WO2019040509A1 - Constituants à matériaux multiples et procédés pour leur fabrication - Google Patents

Constituants à matériaux multiples et procédés pour leur fabrication Download PDF

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Publication number
WO2019040509A1
WO2019040509A1 PCT/US2018/047349 US2018047349W WO2019040509A1 WO 2019040509 A1 WO2019040509 A1 WO 2019040509A1 US 2018047349 W US2018047349 W US 2018047349W WO 2019040509 A1 WO2019040509 A1 WO 2019040509A1
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WO
WIPO (PCT)
Prior art keywords
substrate
product
hybrid
additively manufactured
microstructure
Prior art date
Application number
PCT/US2018/047349
Other languages
English (en)
Inventor
Lee Shaw
Richard GREATBATCH
Brandon BODILY
Gen SATOH
Neville Whittle
Original Assignee
Arconic Inc.
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Filing date
Publication date
Application filed by Arconic Inc. filed Critical Arconic Inc.
Publication of WO2019040509A1 publication Critical patent/WO2019040509A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/60—Treatment of workpieces or articles after build-up
    • B22F10/62—Treatment of workpieces or articles after build-up by chemical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/60—Treatment of workpieces or articles after build-up
    • B22F10/64—Treatment of workpieces or articles after build-up by thermal means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/60—Treatment of workpieces or articles after build-up
    • B22F10/66—Treatment of workpieces or articles after build-up by mechanical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/006—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE 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
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE 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
    • B33Y80/00—Products made by additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE 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
    • B33Y10/00—Processes of additive manufacturing
    • Y—GENERAL 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the present disclosure is directed towards methods of making multi-material components (i.e. two, three, four, or more - a plurality of different materials), and products made therefrom. More specifically, the present disclosure is directed towards methods of making multi -material axisymmetric components including hubs, disks and blisks via additive manufacturing followed by working (e.g., forging) to provide a multi-material hybrid axisymmetric component.
  • Axisymmetric forgings specifically rotating parts like hubs, disks, and blisks, are produced using conventional forging methods: billet, preform, and forging operations to achieve the desired geometry and properties.
  • These forgings are a single alloy composition, based on the composition of the initial ingot/billet raw material utilized in the forging pathway.
  • Axisymmetric forgings are often utilized in rotating applications, including turbine engines, either for aircraft or ground based industrial power generation turbines or other turbomachinery.
  • the operating environment/end-use application of these components results in competing design drivers for these components, which leads to a compromise based on material performance and capabilities.
  • the rotational loading results in high stresses on the center/hub portion, while the extreme edges (e.g., where the blades are found) are exposed to lower loads, but have higher temperature exposure.
  • the axisymmetric rotating parts are configured from additively manufactured multi-materials (e.g., bi-material) such that the high stress region is configured from one material, and the high temperature region is configured from another material.
  • the resulting additively manufactured component is forged to create a monolithic, integral, and/or unitary component having two (or more) materials thereon.
  • a bi-material component reference to multi-material components are herein also included, including two (i.e., bi-material) or more (e.g., 3, 4, or 5 materials), such that the final part has portions or components with characteristics and/or properties specifically tailored to enable the part components to meet or exceed the specifications for use in its environment.
  • a bi-material, or multi-material component may be a component generally comprised of a single material, but with regions of varying microstructure (e.g., regions of equiaxed structure and regions of columnar structure).
  • a method (100) includes additively manufacturing (AM) a hybrid AM preform (110) and working the hybrid AM preform (120), thereby producing a worked hybrid part.
  • Suitable methods for working the hybrid AM preform may include, for instance, forging, rolling, and/or extruding.
  • the additively manufacturing generally comprises directing an AM build around at least a portion of a substrate (115), thereby producing the hybrid AM preform.
  • the directing may comprise directing an AM build perimetrically around at least a portion of the substrate.
  • the method may further include the steps of machining (130), thermally treating (135), and/or modifying the surface of the worked hybrid part (140) (e.g., cleaning, applying a surface treatment, applying a coating, and combinations thereof).
  • the thermally treating (135) may occur before and/or after the machining (130).
  • the method (100) may include thermally treating (135) the worked hybrid AM part after any potential surface modification steps (140).
  • the directing comprises directing a first AM build around a first portion of the substrate, thereby producing a first additively manufactured portion, and directing a second AM build around both (i) a second portion of the substrate and (ii) at least a portion of the first additively manufactured portion, thereby producing a second additively manufactured portion.
  • the substrate comprises a first material
  • the first additively manufactured portion comprises a second material
  • the second additively manufactured portion comprises a third material.
  • the first additively manufactured portion is integral with the first portion of the substrate.
  • the second additively manufactured portion is integral with both (i) at least a portion of the first additively manufactured portion and (ii) the second portion of the substrate. In such embodiments, the second additively manufactured portion may enclose the first additively manufactured portion to the substrate.
  • a method comprises thermally treating (135) a worked hybrid part.
  • the thermally treating (135) comprises annealing, solution heat treating and quenching, aging, and combinations thereof.
  • a method comprises thermally treating (135) the worked hybrid part after the working step, and prior to a machining step.
  • a substrate comprises a cross- sectional configuration of at least one of a square, an octagon, a hexagon, a pentagon, a triangle, an ellipse, a circle, an oval, and combinations thereof.
  • the substrate is an elongated substrate.
  • the substrate is in the form of a solid round bar, or a hollow tube.
  • the substrate is one of a cast product or a worked product.
  • the substrate is a worked product, wherein the worked product is one of an extrusion, a forged product, or a rolled product.
  • the substrate is an additively manufactured substrate.
  • a method comprising: additively manufacturing a hybrid AM preform, including: directing an AM build of a material around (e.g., perimetrically around; circumferentially around) at least a portion of a substrate (e.g., an elongated substrate) to provide an AM build around at least a portion of the substrate, thereby producing a hybrid AM preform having a substrate and an AM build at least partially around the substrate.
  • the substrate may be the same or different material as the AM build, and vice-versa.
  • the hybrid AM preform may be worked (e.g., forged) to make a worked hybrid part (e.g., a forged hybrid part.).
  • the worked hybrid part may have a first region of a first material and a second region of a second material.
  • the hybrid AM preform is not worked after its production, as described in greater detail below.
  • the method may include machining the worked hybrid part.
  • the machining may produce an axisymmetric part (e.g., hub, disk, or blisk).
  • the worked hybrid part may have a dual alloy, hybrid composition.
  • a thermal treatment (e.g., an anneal, a solution heat treatment, an age, and combinations thereof) may be applied to the hybrid part, and at an applicable point in the process (e.g., after the directing step and before the working step (if any); after the working step and before the machining step (if any); after the machining step).
  • an applicable point in the process e.g., after the directing step and before the working step (if any); after the working step and before the machining step (if any); after the machining step).
  • Non-limiting examples of additive manufacturing processes useful in producing the multi-material components described herein include, for instance, DMLS (direct metal laser sintering), SLM (selective laser melting), SLS (selective laser sintering), and EBM (electron beam melting), among others.
  • Any suitable feedstocks may be used, including one or more powders, one or more wires, and combinations thereof.
  • the additive manufacturing feedstock is comprised of one or more powders. Shavings are types of particles.
  • the additive manufacturing feedstock is comprised of one or more wires.
  • a ribbon is a type of wire.
  • the substrate is an elongated substrate.
  • An elongated substrate may be configured, for instance, as a solid round bar, or a hollow tube.
  • the cross-sectional configuration of the elongated substrate is polygonal.
  • the cross-sectional configuration of the elongated substrate is configured as at least one of: a square, an octagon, a hexagon, a pentagon, a triangle, an ellipse, a circle, an oval, or combinations thereof.
  • Non- elongated substrates that may be used may include polygonal substrates such as, for instance, rectangular substrates (e.g., sheets, plates), or cubic substrates.
  • Other non-elongated substrates that may be used may include, for instance, spheroidal substrates (e.g., spheroids, ellipsoids).
  • a hybrid AM product e.g., hybrid AM part, hybrid AM preform, worked hybrid parts
  • the hybrid AM product comprises a substrate portion and an additively manufactured portion, where the substrate portion is comprised of a first material that realizes a first set of material properties, and where the additively manufactured portion is comprised of a second material that realizes a second set of material properties.
  • the first and second materials may be tailored for the environment of the end-use application for the hybrid AM product.
  • the tailored material properties may relate to one or more of a strength (e.g., tensile yield strength, ultimate tensile strength), a strength at elevated temperature, corrosion resistance (e.g., stress corrosion cracking resistance, oxidation resistance), creep resistance, fatigue life, crack propagation resistance, and stress rupture resistance.
  • the first material may realize one or more of these properties that exceeds those of the second material, and vice versa.
  • the methods described herein may be used to produce a multi-material AM product comprised of three or more materials, and each material may similarly be tailored for the environment of the end-use application for the multi-material AM product.
  • a worked hybrid part comprises a substrate portion and an additively manufactured portion, wherein the substrate portion comprises a first material and wherein the additively manufactured portion comprises a second material.
  • the first material is different from the second material.
  • the first material has a first set of properties
  • the second material has a second set of properties.
  • the first set of properties is different from the second set of properties.
  • a first set of properties comprises a first tensile yield strength and second set of properties comprises a second tensile yield strength, wherein the first tensile yield strength is greater than the second tensile yield strength.
  • the second tensile yield strength is greater than the first tensile yield strength.
  • a first set of properties comprises a first high temperature yield strength and a second set of properties comprises a second high temperature yield strength, wherein the second high temperature yield strength is greater than the first high temperature yield strength. In one embodiment, the first high temperature yield strength is greater than the second high temperature yield strength.
  • the hybrid AM part is configured with a first material along a high stress region, a second material along the elevated temperature region, and a transition region such that the first material extends from the central portion to towards the high temperature region, such that the second material commences out of the high stress zone and the first material commences out of the high temperature zone.
  • the substrate e.g., an elongated substrate
  • the substrate is additively manufactured.
  • the substrate is a wrought product, such as a rolled product, a forged product, or an extruded product. In one or more of the described embodiments, the substrate is cast. In one or more of the described embodiments, the substrate is an elongated substrate.
  • the first material of the substrate comprises a first microstructure (or microstructures).
  • the second material of the AM build comprises a second microstructure.
  • the hybrid AM part comprises a wrought structure throughout.
  • the forged hybrid part is machined to provide an axisymmetric part (e.g., for rotating applications).
  • the forged hybrid part is thermally treated.
  • the part after thermally treating, is machined to provide an axisymmetric part (e.g., configured for rotating applications).
  • the method further comprises cleaning the hybrid AM part.
  • the method further comprises surface coating the hybrid AM part.
  • the method further comprises applying a coating to the hybrid AM part.
  • a component comprising: an integral multi-material axisymmetric forged part (e.g., having a wrought microstructure).
  • a component comprising: a monolithic multi -material axisymmetric forging.
  • a component comprising: an integral multi -material axisymmetric forging comprising at least two materials, wherein the interface between the first material and the second material is worked during the forging step.
  • the present invention may allow to utilize an integral multi-material axisymmetric forging to manufacture a component that includes at least two materials, where the interface between the first material and the second is produced using an additive manufacturing technique, and not a conventional welding technique (e.g., fusion welding, friction welding, linear friction welding).
  • the axisymmetric components are configured for rotating applications (e.g., aerospace applications, automotive applications, and/or turbine applications).
  • a component comprising: an integral bi-metallic-material axisymmetric forging configured as an aerospace component.
  • a component comprising: an integral bi-metallic-material axisymmetric forging configured as an aerospace component selected from the group consisting of: a hub, a disk, and a blisk.
  • a component comprising: an integral bi-metallic-material axisymmetric forging configured as an aerospace component selected from the group consisting of: a hub, a disk, and a blisk, wherein the axisymmetric forging is additively manufactured and comprises a wrought microstructure).
  • a component comprising: an integral bi-metallic-material axisymmetric forging configured as a hub.
  • a component comprising: an integral bi-metallic-material axisymmetric forging configured as a disk.
  • a component comprising: an integral bi-metallic-material axisymmetric forging configured as a blisk.
  • hub means: a rotating component (e.g., in a jet engine).
  • disk means: the components that are integral with the hub with the fan blades attached to it. (e.g., includes a joint between each individual blade). In some embodiments, the disk and blisk components are made separately, then put together and/or otherwise assembled.
  • the "blisk” means: a forged hub with the blades made all in an integral component, with spare material machined away (e.g., there is no joint between each individual blade).
  • a high strength core material may be used in the center of the disk and a potentially lower strength but higher temperature capable material is positioned around the core (e.g., around the rim) of the disk. Then, blades may be attached via mechanical means.
  • the resulting assembly may be a hub having a rim having better temperature tolerances, with blades attached along conventional lines, such that the assembly includes composite disks that are mechanically attached or welded to the hub.
  • the blades are additively manufactured to the hub.
  • axisymmetric means: symmetrical about an axis of a component or device.
  • axisymmetric components may be configured with repeating/periodic angular geometry (e.g., repeating features about a central radius portion, an example being a gear, integrally bladed disc, or impeller).
  • additive manufacturing means: “a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies", as defined in ASTM F2792-12a entitled “Standard Terminology for Additively Manufacturing Technologies”.
  • additive systems means machines and related instrumentation used for additive manufacturing.
  • “grain” takes on the meaning defined in ASTM El 12 ⁇ 3.2.2, i.e., "the area within the confines of the original (primary) boundary observed on the two- dimensional plane of-polish or that volume enclosed by the original (primary) boundary in the three-dimensional object".
  • “grain microstructure” means the fine structure (in a metal or other material) that can be made visible and examined with a microscope.
  • microstructure of a material can strongly influence physical properties (e.g., strength, toughness, ductility, hardness, corrosion resistance, high/low temperature behavior or wear resistance) of the material and ultimately whether the component or part is acceptable for its end-use applications.
  • physical properties e.g., strength, toughness, ductility, hardness, corrosion resistance, high/low temperature behavior or wear resistance
  • microstructures include columnar and equiaxed grain structures.
  • columnar structure means a grain microstructure predominately comprising columnar grains.
  • a columnar structure may be characterized by the visual observation of structures having an aspect ratio resembling, or characterized by, pillared or column-type architecture.
  • a columnar structure comprises at least 60% columnar grains.
  • a columnar structure comprises at least 75% columnar grains.
  • a columnar structure comprises at least 90% columnar grains.
  • a columnar structure comprises at least 95% columnar grains.
  • a columnar structure comprises at least 99% columnar grains.
  • columnar grains generally have an average aspect ratio of at least 4: 1 as measured in the YZ and/or XZ planes, wherein the Z plane is the build direction.
  • the "aspect ratio” is determined using commercial software Edax OEVI version 8.0 or equivalent. The commercial software fits an ellipse to the perimeter points of the grain.
  • columnar grains have an average aspect ratio of at least 5: 1.
  • columnar grains have an average aspect ratio of at least 6: 1.
  • columnar grains have an average aspect ratio of at least 7: 1.
  • columnar grains have an average aspect ratio of at least 8: 1.
  • columnar grains have an average aspect ratio of at least 9: 1.
  • columnar grains have an average aspect ratio of at least 10: 1.
  • the amount (volume percent) of columnar grains in a product may be determined by EBSD (electron backscatter diffraction) analysis of a suitable number of SEM micrographs of the product. Generally at least 5 micrographs should be analyzed.
  • the products may be analyzed in an as-built condition, or in a condition realized after subsequent post-processing (e.g., thermal treatments and/or working).
  • the "as-built condition” means the condition of an additively manufactured product after production and absent of any subsequent mechanical, thermal or thermomechanical treatments.
  • equiaxed structure means a grain microstructure predominately comprising equiaxed grains.
  • an equiaxed structure comprises at least 60% equiaxed grains.
  • an equiaxed structure comprises at least 75% equiaxed grains.
  • an equiaxed structure comprises at least 90% equiaxed grains.
  • an equiaxed structure comprises at least 95% equiaxed grains.
  • an equiaxed structure comprises at least 99% equiaxed grains.
  • “Equiaxed grains” generally have an average aspect ratio of less than 4: 1 as measured in the XY, YZ, and XZ planes.
  • “equiaxed” means grains in a microstructure that have axes of approximately the same length.
  • the “aspect ratio” is determined using commercial software Edax OEVI version 8.0 or equivalent. The commercial software fits an ellipse to the perimeter points of the grain.
  • “aspect ratio” is the inverse of: the length of the minor axis of the ellipse divided by the length of the major axis of the ellipse as determined using commercial software.
  • equiaxed grains have an average aspect ratio of not greater than 4: 1.
  • equiaxed grains have an average aspect ratio of not greater than 3 : 1. In yet another embodiment, equiaxed grains have an average aspect ratio of not greater than 2: 1. In another embodiment, equiaxed grains have an average aspect ratio of not greater than 1.5 : 1. In yet another embodiment, equiaxed grains have an average aspect ratio of not greater than 1.1 : 1.
  • the amount (volume percent) of equiaxed grains in a product may be determined by EBSD (electron backscatter diffraction) analysis of a suitable number of SEM micrographs of the product. Generally at least 5 micrographs should be analyzed. The products may be analyzed in an as-built condition, or in a condition realized after subsequent post-processing (e.g., thermal treatments and/or working).
  • a worked hybrid part comprises a substrate portion and at least one additively manufactured portion.
  • a worked hybrid part comprises a substrate portion and an additively manufactured portion, wherein the substrate portion comprises a first microstructure, and wherein the additively manufactured portion comprises a second microstructure.
  • the first microstructure and microstructure are one of an equiaxed microstructure and a columnar microstructure.
  • the additively manufactured portion comprises a columnar structure.
  • a columnar structure may, for instance, facilitate improved properties, such as improved damage tolerance properties (e.g., fatigue, creep).
  • the substrate comprises an equiaxed microstructure
  • the additively manufactured portion comprises a columnar microstructure
  • directed energy deposition means: an additive manufacturing process in which focused energy is used to fuse materials by melting as they are being deposited.
  • the directed energy deposition AM method can utilize powder or wire as an additive manufacturing feedstock/feed material.
  • energy source means: the energy source configured for transforming an additive manufacturing feed material or feedstock into an AM build.
  • Some non-limiting examples of focused thermal energy sources include a laser beam, an electron beam, a plasma arc, and/or combinations thereof.
  • One or more energy sources may be used during an additive manufacturing process.
  • AM feedstock means: one or more material(s) that are directed into an AM machine and deposited via an energy source into an AM build (e.g., build layer) during additive manufacturing, via the energy source.
  • the AM feedstock may be any of the “feedstocks” described below.
  • the AM process and related machine may be a directed energy powder deposition (e.g., Optomec machine).
  • the AM process and related machine may be a directed energy wire deposition (e.g., EB gun, Sciaky machine).
  • the hybrid products referenced herein are constructed and/or built via friction welding.
  • a layer of material is deposited with an intermediate friction weld, after which the hybrid preform may be worked.
  • the layer of material is deposed via solid state deposition, by friction methods (rather than liquid techniques.)
  • AM part means: the part made via additive manufacturing.
  • a hybrid AM part is considered an AM preform, and undergoes further post-AM forming processing steps (e.g., heat treatments, working, machining, milling, coating, surface treatments, and/or the like) before being utilized in an end-use application.
  • processing steps e.g., heat treatments, working, machining, milling, coating, surface treatments, and/or the like
  • a hybrid AM part is configured for direct use in end-use applications (e.g., with no further post processing steps).
  • AM build means: the AM part and/or optional build substrate, which is partially formed (e.g., in the process of being additively manufactured).
  • AM build layer means: a discrete portion of an AM part build, which can be composed of a series of AM deposition paths (e.g., AM beads).
  • AM deposition path means: the unit of AM build in a directed energy deposition AM process, as the AM material is deposited in a bead or path along an additive build and/or substrate.
  • feedstock means the material that is fed into the additive system that is utilized by the additive system to build an AM part.
  • feedstocks for use as an AM feedstock include aluminum, aluminum alloys, titanium, titanium alloys, steel, steel alloys, nickel, nickel alloys, cobalt, cobalt alloys, and combinations thereof.
  • the feedstock may include metals or alloys of titanium, aluminum, nickel (e.g., INCO EL), steel, and stainless steel, and titanium aluminide, among others.
  • An alloy of titanium is an alloy having titanium as the predominant alloying element.
  • An alloy of aluminum is an alloy having aluminum as the predominant alloying element.
  • An alloy of nickel is an alloy having nickel as the predominant alloying element.
  • An alloy of steel is an alloy having iron as the predominant alloying element, and at least some carbon.
  • An alloy of stainless steel is an alloy having iron as the predominant alloying element, at least some carbon, and at least some chromium.
  • the feedstock may be a titanium alloy.
  • the feedstock may comprise a Ti-6A1-4V alloy.
  • the feedstock may be an aluminum alloy.
  • the aluminum alloy means an aluminum alloy selected from the group consisting of lxxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, 7xxx, and 8xxx series aluminum alloys registered with the Aluminum Association and unregistered variants of the same, as defined by the Aluminum Association document "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” (2009).
  • the aluminum alloy is a lxxx series aluminum alloy.
  • the aluminum alloy is a 2xxx series aluminum alloy.
  • the aluminum alloy is a 3xxx series aluminum alloy.
  • the aluminum alloy is a 4xxx series aluminum alloy.
  • the aluminum alloy is a 5xxx series aluminum alloy.
  • the aluminum alloy is 6xxx series aluminum alloy.
  • the aluminum alloy is a 7xxx series aluminum alloy.
  • the aluminum alloy is an 8xxx series aluminum alloy.
  • the feedstock may be a nickel alloy.
  • the feedstock may be one of a steel and a stainless steel.
  • the feedstock may be a metal matrix composite (e.g., ceramic or entrained particulate within one or more of the aforementioned feedstock metal or metal alloy materials).
  • a metal matrix composite e.g., ceramic or entrained particulate within one or more of the aforementioned feedstock metal or metal alloy materials.
  • the feedstock may comprise a titanium aluminide alloy.
  • a titanium alloy is a titanium aluminide alloy.
  • the titanium aluminide alloy may include at least 48 wt. % Ti and at least one titanium aluminide phase, wherein the at least one titanium aluminide phase is selected from the group consisting of Ti 3 Al, TiAl and combinations thereof.
  • the titanium aluminide alloy includes at least 49 wt. % Ti.
  • the titanium alloy includes at least 50 wt. % Ti.
  • the titanium aluminide alloy includes 5-49 wt. % aluminum.
  • the titanium aluminide alloy includes 30-49 wt. % aluminum, and the titanium alloy comprises at least some TiAl.
  • the titanium aluminide alloy includes 5-30 wt. % aluminum, and the titanium aluminide alloy comprises at least some Ti 3 Al.
  • a method comprises providing a substrate of a first material, depositing a second material onto the substrate, wherein at least a portion of the depositing step occurs while the substrate is rotating around its longitudinal axis (such that the second material is additive manufactured as the component rotates).
  • the resulting AM deposition is configured to provide a continuous circumferential deposition of second material around at least a portion of the outer surface of (e.g., around the perimeter of) a region of the first material (e.g., an elongated substrate.)
  • a deposition e.g., a continuous circumferential deposition
  • a second material is configured to provide a uniform cross-section along the component's length.
  • a deposition (e.g., a continuous circumferential deposition) of a second material is configured to provide a non-uniform cross-section along the component's length.
  • the deposition (e.g., a continuous circumferential deposition) of the second material is configured to provide a tapered part component, a discontinuous portion, and/or varying composition (e.g., a gradient).
  • the component is sufficiently long to enable holding and rotation of the resulting component while additively manufacturing along at least a portion and/or end of the component (i.e. to form the hybrid part).
  • the exemplary deposition methods described herein may be applied to an internal surface, instead of to an exterior surface.
  • the build substrate is a tube, or other hollow shape, or shape with an interior surface
  • the deposition of the second material could be applied to the interior surfaces of the substrate.
  • the second material may be deposited on the interior surface of the substrate.
  • the choice as to what surface apply the second material may be based at least in part on design requirements, geometry of the substrate material, and which material property combination best meets the final design requirements.
  • the production of the multi-material metallic preform can be accomplished with deposition of the second material on either of the surfaces of the substrate.
  • the preform shape tailored for a working operation e.g., for a forging, rolling, or extrusion operation.
  • the substrate is configured having a cross sectional shape of a polygon.
  • polygonal cross-sectional shapes include: triangular, round, square, pentagonal, hexagonal, octagonal, etc.
  • the first material is different from the second material.
  • the first material is the same alloy as the second material.
  • the second material is deposited such that the resulting microstructure and/or chemistry differs from the substrate (first material) to the AM build
  • a substrate and an AM build are comprised of the same material (e.g., the same metal alloy) and have different microstructures (e.g., equiaxed; columnar).
  • a hybrid AM part comprises a substrate having an equiaxed structure and at least one additively manufactured portion comprising a columnar structure.
  • the ends of the hybrid AM preform are cut/removed from the hybrid AM preform prior to working.
  • the hybrid AM preform may be machined prior to working. In some embodiments, this machining step may be used to prepare the hybrid AM preform for the working operation (e.g., remove material to achieve the predetermined geometry for working and/or develop an acceptable surface condition for working).
  • the working comprises forging
  • the method comprises forging the hybrid AM preform to produce a forged part.
  • the forging step is configured to impart a predetermined amount of strain in the forged component (assures a wrought, non-AM, microstructure and properties for both the substrate and the AM deposited material).
  • the method further comprises thermomechanical working, as to promote a more wrought microstructure in the resulting part.
  • a working operation is configured to promote improved properties (e.g., wrought microstructure) in the resulting part.
  • post-working operations are performed to at least partially transform the part and promote microstructural changes, thereby achieving a preferred microstructure adjacent to a non-AM, wrought microstructure.
  • working of the hybrid AM preform is performed such that material flows and redistributes to produce one or more desired geometries.
  • flow lines of a material e.g., first and/or second materials
  • a substrate profile e.g., geometric shaping of the substrate and core
  • an AM build configuration such that, due to the working step, the first material is produced in the first location and the second material is produced in the second location.
  • the interface there is an interface between a first material and a second material.
  • the interface is produced via the working step such that the interface is outside of the high stress zone (e.g., in the low stress zone and lower temperature region).
  • the substrate is configured with a varying profile or dimension, such that the hybrid AM preform is tailored for providing an axisymmetric part post-working, with portions of the part specifically tailored (e.g., with a first material and/or second material) for end-use applications of the part.
  • the interface between the first material and second material is graded (e.g., configured as a gradient from 100% of first material to 100% of second material, with varying degrees of first material and second material therebetween).
  • the interface between the first material and second material is an adjacent transition (e.g., the first material is bonded directly to the second material).
  • Ti-6242 material i.e., Ti-6Al-2Sn-4Zr-2Mo
  • it may be useful to create a gradient composition and/or zone between the layers/regions of first and second material e.g., reduce stress concentrations and/or reduce discrete material changes that could result in unintended or undesirable performance characteristics of the material interface.
  • the composition of the AM feedstock is varied during deposition.
  • two wires can be co-fed, with varying deposition rates of the first and second wires to achieve the desired transition/gradient from the first material to the second material.
  • the transition/gradient is made by varying the chemistry of the powder that is applied (e.g., with one or more powder feeders and/or multiple nozzles to feed the different powders) or powder having varied composition.
  • the gradient is configured to improve properties between the first material and second material in a direction extending from the substrate (e.g., in a radial direction).
  • the gradient is configured to improve properties between the first material and second material in an axial direction (along the length of the component as well).
  • one radial section e.g., centrally configured
  • the hybrid AM preform may then be further processed (forged, machined, etc.) to provide the final, multi-component part/assembly.
  • One or more embodiments of the present disclosure can be utilized to produce an "axisymmetric" part that has circumferential segments of specified degrees that repeat around the axis of symmetry (e.g., individual teeth of a gear).
  • the gradient is configured to improve properties between the first material and second material in a circumferential direction (around the axis of symmetry as well).
  • axisymmetric configurations include: a shallow helix, a single rib on an outside surface of a part, a threaded configuration on a surface of a part, or a spline.
  • One or more embodiments of the present disclosure can be utilized to produce a part having a spiral-shaped geometry (e.g., a turbocharger wheel, an auger, or a heat exchanger).
  • a part having a spiral-shaped geometry e.g., a turbocharger wheel, an auger, or a heat exchanger.
  • the gradient is configured to improve properties between the first material and second material in an arbitrary direction.
  • a bar or tube of Ti-6A1-4V product (high strength) is configured with additively manufactured deposits of Ti-6242 and/or Ti-6246 (higher temperature, creep or corrosion resistance than the Ti-6A1-4V), such that material locations in the structure are tailored to the design requirements of the end-use application, resulting in improved properties.
  • one or more embodiments, of the present disclosure result in an improved performance of the hub, disk, blisk (end-use application), and/or assembled component, as compared to the conventional unialloy structure.
  • the material e.g., first material or second material
  • the material are selected from at least one of: an aluminum alloy, titanium alloy (including titanium aluminides), nickel, and/or other super alloy.
  • the working step comprises forging
  • the forging step may comprise heating the hybrid AM preform to a stock temperature, and contacting the hybrid AM preform with a forging die.
  • the forging die may be a temperature that is at least 10° F. lower than the stock temperature, (i.e., non-isothermal forging)
  • the forging die is a temperature that is at least 25° F. lower than the stock temperature.
  • the forging die is a temperature that is at least 50° F. lower than the stock temperature.
  • the forging die when the contacting step is initiated, is a temperature that is at least 100° F. lower than the stock temperature. In yet another embodiment, when the contacting step is initiated, the forging die is a temperature that is at least 200° F. lower than the stock temperature.
  • the working step comprises forging
  • the forging step may comprise heating the hybrid AM preform to a stock temperature, and contacting the hybrid AM preform with a forging die.
  • the contacting step may comprise deforming the hybrid AM preform via the forging die.
  • Figure 7 shows an analytical prediction illustrating the variation in levels of true strain realized within an AM preform during the forging step.
  • the contacting step comprises deforming the hybrid AM preform via the forging die to realize a true strain of from 0.05 to 1.50 in the hybrid AM preform.
  • the forging step may comprise heating the hybrid AM preform to a stock temperature, which can be varied in accordance with the forging process and/or end-use application.
  • the method may include, one or more thermal treatment (processing) steps, such as a solution heat treatment (optionally with a quench), an anneal, and/or an age, among others.
  • the method may include thermally treating the product before and/or after any working step, if employed.
  • the method may include thermally treating the product before and/or after any machining step.
  • anneal refers to a heating process that primarily causes recovery, recrystallization, and/or grain growth of the metal.
  • a product is solution heat treated and optionally quenched.
  • solution heat treating and quenching means heating an alloy body to a suitable temperature, generally above a solvus temperature, holding at that temperature long enough to allow soluble elements (e.g., from soluble phases) to enter into solid solution, and cooling rapidly (i.e., quenching) enough to hold the elements in solid solution.
  • the quenching may facilitate production of a supersaturated solid solution. Suitable methods for quenching may include quenching via air or a liquid (e.g., water). Solution heat treatments may be useful, for instance, alloys that may be precipitation hardened.
  • certain aluminum alloys may be precipitation hardened (e.g., to increase strength). Precipitation hardening may be accomplished, for instance, by subsequent aging treatments (e.g., natural and/or artificial). For instance, subsequent aging treatments may facilitate the precipitation of one or more hardening phases from such supersaturated solutions.
  • Various combinations of (1) solution heat treating and quenching and (2) aging steps may be performed. For instance, an aluminum alloy may be processed to one of a T3, T4, T6, T7, T8, or T9 temper, as defined in ANSI H35.1 (2009).
  • a final therm omechanically worked hybrid AM preform is thermally treated, the thermal treatment step comprises heating the preform to a sufficient temperature for a sufficient amount of time in order to promote final properties.
  • the hybrid AM preform may be worked.
  • the working comprises forging, and the forging step uses a single die to die forge the hybrid AM preform into the final forged product, as described below.
  • the forging step is completed in multiple forging operations.
  • the forging step is done in a single forging operation, wherein the AM preform is once heated to a stock temperature (a single time) prior to contact by the forging die(s).
  • the single forging operation uses a single die.
  • the single die is a blocker die.
  • the dies and/or tooling of the forging process is at a lower temperature than the hybrid AM preform (i.e., in non-isothermal forging).
  • the forging step may include heating the hybrid AM preform to a stock temperature (the target temperature of the preform prior to the forging), and contacting the hybrid AM preform with a forging die.
  • the forging die when the contacting step is initiated, is a temperature that is at least 10° F. lower than the stock temperature. In another embodiment, when the contacting step is initiated, the forging die is a temperature that is at least 25° F. lower than the stock temperature.
  • the forging die when the contacting step is initiated, is a temperature that is at least 50° F. lower than the stock temperature. In another embodiment, when the contacting step is initiated, the forging die is a temperature that is at least 100° F. lower than the stock temperature. In yet another embodiment, when the contacting step is initiated, the forging die is a temperature that is at least 200° F. lower than the stock temperature. In another embodiment, when the contacting step is initiated, the forging die is a temperature that is at least 300° F. lower than the stock temperature. In yet another embodiment, when the contacting step is initiated, the forging die is a temperature that is at least 400° F. lower than the stock temperature. In another embodiment, when the contacting step is initiated, the forging die is a temperature that is at least 500° F. lower than the stock temperature.
  • the final forged hybrid product is optionally thermally treated (e.g.. annealed). Following any optional thermally treating step, a final forged hybrid product may then be machined.
  • the thermally treating step comprises annealing.
  • the annealing step may facilitate the relieving of residual stress in the hybrid AM preform due to the working step.
  • the working comprises forging
  • the hybrid AM preform comprises a Ti-6A1-4V alloy
  • the annealing step may comprise heating the final forged product to a temperature of from about 640° C. (1184° F.) to about 816° C. (1500° F.) and for a time of from about 0.5 hour to about 5 hours.
  • the annealing step may comprise heating the final forged product to a temperature of at least about 640° C. (1184° F.).
  • the annealing step may comprise heating the final forged product to a temperature of at least about 670° C. (1238° F.). In yet another embodiment, the annealing step may comprise heating the final forged product to a temperature of at least about 700° C. (1292° F.). In another embodiment, the annealing step may comprise heating the final forged product to a temperature of not greater than about 760° C. (1400° F.). In yet another embodiment, the annealing step may comprise heating the final forged product to a temperature of not greater than about 750° C. (1382° F.). In another embodiment, the annealing step may comprise heating the final forged product to a temperature of not greater than about 740° C. (1364° F.).
  • the time is at least about 1 hour. In another embodiment, the time is at least about 2 hours. In yet another embodiment, the time is not greater than about 4 hours. In another embodiment, the time is not greater than about 3 hours. In yet another embodiment, the annealing step may comprise heating the final forged product to a temperature of about 732° C. (1350° F.) and for a time of about 2 hours. Similar processing may be used with other working operations (e.g., rolling, extruding).
  • the contacting step may comprise applying a sufficient force to the hybrid AM preform via the forging die to realize a pre-selected amount of true strain in the hybrid AM preform.
  • the applying a sufficient force step comprises deforming the hybrid AM preform via the forging die.
  • true strain et me
  • Lo initial length of the material
  • L the final length of the material.
  • the contacting step may comprise applying sufficient force to the hybrid AM preform via the forging die to realize a true strain of from about 0.05 to about 1.50 in the hybrid AM preform. In another embodiment, the contacting step may comprise applying sufficient force to the hybrid AM preform via the forging die to realize a true strain of at least 0.10 in the hybrid AM preform. In another embodiment, the contacting step may comprise applying sufficient force to the hybrid AM preform via the forging die to realize a true strain of at least 0.20 in the hybrid AM preform. In yet another embodiment, the contacting step may comprise applying sufficient force to the hybrid AM preform via the forging die to realize a true strain of at least 0.25 in the hybrid AM preform.
  • the contacting step may comprise applying sufficient force to the hybrid AM preform via the forging die to realize a true strain of at least 0.30 in the hybrid AM preform. In yet another embodiment, the contacting step may comprise applying sufficient force to the hybrid AM preform via the forging die to realize a true strain of at least 0.35 in the hybrid AM preform. In another embodiment, the contacting step may comprise applying sufficient force to the hybrid AM preform via the forging die to realize a true strain of not greater than 1.00 in the hybrid AM preform. In yet another embodiment, the contacting step may comprise applying sufficient force to the hybrid AM preform via the forging die to realize a true strain of not greater than 0.90 in the hybrid AM preform.
  • the contacting step may comprise applying sufficient force to the hybrid AM preform via the forging die to realize a true strain of not greater than 0.80 in the hybrid AM preform. In yet another embodiment, the contacting step may comprise applying sufficient force to the hybrid AM preform via the forging die to realize a true strain of not greater than 0.70 in the hybrid AM preform. In another embodiment, the contacting step may comprise applying sufficient force to the hybrid AM preform via the forging die to realize a true strain of not greater than 0.60 in the hybrid AM preform. In yet another embodiment, the contacting step may comprise applying sufficient force to the hybrid AM preform via the forging die to realize a true strain of not greater than 0.50 in the hybrid AM preform.
  • the contacting step may comprise applying sufficient force to the hybrid AM preform via the forging die to realize a true strain of not greater than 0.45 in the hybrid AM preform. In yet another embodiment, the contacting step may comprise applying sufficient force to the hybrid AM preform via the forging die to realize a true strain of about 0.40 in the hybrid AM preform.
  • a final forged hybrid product may realize an amount (e.g., a pre-selected amount) of true strain due to the contacting step.
  • the strain realized by the final forged hybrid product may be non-uniform throughout the final forged product due to, for example, the shape of the forging dies and/or the shape of the hybrid AM preform.
  • the final forged hybrid product may realize areas of low and/or high strain.
  • preform design, substrate design and material placement, including the location and interfaces of the materials is important in ensuring acceptable performance in the final application.
  • the AM preform design can be such that substrate material is placed in areas that receive low strain. This may be because the substrate is a wrought material and does not need to achieve additional forging strain to meet the required material performance. In some embodiments, materials that tolerate, or require high amounts of strain to meet performance requirements will be placed in areas that realize high amounts of strain. Thus, the combination of preform design and forging process can ensure that the substrate or different materials are located in areas where the material characteristics combine with the realized forging strain to achieve the desired attributes. In some embodiments, the additive manufacturing build direction is adjusted/adjustable, such that the microstructure (e.g., grain structure) in different parts of the preform is better suited to the material flow and amount of strain that it will see. (e.g., change the direction of the columnar growth so that it is more easily broken up by the forging step).
  • the microstructure e.g., grain structure
  • a method (200) may comprise producing a hybrid AM part (210), absent a working step.
  • the producing (210) comprises depositing, via additive manufacturing, a material around at least a portion of an outer surface of a substrate (215).
  • the method may further include the steps of machining (220), thermally treating (225), and/or modifying the surface of the hybrid AM part (230) (e.g., cleaning, applying a surface treatment, applying a coating, and combinations thereof).
  • the thermally treating (225) may occur before and/or after the machining (220). While not shown in the illustrated embodiment, the method (200) may include thermally treating (225) the worked hybrid AM part after any potential surface modification steps (230).
  • a method comprises first depositing, via additive manufacturing, a second material around a first portion of the outer surface of the substrate, thereby producing a first additively manufactured portion, and second depositing, via additive manufacturing, a third material around both (i) at least a portion of an outer surface of the first additively manufactured portion and (ii) a second portion of the outer surface of the substrate.
  • the substrate is generally comprised of a first material. Due to the first depositing, the first additively manufactured portion may be integral with the first portion of the outer surface of the substrate.
  • the second additively manufactured portion may be integral with both (i) at least a portion of the outer surface of the first additively manufactured portion and (ii) the second portion of the outer surface of the substrate.
  • the second additively manufactured portion may enclose (e.g., encapsulate) the first additively manufactured portion to the substrate.
  • a method comprises machining (220) the hybrid AM part. In one embodiment, a method comprises thermally treating (225) the hybrid AM part. In one embodiment, a method comprises thermally treating (235) the hybrid AM part after the producing step (210), and prior to a machining step (220). In one embodiment, a method comprises thermally treating (235) the hybrid AM part, wherein the thermally treating (235) comprises annealing, solution heat treating and quenching, aging, and combinations thereof. In one embodiment, a method comprises applying a coating to the AM hybrid part.
  • a hybrid AM part comprises a substrate, wherein at least a portion of the substrate comprises a cross-sectional configuration of at least one of a square, an octagon, a hexagon, a pentagon, a triangle, an ellipse, a circle, an oval, and combinations thereof.
  • the substrate is an elongated substrate.
  • the substrate is in the form of a solid round bar, or a hollow tube.
  • the substrate is one of a cast product or a worked product.
  • the substrate is a worked product, wherein the worked product is one of an extrusion, a forged product, or a rolled product.
  • the substrate is an additively manufactured substrate.
  • an AM hybrid part comprises a substrate portion and at least one additively manufactured portion.
  • an AM hybrid part comprises a substrate comprising a first material, and an additively manufactured portion comprising a second material.
  • the first material and second material are different.
  • an AM hybrid part comprises a substrate portion comprising a first microstructure and an additively manufactured portion comprising a second microstructure.
  • the first microstructure and second microstructure are one of an equiaxed microstructure and a columnar microstructure.
  • the substrate comprises an equiaxed structure and the additively manufactured portion comprises a columnar structure.
  • the AM hybrid part is an axisymmetric part. In one embodiment, the AM hybrid part is an axisymmetric part, wherein the axisymmetric part is one of an aerospace component, an automotive component, and a turbine component. In one embodiment, the AM hybrid part is one of a hub, disk, and a blisk.
  • the methods described above may be used to produce components such as hubs, disks, and blisks.
  • the methods described herein may be suitable for producing products for use in a variety of industries.
  • the new hybrid additively manufactured products may be in the form of aerospace components such as heat exchanger components and turbine components.
  • a hybrid additively manufactured product is in the form of a compressor component (e.g., a turbocharger impeller wheel).
  • a compressor component e.g., a turbocharger impeller wheel
  • Non-limiting examples of automotive applications may include interior or exterior trim/appliques, pistons, valves, and/or turbochargers.
  • Other examples of automotive applications may include engine components and/or exhaust components, such as the manifold.
  • the hybrid additively manufactured products of the present disclosure may also be utilized in a variety of consumer products, such as any consumer electronic product, including laptops, cell phones, cameras, mobile music players, handheld devices, computers, televisions, microwave, cookware, washer/dryer, refrigerator, sporting goods, or any other consumer electronic product.
  • the visual appearance of the consumer electronic product meets consumer acceptance standards.
  • the hybrid additively manufactured products are utilized in a structural application.
  • the hybrid additively manufactured products are utilized in an aerospace structural application.
  • the hybrid additively manufactured products may be in the form of various aerospace structural components, including floor beams, seat rails, fuselage framing, bulkheads, spars, ribs, longerons, and brackets, among others.
  • the hybrid additively manufactured products are utilized in an automotive structural application.
  • the hybrid additively manufactured products may be in the form of various automotive structural components including nodes of space frames, shock towers, and sub frames, among others.
  • a hybrid additively manufactured product is a body-in-white ( ⁇ ) automotive product.
  • the hybrid additively manufactured products may be utilized in an industrial engineering application.
  • the hybrid additively manufactured products may be in the form of various industrial engineering products, such as tread-plate, tool boxes, bolting decks, bridge decks, and ramps, among others.
  • the hybrid additively manufactured products of the present disclosure may be utilized in a variety of products including the likes of medical devices, transportation systems and security systems, to name a few.
  • the hybrid additively manufactured products may be incorporated in goods including the likes of car panels, media players, bottles and cans, office supplies, packages and containers, among others.
  • a cross-section of part is evaluated under a microscope, in order to assess the microstructure and chemical composition across the grain.
  • the build layers and/or forged product microstructure are visible, along with the grain orientation, and contrast with the different material and/or microstructure of the substrate first material (e.g., generally wrought structure, since in some instances, this is non-additively manufactured).
  • chemistry can be analytically evaluated and confirmed (e.g., to be two or more different materials) via EDF or ICP, for example.
  • Products made in accordance with the methods described above may comprise a first zone comprising a core, and a second zone comprising a shell, where the shell at least partially covers the core, at least one of the core and the shell comprises a metallic material, and the core and the shell comprise one of a columnar structure and an equiaxed structure. See, for instance, Figures 8A-8C.
  • the shell may be an additively manufactured portion as described above.
  • the shell comprises a plurality of additively manufactured layers.
  • the first zone comprises an equiaxed structure.
  • the second zone comprises a columnar structure.
  • the first zone comprises a wrought microstructure.
  • the second zone comprises a wrought microstructure.
  • the product comprises a transition zone, and the transition zone connects the first zone to the second zone.
  • the transition zone comprises a mixture of equiaxed grains and columnar grains (e.g., in a gradient from a zone comprising columnar grains to a zone comprising equiaxed grains).
  • the core is in the form of an elongated substrate. In one embodiment, the core is in the form of an axisymmetric substrate. In one embodiment, the core is in the form of a solid round bar, or a hollow tube. In one embodiment, the core is in the form of a cast product, a wrought product, or an additively manufactured product. In one embodiment, the core is in the form of a substrate comprising a cross-sectional shape of one or more of a square, an octagon, a hexagon, a pentagon, a triangle, an ellipse, a circle, an oval, and combinations thereof.
  • the second zone covers at least a portion of the surface area of the core. In one embodiment, the second zone covers at least 50% of the surface area of the core. In another embodiment, the second zone covers at least 75% of the surface area of the core. In yet another embodiment, the second zone covers at least 85% of the surface area of the core. In another embodiment, the second zone covers at least 95% of the surface area of the core. In yet another embodiment, the second zone covers at least 99% of the surface area of the core. In one embodiment, the second zone covers the entirety of the surface area of the core.
  • the core comprises a first metallic material and the shell comprises a second metallic material.
  • the first metallic material is different from the second metallic material.
  • the first metallic material comprises a titanium alloy, an aluminum alloy, a nickel alloy, a steel, and a stainless steel, and combinations thereof.
  • the second metallic material comprises a titanium alloy, an aluminum alloy, a nickel alloy, a steel, and a stainless steel, and combinations thereof.
  • a product is an AM hybrid preform. In one embodiment, a product is an AM hybrid part. In one embodiment, a product is a worked hybrid part. In one embodiment, a product is an aerospace component, wherein the aerospace component is one of a hub, a disk, and a blisk.
  • Figure 1A depicts an embodiment of a method for producing a worked hybrid part.
  • Figure IB depicts an embodiment of a method for producing a hybrid AM part.
  • Figure 1C depicts a schematic flow chart of various embodiments of the present methods, depicting the building, forging, annealing, machining, and surface finishing steps in accordance with one or more embodiments of the present disclosure.
  • Figure 2 is an image depicting a perspective side view and two plan views of three hybrid AM builds, in accordance with one or more embodiments of the present disclosure.
  • the first material forming the elongated substrate is configured as a rod (solid rod) having a circular cross-section
  • the AM build (EBAM) is depicted in a central region of the elongated substrate.
  • the AM build of the second material is configured perimetrically about the outer diameter of the region of the elongated substrate.
  • the AM build is configured in a circumferential pattern, where the AM deposition paths are configured adjacent and/or overlapping with each other (at least partially) to build up the size of AM hybrid build in a radial direction.
  • the individual beads are visible on the hybrid part, further illustrating the circumferential build of the second material onto the first material (e.g., while rotating the elongated substrate and/or while rotating the additive head (e.g., energy source and feed material) around the elongated substrate.
  • the additive head e.g., energy source and feed material
  • Figures 3 A - 6B correspond to a computational modeling trial that was completed, in which varying material types and configurations of elongated substrate and additive deposition were evaluated under a forging simulation, such that the resulting deformation (e.g., illustrating mass flow directions) was generated, in accordance with one or more embodiments of the present disclosure.
  • FIGs 3 A -3B depict an embodiment of the hybrid AM preform and resulting forging simulation, in which the AM hybrid preform is configured from an elongated substrate (solid rod) of a first material and an AM build circumferentially configured on the elongated substrate of the second material, where the first and second materials are the same alloy (e.g., but can be configured to have different microstructures based on how each portion was configured (e.g., elongated substrate having a wrought structure based on extruded or cast structure) vs. non-wrought structure that is characteristic of AM deposited materials).
  • the first and second materials are the same alloy (e.g., but can be configured to have different microstructures based on how each portion was configured (e.g., elongated substrate having a wrought structure based on extruded or cast structure) vs. non-wrought structure that is characteristic of AM deposited materials).
  • FIG. 3B As shown in Figure 3B, after AM depositing, but before forging, the portions of the elongated substrate that are not covered with AM material were removed.
  • Figure 3A there are two paths that are roughly depicted on the as-forged part (before machining, annealing, or surface finishing) - the line which depicts the central core of the as- machined, final hybrid part, and the estimated flow path of material from the elongated substrate into the final hybrid part (e.g., in a generally outward direction surrounding the central core), in accordance with one or more embodiments of the present disclosure.
  • FIGS 4A -4B depict an embodiment of the hybrid AM preform and resulting forging simulation, in which the AM hybrid preform is configured from an elongated substrate (solid rod) of a first material and an AM build circumferentially configured on the elongated substrate of the second material, where the first and second materials are different alloys.
  • FIGs 5 A -5B depict an embodiment of the hybrid AM preform and resulting forging simulation, in which the AM hybrid preform is configured from an elongated substrate (solid rod) of a first material and an AM build circumferentially configured on the elongated substrate of the second material, where the first and second materials are different alloys.
  • this embodiment has a larger diameter of the elongated substrate and results in a corresponding larger surface area of the central bore that is configured with the first material.
  • Figure 6A-6B depicts a close-up perspective view of another embodiment of the instant disclosure, in which the elongated substrate is configured with a tailored profile/geometry specifically configured to undergo the forging deformation of the simulation.
  • the resulting forged part is configured with a generally uniform thickness of the first material at each position around the central core (hole), in accordance with the present disclosure.
  • Figure 7 depicts the results of a forging simulation which indicate the distribution of strain realized throughout the AM hybrid preform as a result of the forging process. As can be seen, the strain is not uniform and varies throughout the component. The realized strain in the part is a result of AM preform design and final geometry.
  • Figure 8A shows a schematic of an additively manufactured product (e.g., a hybrid AM preform; a hybrid AM part).
  • an additively manufactured product e.g., a hybrid AM preform; a hybrid AM part.
  • Figure 8B shows a cross-sectional schematic of the additively manufactured product of Figure 8 A.
  • Figure 8C shows a cross-sectional schematic of a microstructure of the additively manufactured product of Figure 8 A.
  • the additively manufactured product (800) may be a hybrid AM preform (e.g., for subsequent working and other processing), or may be a hybrid AM part (e.g., for subsequent processing, absent of working).
  • the additively manufactured product (800) is comprised of a substrate (810) and an additively manufactured portion (820).
  • the substrate (810) is shown as being in the form of a solid round bar, although it may be in other forms, such as, for instance, a hollow tube.
  • the cross-sectional shape of substrate (810) is circular and therefore axisymmetric, although other cross-sectional shapes may be used (e.g., a square, an octagon, a hexagon, a pentagon, a triangle, an ellipse, a circle, an oval, and combinations thereof).
  • the additively manufactured portion is shown as being comprised of a plurality of additively manufactured layers in the build direction (i.e., the Z-direction) (825) of the additively manufactured product (800).
  • a plurality of layers may be produced, for instance, by rotating the substrate (810) during deposition of an additive manufacturing process.
  • such an additively manufactured product (800) may comprise a plurality of layers in the build direction, as well as a plurality of additively manufactured layers extending from the substrate (800) to the outer portion of additively manufactured portion (820).
  • the additively manufactured product (800) comprises a first zone (830), a transition zone (840), and a second zone (850).
  • the first zone (830) is a core in the form of a circular substrate (810).
  • the cross-sectional schematic of the additively manufactured product (800) shows the third zone (850) as being comprised of a plurality of additively manufactured layers (845).
  • the transition zone (840) is shown as connecting the first zone (830) to the second zone (850).
  • the transition zone (840) may be formed, for instance, due to the deposition of material on the substrate via additive manufacturing.
  • FIG 8C a cross-sectional schematic of a microstructure of the additively manufactured product (800) of Figure 8A is shown.
  • the additively manufactured product (800) is shown as being comprised of a plurality of microstructures.
  • the first zone (830) is shown as being comprised of an equiaxed structure (835) (defined above)
  • the second zone (850) is shown as being comprised of a columnar structure (855) (defined above).
  • the columnar grains of the columnar structure (855) extend away from the first zone (830).
  • the columnar structure (855) may be realized in an as-built condition, or in a condition realized after one or more post processing steps (e.g., working and/or thermally treating).
  • Columnar structures may be useful in certain applications as columnar grains may realize improved damage tolerance properties (e.g., creep and/or fatigue) relative to equiaxed structures.
  • such columnar structures may be useful for components used in rotational applications.
  • Non- limiting examples of such components may include components such as hubs, disks, and blisks.
  • First region 28 e.g., high strength
  • Second region (e.g., high temperature) 30
  • Final part e.g., post machining, annealing, and/or surface treating, completing one or more of these steps

Abstract

La présente invention concerne des procédés de production de pièces hybrides par FA et des produits fabriqués par ceux-ci. Les procédés comprennent généralement la fabrication additive (FA) d'une pièce de FA hybride (par exemple une préforme) par dépôt, par fabrication additive, d'un matériau autour d'au moins une partie d'une surface externe d'un substrat. La pièce de FA hybride peut ensuite être traitée (par exemple usinée, traitée thermiquement, modifiée en surface). La pièce de FA hybride peut être une préforme de FA hybride qui peut être ensuite travaillée (par exemple, forgée) pour produire une pièce hybride travaillée. De même, la pièce hybride travaillée peut être traitée ultérieurement.
PCT/US2018/047349 2017-08-23 2018-08-21 Constituants à matériaux multiples et procédés pour leur fabrication WO2019040509A1 (fr)

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US201762549091P 2017-08-23 2017-08-23
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US201862623328P 2018-01-29 2018-01-29
US62/623,328 2018-01-29

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EP3581668A1 (fr) * 2018-06-12 2019-12-18 MTU Aero Engines GmbH Procédé de fabrication d'un composant à partir de gamma-tial et composant fabriqué correspondant
EP3848144A1 (fr) * 2020-01-08 2021-07-14 The Boeing Company Procédé de dépôt par friction-malaxage d'additif pour fabriquer un article
EP4238671A1 (fr) * 2022-03-04 2023-09-06 Goodrich Corporation Systèmes et procédés de fabrication de composants de train d'atterrissage à l'aide de titane

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EP2962788A1 (fr) * 2014-06-17 2016-01-06 United Technologies Corporation Procédé de fabrication par méthode additive hybride
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US20140242400A1 (en) * 2013-02-28 2014-08-28 Alstom Technology Ltd Method for manufacturing a hybrid component
EP2962788A1 (fr) * 2014-06-17 2016-01-06 United Technologies Corporation Procédé de fabrication par méthode additive hybride
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EP3581668A1 (fr) * 2018-06-12 2019-12-18 MTU Aero Engines GmbH Procédé de fabrication d'un composant à partir de gamma-tial et composant fabriqué correspondant
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EP4238671A1 (fr) * 2022-03-04 2023-09-06 Goodrich Corporation Systèmes et procédés de fabrication de composants de train d'atterrissage à l'aide de titane

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