US20220305726A1 - System and method of additively manufacturing an object - Google Patents

System and method of additively manufacturing an object Download PDF

Info

Publication number
US20220305726A1
US20220305726A1 US17/839,656 US202217839656A US2022305726A1 US 20220305726 A1 US20220305726 A1 US 20220305726A1 US 202217839656 A US202217839656 A US 202217839656A US 2022305726 A1 US2022305726 A1 US 2022305726A1
Authority
US
United States
Prior art keywords
build material
powder bed
accordance
bonding agent
heat source
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
US17/839,656
Inventor
Scott Michael Oppenheimer
Richard DiDomizio
Jason Harris Karp
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
General Electric Co
Original Assignee
General Electric Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by General Electric Co filed Critical General Electric Co
Priority to US17/839,656 priority Critical patent/US20220305726A1/en
Assigned to GENERAL ELECTRIC COMPANY reassignment GENERAL ELECTRIC COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: OPPENHEIMER, SCOTT MICHAEL, DIDOMIZIO, RICHARD, KARP, JASON HARRIS
Publication of US20220305726A1 publication Critical patent/US20220305726A1/en
Pending legal-status Critical Current

Links

Images

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/10Processes of additive manufacturing
    • B29C64/141Processes of additive manufacturing using only solid materials
    • B29C64/153Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/10Formation of a green body
    • B22F10/16Formation of a green body by embedding the binder within the powder bed
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40Radiation means
    • B22F12/41Radiation means characterised by the type, e.g. laser or electron beam
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/20Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/245Platforms or substrates
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/20Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/255Enclosures for the building material, e.g. powder containers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/20Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264Arrangements for irradiation
    • B29C64/268Arrangements for irradiation using laser beams; using electron beams [EB]
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/20Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264Arrangements for irradiation
    • B29C64/277Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
    • B29C64/282Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED] of the same type, e.g. using different energy levels
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/20Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/295Heating elements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/30Auxiliary operations or equipment
    • B29C64/386Data acquisition or data processing for additive manufacturing
    • B29C64/393Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00Processes of additive manufacturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00Apparatus for additive manufacturing; Details thereof or accessories therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00Data acquisition or data processing for additive manufacturing
    • B33Y50/02Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/10Processes of additive manufacturing
    • B29C64/165Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00Products made by additive manufacturing
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/25Process efficiency

Definitions

  • the field of the disclosure relates generally to additive manufacturing and objects formed therefrom and, more specifically, to additively manufacturing an object from a mixture of a build material and a thermally activated bonding agent.
  • Additive manufacturing is a technology that enables “3D-printing” of objects from various materials, such as metallic powder.
  • additive manufacturing processes such as direct metal laser melting (DMLM)
  • DMLM direct metal laser melting
  • an object is built layer-by-layer by leveling a powder bed and selectively melting predetermined portions of the powder bed using a high-powered laser. After each layer is fused, additional powder is leveled and the laser fuses the next layer, thereby fusing it to the prior layers to fabricate a complete object buried in the powder bed.
  • DMLM may be a time-consuming process capable of producing a limited number of objects within a certain time frame.
  • an object is built layer-by-layer by leveling a powder bed and selectively applying adhesive to predetermined portions of the powder bed. After each layer is adhered, additional powder is leveled and additional adhesive is applied to the powder bed to form a green compact. Upon removal of the green compact from the powder bed, multiple heating steps are then performed to remove the adhesive and to solidify the green compact.
  • the green compact prior to solidification, the green compact has limited strength and durability, which exposes the green compact to the risk of damage. As such, the green compact must be handled carefully during and after removal from the powder bed, which can be a laborious and complex task.
  • a system for use in additively manufacturing an object includes a powder bed configured for containment within a build chamber, wherein the powder bed is formed from a mixture of a build material and a bonding agent.
  • the system also includes a heat source configured to selectively heat the powder bed to a temperature such that the build material is at least partially sintered together by the bonding agent.
  • the heat source also selectively heats the powder bed to the temperature that maintains the build material in a solid state.
  • a method of additively manufacturing an object includes providing a powder bed formed from a mixture of a build material and a bonding agent, and selectively heating the powder bed to a temperature such that the build material is at least partially sintered together to form a compact object, wherein the temperature is selected to maintain the build material in a solid state.
  • the method also includes heating the compact object in an oven to sinter the build material and form a densified object.
  • an object additively manufactured by a process including the following steps.
  • the steps include providing a powder bed formed from a mixture of a build material and a bonding agent, and selectively heating the powder bed to a temperature such that the build material is at least partially sintered together to form a compact object, wherein the temperature is selected to maintain the build material in a solid state.
  • the steps also include heating the compact object in an oven to sinter the build material and form a densified object.
  • FIG. 1 is a block diagram of an exemplary additive manufacturing system
  • FIG. 2 is a flow diagram illustrating an exemplary method of additively manufacturing an object.
  • Approximating language may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about”, “approximately”, and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value.
  • range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.
  • Embodiments of the present disclosure relate to additively manufacturing a compact object from a mixture of a build material and a thermally activated bonding agent.
  • the mixture is used to form a powder bed within a build chamber, and the bonding agent is responsive to heat to cause the build material to be pre-sintered or pre-joined to form a compact object.
  • the compact object is formed by heating predetermined portions of the powder bed to a temperature that facilitates joining the particles of the build material to each other metallurgically while maintaining the build material in a solid state.
  • the metallurgical bond that joins the particles of the build material to each other facilitates forming the compact object having a greater build strength and durability relative to green compacts formed by other known methods.
  • a reduced amount of energy may be used to heat the powder bed to pre-sinter the build material.
  • a plurality of low power laser beams may be emitted from a multiplexed array to facilitate increasing the build speed for the compact object.
  • the manufacturing process described herein enables the use of vigorous depowdering techniques, and reduces the need for certain post-processing steps, as a result of the compact object's high strength and chemically inert bonding.
  • compact object refers to an object made of build material powder that has been metallurgically bonded but that has not yet been fully sintered or densified.
  • FIG. 1 is a block diagram of an exemplary additive manufacturing system 100 .
  • additive manufacturing system 100 includes a build chamber 102 having a moveable build platform 104 .
  • a compact object 106 is fabricated within build chamber 102 on top of moveable build platform 104 , as will be explained in further detail.
  • Additive manufacturing system 100 also includes a heat source 108 and a controller 110 .
  • a powder bed 112 is contained within build chamber 102 , and activation energy 114 generated by heat source 108 selectively heats powder bed 112 to facilitate manufacturing compact object 106 .
  • Compact object 106 is then provided to a depowdering system 115 to remove powder bed material from the surfaces of compact object 106 .
  • compact object 106 is then heated in an oven 116 to form a further solidified, densified, and/or sintered object 118
  • Heat source 108 may include a laser emitter configured to emit a laser beam (i.e., activation energy 114 ) towards powder bed 112 , a spray device configured to apply an activator or catalyst to powder bed 112 , an electrical heater, a light source, or a source of radiation.
  • the laser emitter may include a multiplexed array (e.g., a linear or area array of low power (i.e., less than 1 Watt), solid state, on chip lasers) capable of emitting a plurality of laser beams towards powder bed 112 .
  • heat source 108 may include a projection raster heating device, an electron beam projector, and a spark heating device. As such, the build rate of compact object 106 may be increased.
  • Additive manufacturing system 100 also includes a gas source 120 in flow communication with build chamber 102 .
  • Gas source 120 facilitates forming an inert atmosphere within build chamber 102 for use during the additive manufacturing process.
  • the inert atmosphere may be formed from a gas such as, but not limited to, helium, argon, hydrogen, oxygen, nitrogen, air, nitrous oxide, ammonia, carbon dioxide, and combinations thereof.
  • Data file 122 may be in any form that enables additive manufacturing system 100 to function as described herein.
  • data file 122 may be a computer aided design (CAD) file or scan data.
  • CAD computer aided design
  • scan data is converted into a different file format, such as a stereolithographic or standard triangle language (“STL”) file format.
  • STL stereolithographic or standard triangle language
  • the STL format file is then processed by a slicing program to produce an electronic file that converts the three-dimensional electronic representation of compact object 106 into an STL format file that includes compact object 106 represented as two-dimensional slices.
  • the layer information generated from this process is transmitted to controller 110 , and controller 110 controls the operation of moveable build platform 104 and heat source 108 , for example, to facilitate manufacturing compact object 106 .
  • a portion of moveable build platform 104 may be moved (i.e., lowered) within build chamber 102 . Thereafter, additional powder bed material may be deposited within build chamber 102 and then heated using activation energy 114 . Each time a subsequent layer of powder bed material is deposited within build chamber 102 , a recoater arm (not shown) may be used to smooth the layer such that the layer forms a substantially planar surface within build chamber 102 . The layer is then heated in each successive build cycle.
  • Powder bed 112 is formed from any material that enables additive manufacturing system 100 to function as described herein.
  • powder bed 112 is formed from a mixture including a substantially uniform distribution of a build material and a bonding agent in powder or particulate form.
  • the build material forms the primary structure of compact object 106
  • the bonding agent is a sintering aid that enables particles of build material to be bonded to each other via one or more mechanisms, as will be described in more detail below.
  • the mixture may include any ratio of build material to bonding agent that enables additive manufacturing system 100 to function as described herein.
  • the mixture may include less than about 50 percent, less than about 40 percent, less than about 30 percent, between about 10 percent and about 50 percent, or between about 20 percent and about 40 percent of the bonding agent by volume of the mixture.
  • both the build material and the bonding agent are a metallic material.
  • Example build material includes, but is not limited to, a nickel-based material or a cobalt-based material.
  • the melting point of the build material is equal to or greater than about 1000° C. Alternatively, the melting point of the build material may be less than 1000° C. in other embodiments.
  • the bonding agent may be any material that enables additive manufacturing system 100 to function as described herein.
  • the bonding agent is a sintering aid that enables particles of build material to be bonded to each other via one or more mechanisms.
  • the mechanisms include, but are not limited to, phase change, decomposition, diffusion, and reaction.
  • Phase change occurs when the bonding agent has a lower melting point than the build material.
  • the melting point of the bonding agent may be less than about 1000° C., or less than about 500° C. As such, the bonding agent is meltable at a lower temperature than the build material to facilitate the formation of metallurgical bonds between particles of the build material to form compact object 106 .
  • build material can diffuse rapidly in molten bonding agent to facilitate creating the metallurgical bonds, and non-melting phase change enables higher diffusion and bonding. Formation of the metallurgical bonds facilitates enhancing the strength and durability of compact object 106 .
  • the bonding agent has a melting point that is approximately equal to, or greater than, the melting point of the build material.
  • heat source 108 and/or individual emitters included in heat source 108 , emits activation energy 114 therefrom having a maximum output that facilitates partially sintering the build material together by the bonding agent.
  • the maximum output may provide an amount of activation energy 114 to powder bed 112 that is a predetermined percentage of a volumetric heating value required to melt the build material.
  • the predetermined percentage is less 100 percent, and may be defined within a range between about 60 percent and about 99 percent, within a range between about 70 percent and about 90 percent, defined within a range between about 70 percent and about 80 percent, or may be a percentage value within any of the aforementioned ranges.
  • the maximum output may also provide activation energy 114 for heating the powder bed to a temperature that is greater than a melting point of the bonding agent, but that is also a predetermined percentage of a value of a melting point of the build material.
  • the predetermined percentage is less 100 percent, and may be defined within a range between about 60 percent and about 99 percent, within a range between about 70 percent and about 90 percent, defined within a range between about 70 percent and about 80 percent, or may be a percentage value within any of the aforementioned ranges.
  • a plurality of laser beams may be emitted from a multiplexed array, having a power level within the noted ranges, to facilitate increasing the build speed for the compact object using a heat source that is less costly and that requires less power to operate when compared to energy sources that melt metallic build material, such as those used in direct metal laser melting devices.
  • the bonding agent is a sintering aid that enables particles of the build material to be bonded to each other via one or more mechanisms, such as decomposition.
  • Decomposition occurs when particles having high surface energy are created to enable rapid bonding to the build material.
  • the bonding agent is formed from a compound that includes a bonding component and an antioxidation component.
  • the bonding component bonds the particles of the build material together, and the antioxidation component removes surface oxides from the build material.
  • the presence of oxides on the particles of the build material makes it difficult to bond the particles to each other. Removing the oxides from the particles facilitates increasing the surface energy of the particles, which enhances the natural inclination of the particles to bond to each other.
  • compact object 106 is manufactured with an enhanced strength and durability.
  • Example bonding agents include, but are not limited to, titanium hydride, iron chloride, a low melt alloy material such as standard braze powders, and combinations thereof.
  • titanium hydride When heated, titanium hydride thermally decomposes into its titanium and hydrogen components.
  • the titanium component facilitates providing the metallurgical bond between the particles of powder bed 112
  • the hydrogen component facilitates cleaning the particles of the build material of oxides.
  • iron chloride may be included in the mixture as a standalone additive, or as a coating applied to the particles of the build material.
  • iron chloride thermally decomposes to its iron and chlorine components. The iron component facilitates providing the metallurgical bond between the particles of powder bed 112 .
  • diffusion is initiated via the addition of boron or silicon, for example, to powder bed 112 as a melting point depressant. Additionally, reaction occurs when a thermal barrier is overcome and local reaction, or intermetallic formation, of the build particles occurs.
  • the bonding agent in the mixture may have any average particle size that enables additive manufacturing system 100 to function as described herein.
  • surface energy and average particle size are inversely proportional relative to each other.
  • reducing the average particle size of the bonding agent facilitates increasing the surface energy of the particles, which enhances the natural inclination of the particles to bond to each other.
  • increasing the surface energy of the particles of powder bed 112 may also facilitate the formation of metallurgical bonds therebetween.
  • powder bed 112 is heated to a temperature that partially, but not fully, melts the particles of the bonding agent.
  • the bonding agent has an average particle size of less than about 10 microns.
  • FIG. 2 is a flow diagram illustrating an exemplary method 200 of additively manufacturing object 118 (shown in FIG. 1 ).
  • Method 200 includes providing 202 a powder bed formed from a mixture of a build material and a bonding agent.
  • Method 200 also includes selectively heating 204 the powder bed to a temperature such that the build material is at least partially sintered together to form a compact object.
  • the bonding agent is responsive to heat, but does not need to be melted to pre-sinter or pre-join the build material, which enables a reduced amount of energy to be used to heat the powder bed.
  • the compact object is depowderized, and method 200 further includes heating 206 the compact object in an oven to melt the build material and form the object.
  • An exemplary technical effect of the systems and methods described herein includes at least one of: (a) high speed manufacturing of green compacts having enhanced durability and strength; (b) eliminating the need for adhesive burnout post-processing steps; (c) high speed manufacturing of green compacts using a reduced power output; and (d) forming chemically inert and metallurgical bonds in the green compact to provide the enhanced durability and strength.
  • Exemplary embodiments of systems and methods for use in additively manufacturing an object are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein.
  • the methods and systems may also be used in combination with other additive manufacturing systems, and are not limited to practice with only the systems and methods as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other applications, equipment, and systems that may benefit from the technical effects recited herein.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Optics & Photonics (AREA)
  • Physics & Mathematics (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Toxicology (AREA)
  • Health & Medical Sciences (AREA)
  • Plasma & Fusion (AREA)
  • General Health & Medical Sciences (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Powder Metallurgy (AREA)

Abstract

A system for use in additively manufacturing an object. The system includes a powder bed configured for containment within a build chamber, wherein the powder bed is formed from a mixture of a build material and a bonding agent. The system also includes a heat source configured to selectively heat the powder bed to a temperature such that the build material is at least partially sintered together by the bonding agent. The heat source also selectively heats the powder bed to the temperature that maintains the build material in a solid state.

Description

    BACKGROUND
  • The field of the disclosure relates generally to additive manufacturing and objects formed therefrom and, more specifically, to additively manufacturing an object from a mixture of a build material and a thermally activated bonding agent.
  • Additive manufacturing is a technology that enables “3D-printing” of objects from various materials, such as metallic powder. In some known additive manufacturing processes, such as direct metal laser melting (DMLM), an object is built layer-by-layer by leveling a powder bed and selectively melting predetermined portions of the powder bed using a high-powered laser. After each layer is fused, additional powder is leveled and the laser fuses the next layer, thereby fusing it to the prior layers to fabricate a complete object buried in the powder bed. However, DMLM may be a time-consuming process capable of producing a limited number of objects within a certain time frame. In other known additive manufacturing processes, such as binder jetting, an object is built layer-by-layer by leveling a powder bed and selectively applying adhesive to predetermined portions of the powder bed. After each layer is adhered, additional powder is leveled and additional adhesive is applied to the powder bed to form a green compact. Upon removal of the green compact from the powder bed, multiple heating steps are then performed to remove the adhesive and to solidify the green compact. However, prior to solidification, the green compact has limited strength and durability, which exposes the green compact to the risk of damage. As such, the green compact must be handled carefully during and after removal from the powder bed, which can be a laborious and complex task.
  • BRIEF DESCRIPTION
  • In one aspect, a system for use in additively manufacturing an object is provided. The system includes a powder bed configured for containment within a build chamber, wherein the powder bed is formed from a mixture of a build material and a bonding agent. The system also includes a heat source configured to selectively heat the powder bed to a temperature such that the build material is at least partially sintered together by the bonding agent. The heat source also selectively heats the powder bed to the temperature that maintains the build material in a solid state.
  • In another aspect, a method of additively manufacturing an object is provided. The method includes providing a powder bed formed from a mixture of a build material and a bonding agent, and selectively heating the powder bed to a temperature such that the build material is at least partially sintered together to form a compact object, wherein the temperature is selected to maintain the build material in a solid state. The method also includes heating the compact object in an oven to sinter the build material and form a densified object.
  • In yet another aspect, an object additively manufactured by a process including the following steps is provided. The steps include providing a powder bed formed from a mixture of a build material and a bonding agent, and selectively heating the powder bed to a temperature such that the build material is at least partially sintered together to form a compact object, wherein the temperature is selected to maintain the build material in a solid state. The steps also include heating the compact object in an oven to sinter the build material and form a densified object.
  • DRAWINGS
  • These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
  • FIG. 1 is a block diagram of an exemplary additive manufacturing system; and
  • FIG. 2 is a flow diagram illustrating an exemplary method of additively manufacturing an object.
  • Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of this disclosure. These features are believed to be applicable in a wide variety of systems comprising one or more embodiments of this disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein.
  • DETAILED DESCRIPTION
  • In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings.
  • The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
  • “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.
  • Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about”, “approximately”, and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.
  • Embodiments of the present disclosure relate to additively manufacturing a compact object from a mixture of a build material and a thermally activated bonding agent. The mixture is used to form a powder bed within a build chamber, and the bonding agent is responsive to heat to cause the build material to be pre-sintered or pre-joined to form a compact object. Thus, the compact object is formed by heating predetermined portions of the powder bed to a temperature that facilitates joining the particles of the build material to each other metallurgically while maintaining the build material in a solid state. The metallurgical bond that joins the particles of the build material to each other facilitates forming the compact object having a greater build strength and durability relative to green compacts formed by other known methods. In addition, in embodiments where the bonding agent has a lower melting point than the build material, a reduced amount of energy may be used to heat the powder bed to pre-sinter the build material. As such, a plurality of low power laser beams may be emitted from a multiplexed array to facilitate increasing the build speed for the compact object. In addition, the manufacturing process described herein enables the use of vigorous depowdering techniques, and reduces the need for certain post-processing steps, as a result of the compact object's high strength and chemically inert bonding.
  • As used herein, the term “compact object” refers to an object made of build material powder that has been metallurgically bonded but that has not yet been fully sintered or densified.
  • FIG. 1 is a block diagram of an exemplary additive manufacturing system 100. In the exemplary embodiment, additive manufacturing system 100 includes a build chamber 102 having a moveable build platform 104. A compact object 106 is fabricated within build chamber 102 on top of moveable build platform 104, as will be explained in further detail. Additive manufacturing system 100 also includes a heat source 108 and a controller 110. A powder bed 112 is contained within build chamber 102, and activation energy 114 generated by heat source 108 selectively heats powder bed 112 to facilitate manufacturing compact object 106. Compact object 106 is then provided to a depowdering system 115 to remove powder bed material from the surfaces of compact object 106. In some embodiments, compact object 106 is then heated in an oven 116 to form a further solidified, densified, and/or sintered object 118
  • Heat source 108 may include a laser emitter configured to emit a laser beam (i.e., activation energy 114) towards powder bed 112, a spray device configured to apply an activator or catalyst to powder bed 112, an electrical heater, a light source, or a source of radiation. In one embodiment, the laser emitter may include a multiplexed array (e.g., a linear or area array of low power (i.e., less than 1 Watt), solid state, on chip lasers) capable of emitting a plurality of laser beams towards powder bed 112. Alternatively, heat source 108 may include a projection raster heating device, an electron beam projector, and a spark heating device. As such, the build rate of compact object 106 may be increased.
  • Additive manufacturing system 100 also includes a gas source 120 in flow communication with build chamber 102. Gas source 120 facilitates forming an inert atmosphere within build chamber 102 for use during the additive manufacturing process. For example, the inert atmosphere may be formed from a gas such as, but not limited to, helium, argon, hydrogen, oxygen, nitrogen, air, nitrous oxide, ammonia, carbon dioxide, and combinations thereof.
  • The form and the material buildup of compact object 106 are determined as a function of design data embodied in a data file 122. Data file 122 may be in any form that enables additive manufacturing system 100 to function as described herein. For example, data file 122 may be a computer aided design (CAD) file or scan data. In some embodiments, the CAD file or scan data is converted into a different file format, such as a stereolithographic or standard triangle language (“STL”) file format. The STL format file is then processed by a slicing program to produce an electronic file that converts the three-dimensional electronic representation of compact object 106 into an STL format file that includes compact object 106 represented as two-dimensional slices. The layer information generated from this process is transmitted to controller 110, and controller 110 controls the operation of moveable build platform 104 and heat source 108, for example, to facilitate manufacturing compact object 106.
  • For example, after a layer of powder bed 112 has been processed as a result of being heated by activation energy 114, at least a portion of moveable build platform 104 may be moved (i.e., lowered) within build chamber 102. Thereafter, additional powder bed material may be deposited within build chamber 102 and then heated using activation energy 114. Each time a subsequent layer of powder bed material is deposited within build chamber 102, a recoater arm (not shown) may be used to smooth the layer such that the layer forms a substantially planar surface within build chamber 102. The layer is then heated in each successive build cycle.
  • Powder bed 112 is formed from any material that enables additive manufacturing system 100 to function as described herein. For example, powder bed 112 is formed from a mixture including a substantially uniform distribution of a build material and a bonding agent in powder or particulate form. The build material forms the primary structure of compact object 106, and the bonding agent is a sintering aid that enables particles of build material to be bonded to each other via one or more mechanisms, as will be described in more detail below. Thus, the mixture may include any ratio of build material to bonding agent that enables additive manufacturing system 100 to function as described herein. For example, the mixture may include less than about 50 percent, less than about 40 percent, less than about 30 percent, between about 10 percent and about 50 percent, or between about 20 percent and about 40 percent of the bonding agent by volume of the mixture.
  • In the exemplary embodiment, both the build material and the bonding agent are a metallic material. Example build material includes, but is not limited to, a nickel-based material or a cobalt-based material. In some embodiments, the melting point of the build material is equal to or greater than about 1000° C. Alternatively, the melting point of the build material may be less than 1000° C. in other embodiments.
  • The bonding agent may be any material that enables additive manufacturing system 100 to function as described herein. For example, as described above, the bonding agent is a sintering aid that enables particles of build material to be bonded to each other via one or more mechanisms. The mechanisms include, but are not limited to, phase change, decomposition, diffusion, and reaction. Phase change occurs when the bonding agent has a lower melting point than the build material. The melting point of the bonding agent may be less than about 1000° C., or less than about 500° C. As such, the bonding agent is meltable at a lower temperature than the build material to facilitate the formation of metallurgical bonds between particles of the build material to form compact object 106. For example, build material can diffuse rapidly in molten bonding agent to facilitate creating the metallurgical bonds, and non-melting phase change enables higher diffusion and bonding. Formation of the metallurgical bonds facilitates enhancing the strength and durability of compact object 106. In an alternative embodiment, the bonding agent has a melting point that is approximately equal to, or greater than, the melting point of the build material.
  • Accordingly, in some embodiments, heat source 108, and/or individual emitters included in heat source 108, emits activation energy 114 therefrom having a maximum output that facilitates partially sintering the build material together by the bonding agent. For example, the maximum output may provide an amount of activation energy 114 to powder bed 112 that is a predetermined percentage of a volumetric heating value required to melt the build material. The predetermined percentage is less 100 percent, and may be defined within a range between about 60 percent and about 99 percent, within a range between about 70 percent and about 90 percent, defined within a range between about 70 percent and about 80 percent, or may be a percentage value within any of the aforementioned ranges.
  • The maximum output may also provide activation energy 114 for heating the powder bed to a temperature that is greater than a melting point of the bonding agent, but that is also a predetermined percentage of a value of a melting point of the build material. The predetermined percentage is less 100 percent, and may be defined within a range between about 60 percent and about 99 percent, within a range between about 70 percent and about 90 percent, defined within a range between about 70 percent and about 80 percent, or may be a percentage value within any of the aforementioned ranges. As such, in one embodiment, a plurality of laser beams may be emitted from a multiplexed array, having a power level within the noted ranges, to facilitate increasing the build speed for the compact object using a heat source that is less costly and that requires less power to operate when compared to energy sources that melt metallic build material, such as those used in direct metal laser melting devices.
  • As noted above, the bonding agent is a sintering aid that enables particles of the build material to be bonded to each other via one or more mechanisms, such as decomposition. Decomposition occurs when particles having high surface energy are created to enable rapid bonding to the build material. For example, in one embodiment, the bonding agent is formed from a compound that includes a bonding component and an antioxidation component. The bonding component bonds the particles of the build material together, and the antioxidation component removes surface oxides from the build material. In general, the presence of oxides on the particles of the build material makes it difficult to bond the particles to each other. Removing the oxides from the particles facilitates increasing the surface energy of the particles, which enhances the natural inclination of the particles to bond to each other. As such, compact object 106 is manufactured with an enhanced strength and durability. Example bonding agents include, but are not limited to, titanium hydride, iron chloride, a low melt alloy material such as standard braze powders, and combinations thereof.
  • When heated, titanium hydride thermally decomposes into its titanium and hydrogen components. The titanium component facilitates providing the metallurgical bond between the particles of powder bed 112, and the hydrogen component facilitates cleaning the particles of the build material of oxides. Alternatively, iron chloride may be included in the mixture as a standalone additive, or as a coating applied to the particles of the build material. When heated, iron chloride thermally decomposes to its iron and chlorine components. The iron component facilitates providing the metallurgical bond between the particles of powder bed 112.
  • Alternatively, diffusion is initiated via the addition of boron or silicon, for example, to powder bed 112 as a melting point depressant. Additionally, reaction occurs when a thermal barrier is overcome and local reaction, or intermetallic formation, of the build particles occurs.
  • In addition, the bonding agent in the mixture may have any average particle size that enables additive manufacturing system 100 to function as described herein. In general, surface energy and average particle size are inversely proportional relative to each other. Thus, reducing the average particle size of the bonding agent facilitates increasing the surface energy of the particles, which enhances the natural inclination of the particles to bond to each other. In addition, increasing the surface energy of the particles of powder bed 112 may also facilitate the formation of metallurgical bonds therebetween. For example, in one embodiment, powder bed 112 is heated to a temperature that partially, but not fully, melts the particles of the bonding agent. It is believed, without being bound by any particular theory, that partially melting the bonding agent facilitates the creation of necks or connectors that extend from the bonding particles towards adjacent build particles. Increasing the surface energy of the particles of powder bed 112 facilitates reducing the temperature in which the bonding agent is caused to partially melt and create the necks or connectors. As such, the average particle size of the bonding agent is selected to achieve the aforementioned objectives. Thus, in the exemplary embodiment, the bonding agent has an average particle size of less than about 10 microns.
  • FIG. 2 is a flow diagram illustrating an exemplary method 200 of additively manufacturing object 118 (shown in FIG. 1). Method 200 includes providing 202 a powder bed formed from a mixture of a build material and a bonding agent. Method 200 also includes selectively heating 204 the powder bed to a temperature such that the build material is at least partially sintered together to form a compact object. As described above, the bonding agent is responsive to heat, but does not need to be melted to pre-sinter or pre-join the build material, which enables a reduced amount of energy to be used to heat the powder bed. The compact object is depowderized, and method 200 further includes heating 206 the compact object in an oven to melt the build material and form the object.
  • An exemplary technical effect of the systems and methods described herein includes at least one of: (a) high speed manufacturing of green compacts having enhanced durability and strength; (b) eliminating the need for adhesive burnout post-processing steps; (c) high speed manufacturing of green compacts using a reduced power output; and (d) forming chemically inert and metallurgical bonds in the green compact to provide the enhanced durability and strength.
  • Exemplary embodiments of systems and methods for use in additively manufacturing an object are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods and systems may also be used in combination with other additive manufacturing systems, and are not limited to practice with only the systems and methods as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other applications, equipment, and systems that may benefit from the technical effects recited herein.
  • Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.
  • This written description uses examples to disclose the embodiments, including the best mode, and also to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims (21)

1-20. (canceled)
21. A system for use in additively manufacturing an object, the system comprising:
a powder bed configured for containment within a build chamber, wherein the powder bed comprises a mixture of a build material and a bonding agent; and
a heat source configured to selectively heat the powder bed to a temperature such that the build material is at least partially sintered together by the bonding agent, wherein the heat source selectively heats the powder bed to the temperature that maintains the build material in a solid state.
22. The system in accordance with claim 21, wherein the heat source comprises at least one of a projection raster heating device, an electron beam projector, a spark heating device, or a multiplexed laser array.
23. The system in accordance with claim 21, wherein the heat source has a maximum power level configured to provide an amount of energy to the powder bed that is a predetermined percentage of a volumetric heating value required to melt the build material.
24. The system in accordance with claim 21, wherein the heat source has a maximum power level configured to heat the powder bed to the temperature that is about 70 percent of a value of a melting point of the build material.
25. The system in accordance with claim 21, wherein the heat source has a maximum power level configured to heat the powder bed to the temperature that is greater than a melting point of the bonding agent and that is lower than a melting point of the build material.
26. The system in accordance with claim 21, wherein the powder bed includes less than about 30 percent of the bonding agent by volume of the mixture.
27. The system in accordance with claim 21, wherein the bonding agent has an average particle size of less than 30 microns.
28. The system in accordance with claim 21, wherein the bonding agent has an average particle size of less than 10 microns.
29. The system in accordance with claim 21, wherein the bonding agent comprises at least one of: titanium hydride or iron chloride.
30. The system in accordance with claim 21, wherein the build material comprises at least one of: boron or silicon.
31. The system in accordance with claim 21, wherein, when heated, the bonding agent thermally decomposes into a bonding component and an antioxidation component, and wherein the antioxidation component removes surface oxides from the build material.
32. A system for use in additively manufacturing an object, the system comprising:
a build chamber including a moveable build platform and a powder bed comprising a mixture of a build material and a bonding agent; and
a heat source configured to selectively heat the powder bed to a temperature such that the build material is at least partially sintered together by the bonding agent, wherein the heat source selectively heats the powder bed to the temperature that maintains the build material in a solid state.
33. The system in accordance with claim 32, wherein the heat source comprises at least one of a projection raster heating device, an electron beam projector, a spark heating device, or a multiplexed laser array.
34. The system in accordance with claim 32, wherein the heat source has a maximum power level configured to provide an amount of energy to the powder bed that is a predetermined percentage of a volumetric heating value required to melt the build material.
35. The system in accordance with claim 32, wherein the heat source has a maximum power level configured to heat the powder bed to the temperature that is about 70 percent of a value of a melting point of the build material.
36. The system in accordance with claim 32, wherein the heat source has a maximum power level configured to heat the powder bed to the temperature that is greater than a melting point of the bonding agent and that is lower than a melting point of the build material.
37. The system in accordance with claim 32, wherein the bonding agent has an average particle size of less than 30 microns.
38. The system in accordance with claim 32, wherein the bonding agent comprises at least one of: titanium hydride or iron chloride.
39. The system in accordance with claim 32, wherein the build material comprises at least one of: boron or silicon.
40. The system in accordance with claim 32, wherein, when heated, the bonding agent thermally decomposes into a bonding component and an antioxidation component, and wherein the antioxidation component removes surface oxides from the build material.
US17/839,656 2019-11-01 2022-06-14 System and method of additively manufacturing an object Pending US20220305726A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US17/839,656 US20220305726A1 (en) 2019-11-01 2022-06-14 System and method of additively manufacturing an object

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US16/671,656 US11364679B2 (en) 2019-11-01 2019-11-01 System and method of additively manufacturing an object
US17/839,656 US20220305726A1 (en) 2019-11-01 2022-06-14 System and method of additively manufacturing an object

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
US16/671,656 Continuation US11364679B2 (en) 2019-11-01 2019-11-01 System and method of additively manufacturing an object

Publications (1)

Publication Number Publication Date
US20220305726A1 true US20220305726A1 (en) 2022-09-29

Family

ID=75688678

Family Applications (2)

Application Number Title Priority Date Filing Date
US16/671,656 Active 2040-01-13 US11364679B2 (en) 2019-11-01 2019-11-01 System and method of additively manufacturing an object
US17/839,656 Pending US20220305726A1 (en) 2019-11-01 2022-06-14 System and method of additively manufacturing an object

Family Applications Before (1)

Application Number Title Priority Date Filing Date
US16/671,656 Active 2040-01-13 US11364679B2 (en) 2019-11-01 2019-11-01 System and method of additively manufacturing an object

Country Status (1)

Country Link
US (2) US11364679B2 (en)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20170297097A1 (en) * 2016-04-14 2017-10-19 Desktop Metal, Inc. Fabricating an interface layer for removable support
US20180370127A1 (en) * 2015-07-13 2018-12-27 Eos Gmbh Electro Optical Systems Method and device for producing a three-dimensional object

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6401795B1 (en) 1997-10-28 2002-06-11 Sandia Corporation Method for freeforming objects with low-binder slurry
DE19918282C1 (en) 1999-04-22 2001-01-25 Ald Vacuum Techn Ag Device and method for removing binding material from metal powders
JP5428546B2 (en) 2009-06-04 2014-02-26 三菱マテリアル株式会社 Method for producing aluminum composite having porous aluminum sintered body
US11623389B2 (en) 2017-04-21 2023-04-11 Desktop Metal, Inc. Multi-directional binder jetting additive manufacturing
US10421124B2 (en) 2017-09-12 2019-09-24 Desktop Metal, Inc. Debinder for 3D printed objects
WO2019221708A1 (en) * 2018-05-15 2019-11-21 Hewlett-Packard Development Company, L.P. Three-dimensional printing

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20180370127A1 (en) * 2015-07-13 2018-12-27 Eos Gmbh Electro Optical Systems Method and device for producing a three-dimensional object
US20170297097A1 (en) * 2016-04-14 2017-10-19 Desktop Metal, Inc. Fabricating an interface layer for removable support

Also Published As

Publication number Publication date
US11364679B2 (en) 2022-06-21
US20210129427A1 (en) 2021-05-06

Similar Documents

Publication Publication Date Title
Fang et al. Study on metal deposit in the fused-coating based additive manufacturing
JP6717573B2 (en) Additive manufacturing method using fiber reinforcement
EP3408096B1 (en) Laser pulse shaping for additive manufacturing
JP6789694B2 (en) Additional manufacturing of joint preforms
US20150224607A1 (en) Superalloy solid freeform fabrication and repair with preforms of metal and flux
US12064813B2 (en) Additive manufacturing method with controlled solidification and corresponding device
JP2017185804A (en) Apparatus and method for selective laser sintering of object with void
EP3187285B1 (en) Powder for layer-by-layer additive manufacturing, and process for producing object by layer-by-layer additive manufacturing
JP2011021218A (en) Powder material for laminate molding, and powder laminate molding method
Paul et al. Metal additive manufacturing using lasers
US10821521B2 (en) Article surface finishing method
US20120219726A1 (en) Method and device for producing a component
US10384285B2 (en) Method of selective laser brazing
CN108290216B (en) Powder for 3D printing and 3D printing method
JP3752427B2 (en) Solid object modeling method
US20170216971A1 (en) Use of variable wavelength laser energy for custom additive manufacturing
Medina Development and application of a CFD model of laser metal deposition
EP3766604A1 (en) Method and device for purging an additive manufacturing space
Su et al. Investigation of fully dense laser sintering of tool steel powder using a pulsed Nd: YAG (neodymium-doped yttrium aluminium garnet) laser
US11090861B2 (en) Systems and methods for lateral material transfer in additive manufacturing system
US11364679B2 (en) System and method of additively manufacturing an object
EP2918359A1 (en) Sintering particulate material
JP2019039067A (en) Continuous additive manufacture of high pressure turbine
EP3838444A1 (en) Method and device for removing impurities in additive manufacture using helium and hydrogen gases
CN110064756A (en) A kind of method of selective laser melting (SLM) molding

Legal Events

Date Code Title Description
AS Assignment

Owner name: GENERAL ELECTRIC COMPANY, NEW YORK

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:OPPENHEIMER, SCOTT MICHAEL;DIDOMIZIO, RICHARD;KARP, JASON HARRIS;SIGNING DATES FROM 20191021 TO 20191024;REEL/FRAME:060189/0855

STPP Information on status: patent application and granting procedure in general

Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION

STPP Information on status: patent application and granting procedure in general

Free format text: NON FINAL ACTION MAILED

STPP Information on status: patent application and granting procedure in general

Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER

STPP Information on status: patent application and granting procedure in general

Free format text: FINAL REJECTION MAILED

STPP Information on status: patent application and granting procedure in general

Free format text: ADVISORY ACTION MAILED