• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    Disclosed is a nickel alloy for direct metal laser melting. The alloy contains a powder comprising about 1.6 to about 2.8 weight percent aluminum, about 2.2 to about 2.4 weight percent titanium, about 1.25 to about 2.05 weight percent. Niobium, about 22.2 to about 22.8 weight percent chromium, about 8.5 to about 19.5 weight percent cobalt, about 1.8 to about 2.2 weight percent tungsten, about 0, 07 to about 0.1 wt .-% carbon, about 0.002 to about 0.015 wt .-% boron and about 40 to about 70 wt .-% nickel. In addition, methods and articles (102) are disclosed.
    公开号:CH710177A2
    申请号:CH01324/15
    申请日:2015-09-11
    公开日:2016-03-31
    发明作者:Yan Cui；Ganjiang Feng；Srikanth Chandrudu Kottilingam；Shan Liu；David Edward Schick
    申请人:Gen Electric；
    IPC主号:
    专利说明:

    BACKGROUND TO THE INVENTION
    The invention generally relates to materials for direct metal laser melting (DMLM) techniques.
    [0002] DMLM, sometimes referred to as Selective Laser Melting (SLM), is an additive manufacturing technology that can be used to make parts with complex geometries, but which can dispense with the tooling techniques common in non-additive manufacturing techniques. Often, DMLM uses 3D CAD data in a digital format in conjunction with a power source, usually a high power laser, to produce three-dimensional metal or alloy parts by fusing particles of metallic powders or alloy powders. Due to this fact, the quality of the DMLM powder used will directly affect the physical properties and the quality of the resulting part.
    Previous embodiments have utilized a number of materials for DMLM. For example, so far stainless steel, aluminum, martensitaushärtender (or tool) steel, titanium alloys and cobalt chrome were used. However, there is a need to develop a better DMLM powder.
    BRIEF SUMMARY OF THE INVENTION
    Embodiments of the invention described herein may include a nickel alloy for direct metal laser melting, the nickel alloy comprising: a powder containing: about 1.6 to about 2.8 weight percent aluminum; about 2.2 to about 2.4 weight percent titanium; about 1.25 to about 2.05 weight percent niobium; from about 22.2 to about 22.8 weight percent chromium; from about 8.5 to about 19.5 weight percent cobalt; about 1.8 to about 2.2 wt.% tungsten; from about 0.07 to about 0.1 weight percent carbon; from about 0.002 to about 0.015 weight percent boron; and about 40 to about 70 wt% nickel.
    Embodiments of the invention may further include a method of making an article, the method including: providing a 3D design file of the article; and repeatedly applying a source of energy to a powder by means of a 3D printer layer by layer according to the 3D design file, wherein the powder contains: about 1.6 to about 2.8 weight percent aluminum; about 2.2 to about 2.4 weight percent titanium; about 1.25 to about 2.05 weight percent niobium; from about 22.2 to about 22.8 weight percent chromium; from about 8.5 to about 19.5 weight percent cobalt; about 1.8 to about 2.2 wt.% tungsten; from about 0.07 to about 0.1 weight percent carbon; from about 0.002 to about 0.015 weight percent boron; and about 40 to about 70 wt% nickel.
    BRIEF DESCRIPTION OF THE DRAWING
    These and other features of the disclosure will become more apparent from the following detailed description of the various embodiments of the invention, taken in conjunction with the accompanying drawings, which illustrate various aspects of the invention.
    FIG. 1 shows a block diagram of an additive manufacturing process that uses a non-transitory computer-readable storage medium that stores code that represents an article, in accordance with embodiments of the disclosure.
    It should be noted that the drawings may not be to scale. The drawings are merely illustrative of typical aspects of the invention and therefore should not be taken as limiting the scope of the invention. In the drawings, like reference numerals designate like elements. The detailed description will explain, with reference to the drawings, embodiments of the invention together with advantages and features.
    DETAILED DESCRIPTION OF THE INVENTION
    In the following, a nickel alloy for use in direct metal laser melting is disclosed. The nickel alloy can be used advantageously in connection with welding, sintering and laser melting. The nickel alloy is in the form of a powder, the powder containing aluminum, titanium, niobium, chromium, cobalt, tungsten, carbon, boron and nickel. The unique combination of proportions of aluminum and titanium provides improved characteristics in terms of short-term strength, creep, corrosion resistance and heat corrosion resistance.
    In some embodiments, the nickel alloy may contain about 1.6 to about 2.8 weight percent aluminum and about 2.2 to about 2.4 weight percent titanium. This chemical composition allows a good balance between high heat resistance and a degree of weldability. These and other features will become more apparent in light of the descriptions below.
    In some embodiments, the nickel alloy powder may further contain the following proportions; about 1.25 to about 2.05 weight percent niobium; from about 22.2 to about 22.8 weight percent chromium; from about 8.5 to about 19.5 weight percent cobalt; about 1.8 to about 2.2 wt.% tungsten; from about 0.07 to about 0.1 weight percent carbon; from about 0.002 to about 0.015 weight percent boron; and about 40 to about 70 wt% nickel. In some embodiments, the nickel alloy powder contains small particles. For example, the dimension of the particles may be about 44 μm or less. Due to the heat source and the ease of melting or sintering the particles of the powder, this dimensional parameter supports suitability for use with DMLM. In a further embodiment, the particles may have a diameter of greater than or equal to about 10 microns. It should be understood that these dimensional ranges may vary by 5 microns, and that particles of the powder within the dimensional range may be synthesized or filtered to a particular size by any currently known or future developed technique. In some embodiments, a mesh of a specific mesh size can be used to filter the particles, and in some cases, a mesh of the largest mesh size and a mesh of the smallest mesh size can be used to provide an upper limit and a lower limit on the diameter of the mesh Specify particles of nickel alloy powder.
    In further embodiments, the nickel alloy powder disclosed above is used in a method of making an article. In particular, the method may include providing a 3D design file of the article. Subsequently, the above-described alloy powder is repeatedly coated in a layered manner by means of a 3D printer, and an energy source is applied to the powder. As discussed above, the powder used in the manufacturing process produces an article having a short-term strength characteristic as measured by a stress range percentage and a number of cycles to crack nucleation. The article also has the characteristics of low creep, a characteristic of high corrosion resistance, and a high heat corrosion resistance characteristic. Articles according to embodiments of the present invention are stronger than conventional alloys because of these characteristics, for example, but not limited to, HastX, IN617 and IN625.
    The article of the manufacturing process can be used in a number of applications. For example, the article can be used as a component of a turbine. The article can be used for first stage and later stage turbine nozzle applications and for use in large blades for turbines.
    To illustrate an exemplary additive manufacturing method, such as DMLM, FIG. 1 shows a schematic block diagram of an illustrative computer-aided additive manufacturing system 100 for creating an article 102. In this example, the system 100 is set up for DMLM. Of course, the general teachings of the disclosure apply equally to other forms of additive manufacturing. The article 102 is shown as a double-walled turbine element; however, it should be understood that the additive manufacturing process readily adapts to produce any article. The AM system 100 generally includes a computer-aided additive manufacturing (AM) control system 104 and an AM printer 106. The AM system 100 executes, as described below, a code 120 that includes a set of includes computer executable instructions that define the article 102 to physically generate the object using the AM printer 106. Each AM process may use different raw materials, for example, in the form of a fine powder, a liquid (eg, polymers), a film, and the like, of which a reservoir 110 may be stocked in a chamber 110 of the AM printer 106, including the nickel alloy powder disclosed above , As can be seen, an applicator 112 can produce a thin layer of raw material 114 which is spread as the unprinted web, from which each successive layer of the final object is created. In other cases, the applicator 112 may apply or print the next layer as defined by the code 120 directly onto a previous layer, the material being, for example, a polymer. In the example shown, a laser or electron beam 116, as defined by the code 120, fuses particles for each layer. Different parts of the AM printer 106 may move to accommodate the addition of each new layer, e.g. For example, a build platform 118 may sink, and / or the chamber 110 and / or applicator 112 may rise after each shift.
    The AM control system 104 is shown as computer program code performed on the computer 130. For this purpose, the computer 130 is shown having a memory 132, a processor 134, an input / output (I / O) interface 136, and a bus 138. Further, the computer 130 is shown communicating with an external input-output (I / O) device / resource 140 and a memory system 142. Generally, the processor 134 executes computer program code, e.g., computer code, in response to instructions from the code 120 representing the article 102 as described herein. the AM control system 104 stored in the random access memory 132 and / or in the storage system 142. During execution of the computer program code, processor 134 may read in and / or read data from memory 132, memory system 142, input-output device 140, and / or AM printer 106. The bus 138 provides a communication link between each of the components in the computer 130, and the input-output device 140 may include any means (eg, a keyboard, a pointing device, a display device, and the like) that allows a user to navigate Computer 140 interactive to use. The computer 130 merely illustrates different possible combinations of hardware and software. For example, the processor 134 may include a single processing unit or may be distributed to one or more processing units at one or more locations, such as a client and server. Likewise, memory 132 and / or storage system 142 may reside at one or more physical sites. Memory 132 and / or storage system 142 may include any combination of various types of non-transitory computer-readable storage media, such as magnetic media, optical media, random access memory (RAM), read-only memory (ROM), and the like. The computer 130 may include any type of computing device, such as a network server, a desktop computer, a laptop, a hand-held device, a cell phone, a pager, a personal data assistant (PDA), and the like.
    Additive manufacturing methods begin with a non-transitory computer-readable storage medium (e.g., memory 132, storage system 142, and the like) that stores code 120 that represents article 102. As noted, the code 120 includes a set of computer-executable instructions that define the article 102 that may be used to physically generate the object as the code executes the system 100. For example, the code 120 may include a well-defined 3D model of the object 102, and may be any of a wide variety of well-known computer aided design (CAD) software systems, such as AutoCAD®, TurboCAD®, DesignCAD 3D Max, and the like. be generated. In this regard, the code 120 may use any currently known or future developed file format. For example, the code 120 may be in the form of the Standard Tessellation Language (STL) created for stereolithography modeling CAD programs of 3D systems or an additive manufacturing file (AMF) that is a standard of the American Society of Mechanical Engineers (ASME). which is an extensible markup language (XML) based format designed to allow any CAD software to describe the shape and composition of any three-dimensional object to be fabricated on any AM printer. The code 120 may be translated as required between various formats, converted into a set of data signals and transmitted, received as a set of data signals and converted into code, stored and the like. The code 120 may be an input to the system 100 and may be from a part developer, an intellectual property (IP) provider, a design company, the user or owner of the system 100, or other sources. In either case, the AM control system 104 executes the code 120, the article 102, into a series of thin layers which it assembles by means of the AM printer 106 in successive layers of liquid, powder, foil, or other material. In the example of DMLM, each layer is fused to the exact geometry defined by the code 120 and merged with the previous layer. Thereafter, the article 102 may be subjected to any surface treatment, e.g. a finishing, sealing, polishing, mounting on another part of the burner tip and the like.
    The terminology used herein is merely for the convenience of explanation of specific embodiments and is not intended to limit the description. As used herein, the singular forms of definite and indefinite articles are also intended to include plural forms, unless the context expressly indicates otherwise. It is further understood that the terms "comprising" and / or "having" as used in this specification specify the presence of said features, integers, steps, operations, operations, elements, and / or components, but not the presence or addition of individual ones or several other features, integers, steps, operations, operations, elements, components and / or groups thereof.
    While the invention has been described in detail only by means of a limited number of embodiments, it should be readily understood that the invention is not limited to such described embodiments. Rather, the invention may be modified to embody any number of variations, modifications, substitutions, or equivalent arrangements not heretofore described, which, however, are within the scope of the invention. While various embodiments of the invention have been described, it is further understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be considered limited by the foregoing description, but rather is limited only by the scope of the appended claims.
    Disclosed is a nickel alloy for direct metal laser melting. The alloy includes a powder comprising about 1.6 to about 2.8 weight percent aluminum, about 2.2 to about 2.4 weight percent titanium, about 1.25 to about 2.05 weight percent. Niobium, about 22.2 to about 22.8 weight percent chromium, about 8.5 to about 19.5 weight percent cobalt, about 1.8 to about 2.2 weight percent tungsten, about 0, 07 to about 0.1 wt .-% carbon, about 0.002 to about 0.015 wt .-% boron and about 40 to about 70 wt .-% nickel. In addition, methods and articles (102) are disclosed.
    LIST OF REFERENCE NUMBERS
    [0020]<Tb> 100 <September> AM system<Tb> 102 <September> Article<Tb> 104 <September> AM-control system<Tb> 106 <September> Printers<Tb> 110 <September> Chamber<Tb> 112 <September> Applicator<Tb> 114 <September> Raw Material<Tb> 116 <September> electron<Tb> 118 <September> building platform<Tb> 120 <September> Code<Tb> 130 <September> Computers<Tb> 132 <September> Memory<Tb> 134 <September> Processor<Tb> 136 <September> input / output (I / O) interface<Tb> 138 <September> Bus<Tb> 140 <September> input / output (I / O) device<Tb> 142 <September> Storage System
    权利要求:
    Claims (8)
    [1]
    1. Nickel alloy for direct metal laser melting, the nickel alloy comprising:a powder that contains:about 1.6 to about 2.8 weight percent aluminum;about 2.2 to about 2.4 weight percent titanium;about 1.25 to about 2.05 weight percent niobium;about 22.2 to about 22.8 wt% chromium;about 8.5 to about 19.5 weight percent cobalt;about 1.8 to about 2.2 wt.% tungsten;about 0.07 to about 0.1 weight percent carbon;about 0.002 to about 0.015 weight percent boron; andabout 40 to about 70 weight percent nickel.
    [2]
    2. Nickel alloy according to claim 1, wherein the powder contains particles with a dimension of less than or equal to about 44 microns.
    [3]
    3. Nickel alloy according to claim 2, wherein the powder contains particles having a dimension of greater than or equal to about 10 microns.
    [4]
    4. A method of making an article (102), the method comprising:Providing a 3D design file of the article (102); andLayer by layer repeated application of an energy source to a powder by means of a 3D printer (106) according to the 3D design file, wherein the powder contains:about 1.6 to about 2.8 weight percent aluminum;about 2.2 to about 2.4 weight percent titanium;about 1.25 to about 2.05 weight percent niobium;about 22.2 to about 22.8 wt% chromium;about 8.5 to about 19.5 weight percent cobalt;about 1.8 to about 2.2 wt.% tungsten;about 0.07 to about 0.1 weight percent carbon;about 0.002 to about 0.015 weight percent boron; andabout 40 to about 70 weight percent nickel.
    [5]
    5. The method of claim 4, wherein the powder contains particles having a dimension of less than or equal to about 44 microns.
    [6]
    6. The method of claim 5, wherein the powder contains particles having a size of greater than or equal to about 10 microns.
    [7]
    The method of claim 6, wherein the applying includes welding, sintering or laser melting.
    [8]
    A method according to any one of the preceding claims, wherein the article (102) includes a turbine component.
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    同族专利:
    公开号 | 公开日
    JP2016060967A|2016-04-25|
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    引用文献:
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    法律状态:
    2017-03-15| NV| New agent|Representative=s name: GENERAL ELECTRIC TECHNOLOGY GMBH GLOBAL PATENT, CH |
    2018-08-15| AZW| Rejection (application)|
    优先权:
    申请号 | 申请日 | 专利标题
    US14/491,471|US20160082511A1|2014-09-19|2014-09-19|Materials for direct metal laser melting|
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