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Method and composition for metal free form fabrication

a technology of free form fabrication and metal, applied in the direction of additive manufacturing, process efficiency improvement, transportation and packaging, etc., can solve the problems of difficult or impossible to achieve parts by many prior art processes

Inactive Publication Date: 2005-09-01
THE BOEING CO +1
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

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Problems solved by technology

Metal free form fabrication by layered-build powder processes such as selective laser sintering (SLS) can be utilized to fabricate parts which have a configuration which would make the parts difficult or impossible to achieve by many prior art processes.

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  • Method and composition for metal free form fabrication
  • Method and composition for metal free form fabrication
  • Method and composition for metal free form fabrication

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Embodiment Construction

[0011] This embodiment of the present invention relates to metal free form fabrication and more specifically to accomplishing the free form fabrication using a layered-build powder process, such as selective laser sintering (SLS), of a blend of metallic and polymer particles to form a green body, followed by thermal consolidation of the green body into a solid metal part. A basic method that presently exists in the prior art is disclosed in three U.S. patents, namely U.S. Pat. No. 5,745,834 (Bampton et al), U.S. Pat. No. 5,932,055 (Newell et al) and U.S. Pat. No. 6,365,093 (Ryang et al).

[0012] This embodiment of the present invention is directed toward making improvements in this technology relating to the formulation of the blend itself, and also relating the methods disclosed in those patents. Accordingly, it is believed that a clearer understanding of the present invention can be obtained by first describing the formulation and methods of the prior art as presented in these thre...

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Abstract

A method of direct metal fabrication to form a metal part which has a relative density of at least 96%. There is provided a powder blend which comprises a parent metal alloy, a powdered lower-melting-temperature alloy that comprises greater than 10% of total weight of the powder blend, and an organic polymer component (a thermoplastic polymer and a thermosetting polymer) that comprises less than 3% by weight of a total weight of the powdered blend. There is a laser-build powder processing operation (a selective laser sintering (SLS) operation) to fabricate a green body. The green body is then placed in a furnace and the temperature raised to sufficiently high temperature to perform a supersolidus liquid phase sintering operation to form the metal part.

Description

FIELD OF THE INVENTION [0001] The present invention relates to metal free form fabrication, and more particularly to the formation of a green part by layered-build powder processes, such as selective laser sintering and subjecting the green part to a thermal cycle to form a finished part having a relatively high density. BACKGROUND ART [0002] Metal free form fabrication by layered-build powder processes such as selective laser sintering (SLS) can be utilized to fabricate parts which have a configuration which would make the parts difficult or impossible to achieve by many prior art processes. The formulation which is used in this process is a powdered blend of a parent alloy, a lower-melting-temperature alloy, and polymer particles. The lower-melting-temperature alloy may have substantially the same ingredients as the parent alloy, with the addition of a minor amount of a eutectic forming element in the lower-melting-temperature alloy. A thermoplastic polymer, such as nylon, functio...

Claims

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Application Information

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IPC IPC(8): B22F1/00B22F1/10B22F1/103B22F3/105B22F7/00
CPCB22F1/0003B22F1/0059B22F3/1055B22F2001/0066B22F2998/10B22F3/1035B22F3/15B33Y70/00B33Y10/00Y02P10/25B22F1/103B22F1/10B22F10/28B22F1/00
Inventor CANZONA, GUIDOGOODIN, WESLEY D.BAMPTON, CLIFFORD C.
Owner THE BOEING CO
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