 wt % rhenium,
b) 0.1-1.0 wt % aluminum, and
c) 0.1-1.0 wt % titanium, and
nickel making up a balance of the weight of the alloy.

### Claim 14 (depends on 12)

The component according to claim 12, wherein the alloy comprises:
30-35 wt % cobalt,
26-31 wt % chromium,
0.01-0.1 wt % carbon,
0.25-1.5 wt % niobium,
1.5-4.5 wt % tungsten, and
at least one of:
a) 0.1-3.0 wt % rhenium,
b) 0.1-1.0 wt % aluminum, and
c) 0.1-1.0 wt % titanium, and
nickel making up a balance of the weight of the alloy.

### Claim 15 (depends on 12)

The component according to claim 12, wherein the alloy is a solid solution.

### Claim 16 (depends on 12)

The component according to claim 12, wherein the metal matrix is included at 95.0-99.5 wt % of the component.

### Claim 17 (depends on 16)

The component according to claim 16, wherein the ceramic particles consist of yttrium oxide.

### Claim 18 (depends on 12)

The component according to claim 12, wherein the ceramic particles are included at 0.9-1.1 wt % of the component.

### Claim 19 (depends on 18)

The component according to claim 18, wherein the ceramic particles are micron size.

### Claim 20 (depends on 19)

The component according to claim 19, wherein the ceramic particles have an average particle size of 100-200 nm.