Additive manufacturing hot isostatic pressure process for manufacturing parts

Abstract

Continuous layers are printed, where each layer comprises at least one layer of components, and where the layers of components are surrounded by a hot isostatic pressing (HIP) jacketed sheet. The HIP sheath forms a sealed container, and components within the HIP sheath are handled in the HIP.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 542,423, filed on October 4, 2023, and U.S. Provisional Patent Application No. 63 / 420,257, filed on October 28, 2022, each of which is incorporated herein by reference in its entirety.

[0003] Statement Regarding Federally Sponsored Research or Development

[0004] Certain aspects of the invention were developed under the support of the U.S. Department of Energy (DOE). The U.S. government has certain rights in some of these inventions. Background Art 1). Technical Field

[0005] The present invention relates to a method of forming a component and an article of manufacture for forming a component.

[0006] 2). Discussion of Related Art

[0007] In recent years, the nuclear power industry has been exploring the use of conventional powder metallurgy (PM) and hot isostatic pressing (HIP) techniques to fabricate large near - net - shape parts for high - pressure components and other power - generation - related applications. Powder metallurgy has many advantages over other large - scale manufacturing methods (such as casting, welding, forging, etc.), including fabricating near - net - shaped (NNS) components with controlled chemistry and improved microstructures in the components.

[0008] As shown in FIGS. 1(a) and 1(b), large parts are fabricated in a PM - HIP process by first fabricating a conformal HIP envelope 40 or die that is slightly larger in size than the shape of the component 42. The HIP envelope 40 is typically fabricated by welding a thin low - carbon steel sheet to an approximate shape of the component 42 and equipping the die with a series of ports through which metal powder can be introduced. Then, the HIP envelope 40 is uniformly filled with metal powder, evacuated, and sealed. After leak - checking the HIP envelope 40 to confirm the welding quality, the HIP envelope 40 is placed in a HIP for processing, which involves applying heat and pressure. During this process, the HIP envelope 40 compresses the metal powder, which sinters and consolidates the metal powder to full density. Typical HIP process parameters range from 500 °C to 1200 °C and a pressure of 7 ksi to 45 ksi. After the HIP process, the HIP envelope 40 is removed from the consolidated NNS component 42 by machining or acid - etching the low - carbon steel.

[0009] Typically, the design and manufacture of the HIP can 40 is critical to the successful manufacture of component 42 using PM-HIP technology. The manufacture of the HIP can is an engineering and labor-intensive process that involves designing and manufacturing a conformal mold that collapses under high pressure and temperature. In addition, the geometry of component 42 manufactured in this process is limited by the geometry of the HIP can 40 and the ability to uniformly fill the mold with metal powder, which is critical to the quality of component 42.

[0010] To overcome the limitations of the prior art in manufacturing components using PM-HIP technology, a new method is needed that can reduce the unit cost associated with manufacturing geometrically complex HIP cans and improve the uniform filling density of the metal powder within the HIP can 40. Ideally, the method would have the following characteristics:

[0011] (A) A conformal welded HIP can 40 is not required during the manufacture of component 42. As shown in Fig. 1(a), even a relatively simple HIP can 40 can be made by welding together a large number of individual low-carbon steel pieces 44. In addition to the engineering costs associated with the design of the HIP can 40, there are significant labor costs associated with the manufacture and final assembly of the parts of the HIP can 40, and the more complex the geometry of component 42, the higher the labor and material costs associated with the manufacture of the HIP can 40.

[0012] (B) Provide qualified data on the uniformity of the metal powder filling density in the HIP can 40. Uniform filling of the HIP can 40 with metal powder is critical to the quality of component 42. Metal powders used in powder metallurgy have a wide particle size distribution (PSD) to increase the bulk density of the powder in the HIP can 40. During the filling process, mechanical vibration is used to increase the filling density, but this vibration also causes size separation in the powder filling. In addition, in a geometrically complex HIP can 40, there may be variations in the powder filling density, which may affect the quality of the final component. In-process measurement of the local filling density in component 42 would allow a means to qualify the powder filling prior to the HIP process and reduce part-to-part variability. Summary of the Invention

[0013] We describe an additive manufacturing (AM) process that uses a multi-material three-dimensional (3D) printing technique combined with a conventional PM-HIP process to manufacture geometrically complex components. In addition, the technique allows for real-time measurement of the individual powder masses throughout the 3D printing process, which gives a direct measurement of the filling density of the components within the HIP can. Below, we describe two different component manufacturing methods:

[0014] Multi-material 3D printing techniques for manufacturing components using 3D printed HIP jackets allow for the 3D printing of both components and HIP jackets within the same build box. Post-print heat treatment of the 3D powder structure results in the fabrication of a fully dense 3D printed HIP jacket around the unsintered powder structure, which is then processed in a conventional HIP cycle. This method eliminates the need to fabricate a conformal welded HIP jacket, but is limited by the size of the furnace used to heat treat the build box.

[0015] Component manufacturing can be carried out using non-conformal welded HIP jackets. Multi-material 3D printing techniques allow for the 3D printing of components and support powder within non-conformal welded HIP jackets. After printing is complete, the jacket is degassed and sealed for HIP processing. During the HIP process, the metal powder is sintered and consolidated under pressure transmitted through the support powder. The support powder can remain loose during the HIP process or can alternatively be sintered together with the metal powder, requiring easy separation from the component after HIP processing. This method eliminates the need to fabricate a conformal HIP jacket and is only limited by the size of the multi-material 3D printer and the size of the HIP.

[0016] These manufacturing processes not only allow for the fabrication of complex parts and in-process monitoring of 3D powder packing density, but also have the potential to reduce the unit cost of PM-HIP parts by eliminating the fabrication of conformal welded HIP jackets in the PM-HIP manufacturing process.

[0017] The present invention provides a method of forming a component, the method comprising printing successive layers, wherein each layer comprises at least one layer of the component, and wherein the layers of the component are surrounded by sheets of a hot isostatic pressing (HIP) jacket.

[0018] The present invention also provides a method of forming a component, the method comprising positioning a HIP jacket forming a sealed container and a component within the HIP jacket in a HIP, the component comprising successive printed layers, wherein each layer comprises at least one layer of the component, and wherein the layers of the component are surrounded by sheets of the HIP jacket, using the HIP to increase the temperature within the HIP jacket and the pressure outside the HIP jacket to deform the HIP jacket, removing the HIP jacket and the component within the HIP jacket from the HIP, and removing the component from the HIP jacket.

[0019] The present invention also provides an article comprising a HIP jacket forming a sealed container and a component within the HIP jacket, the component comprising successive printed layers, wherein each layer comprises at least one layer of the component, and wherein the layers of the component are surrounded by sheets of the HIP jacket, wherein the HIP jacket is insertable into a HIP to increase the pressure on the outside of the HIP jacket, thereby deforming the HIP jacket. Description of the Drawings

[0020] The present invention is further described by way of example with reference to the accompanying drawings, in which:

[0021] Figure 1(a) is a perspective view of a welded HIP jacket;

[0022] Figure 1(b) is a perspective view of the component;

[0023] Figures 2(a) to 2(c) is a perspective view of a 3D computer-aided design (CAD) model;

[0024] Figures 3(a) to 3(c) Each shows a perspective view of the corresponding layer of the CAD model and the layer built and printed in 3D;

[0025] Figure 4(a) is a perspective view of the component removed from the support powder;

[0026] Figure 4(b) is a perspective view of the component in Figure 4(a);

[0027] Figure 5(a) is a perspective view of a 3D printer;

[0028] Figure 5(b) is a graph of multi-material printing quality against time.

[0029] Figure 5(c) is a close-up photograph of a multi-material printed layer;

[0030] Figure 6 (a) to 6(j) show the manufacturing of complex components;

[0031] Figures 7.1(a) to 7.1(f) show the manufacturing of components into non-conformal welded HIP jackets using multi-material 3D printing with powder;

[0032] Figures 7.2(a) to 7.2(e) show the use of multi-material 3D printing with powder to manufacture components to form components and HIP jackets in the same build cylinder;

[0033] Figures 8(a) to 10 are perspective views showing a large-scale AM-HIP manufacturing system;

[0034] Figures 11(a) to 11(h) show the manufacturing of refractory components by 3D printing a refractory metal HIP jacket around the component;

[0035] Figure 12 is a top plan view showing alternative cross-sections of the HIP jacket and the part produced therefrom;

[0036] Figures 13(a) to 13(h) show the UHTC manufacturing process;

[0037] Figure 14(a) and 14(b) is a side cross-sectional view of a 3D printed powder component in support powder;

[0038] Figures 15(a) to 15(e) Shows perspective views of the same cylindrical tube manufactured using HIP jackets of different shapes and arrangements within the HIP jacket;

[0039] Figure 16(a) And 16(b) Each shows a pre-HIP CAD model and the expected deformation of the part due to non-isotropic pressure within the HIP jacket after the HIP cycle;

[0040] Figures 17(a) to 17(e) Are various views of parts that are more difficult to manufacture due to their complex geometry;

[0041] Figure 18(a) And 18(b) Are cross-sectional side views of configurations that allow for a more isotropic pressure distribution;

[0042] Figure 19 Is after using Figure 18(a) And 18(b) Perspective view of the part removed from the HIP jacket after manufacturing with the processes in;

[0043] Figure 20 Is a graph showing the viscosity of some glass as a function of temperature;

[0044] Figure 21(a) And 21(b) Are cross-sectional side views of configurations in which the support powder includes a small amount of molten salt;

[0045] Figure 22(a) And 22(b) Are perspective and cross-sectional side views showing a simple cylindrical glass wrap around a powder component tube;

[0046] Figure 23(a) And 23(b) Shows Figure 22(a) And 22(b) Perspective and cross-sectional side views of the same powder component tube in, where the glass material is also located within the center of the tube;

[0047] Figure 24(a) And 24(b) Is a perspective view showing the manufacture of an extremely complex structure;

[0048] Figure 25 Shows a typical HIP process cycle;

[0049] Figure 26 Shows a typical HIP process flow diagram for manufacturing using NNS components with a glass component around the part;

[0050] Figures 27(a) to 27(e)illustrates the manufacture of tubular ball parts by fusing glass in an open HIP capsule; and

[0051] Figures 28(a) to 28(e) is a perspective view of a geometrically complex component that has been manufactured. Detailed Description

[0052] Our multi-material 3D powder printing technology allows for the rapid and structured deposition of multiple materials on a layer-by-layer basis to form a 3D powder structure within a build box. The basic aspects of this technology are the use of "main material", "negative form", and "auxiliary" powders. By convention, the main material powder and the auxiliary powder form a consolidated component after processing (e.g., controlled atmosphere furnace, HIP, etc.), while the negative form powder confines the other powders to a specific shape in each layer. Thus, the negative form powder serves as a support structure for additive manufacturing in the powder bed, which remains loose or is easily removed after processing of the build box. In the following example, a multi-material main material / auxiliary powder component is printed in a negative form support powder. In this example, the component is a copper rotor with soft magnetic composite poles, which is supported by zircon sand.

[0053] As Figure 2(a) , 2(b) and 2(c) show, the selective powder deposition process begins with a multi-material CAD model 46 of the component and all other powders used to fabricate or support the component during the additive manufacturing process. Figure 2(a) shows the CAD model 46 of the rotor printed with the main material and auxiliary powder. Figure 2(b) shows an external view of the supporting negative form powder. The complete 3D powder structure consists of the negative form, main material, and auxiliary powder, where the volume of the CAD model 46 is 100% filled. Figure 2(c) shows the position of the multi-material rotor inside the negative form support block. During the 3D printing process, all materials are deposited layer by layer within the build box, which is slightly larger than the negative form support material shown in Figure 2(b).

[0054] After slicing the CAD model 46, a multi-material 3D printing system control program is used during the AM process to generate and monitor instructions. As Figures 3(a) to 3(c) shown, the powder deposition process is repeated on a layer-by-layer basis to form a 3D multi-material powder component 42 surrounded by a 3D powder support structure. Figure 3(a) shows a constructed layer 58, which is one of the top layers of the rotor assembly, along with a portion of the negative form zircon that forms the support powder 48. Figure 3(b) shows a constructed layer 65, which shows the top layer of copper encapsulating the rotor poles of the component 42. Figure 3(c) shows a constructed layer 79, which is the top of the negative form support powder 48 covering the 3D powdered rotor structure. The print consists of 90 layers and takes approximately 18 hours to complete a 0.5 mm thick layer. The 3D powder structure within the build box maintains its shape during the printing process without using any binder and is fully supported by the negative form support sand within the build box.

[0055] After the 3D powder printing process, the rotor is consolidated using sintering heat treatment under a controlled atmosphere. During the first part of the heat treatment cycle, the entire build box is heated to the sintering temperature at a controlled rate. After soaking at the sintering temperature, the build box is slowly cooled to room temperature. Upon cooling, the multi-material part 42 is easily removed from the loose zircon sand. Figure 4(a) shows the rotor in the build box after heat treatment. The entire assembly is easily removed from the zircon powder, which does not sinter during the entire heat treatment procedure. Figure 4(b) shows the same part 42 after machining the top layer of copper from the rotor surface to expose the soft magnetic composite poles.

[0056] Unlike other AM systems, our multi-material printer can print many types of powders during the deposition process, including most low-cost powder metallurgy feedstocks, molding sands, ceramics, and many other powders, as long as there are no flow restrictions through the print head. Additionally, the mass of the build box is measured in real time during the printing process and associated with the specific powder being printed. This allows for in-process quality identification and direct measurement of any part-to-part variations during the AM process. Typically, for the same multi-material print toolpath, the powder mass variation of the main material part is less than 1%. Figure 5(a) shows a printer called the "GL-250 Multi-Material 3D Printer" used by Grid Logic Inc. in Lapeer, Michigan. This commercial multi-material additive manufacturing system is capable of printing three different powders in an orderly manner. Printer-specific instructions are automatically generated from the input CAD data with little or no operator input. The powder deposition process can be carried out in the build cylinder or on any sufficiently stable surface. Figure 5(b) shows an exemplary graph of multi-material print quality versus time demonstrating in-process qualification measurements of the technique. Figure 5(c) is a close-up photograph of a multi-material printed layer, which illustrates the high quality of powder deposition that can be achieved using this technique.

[0057] Figure 6 (a) through 6(j) show a selection of metal parts fabricated using our multi-material 3D printing technology. To date, the high-speed multi-material 3D printer has a powder deposition rate of over 20 cm 3 / minute, which corresponds to a build rate of approximately 9.4 kg / hour for parts made from commercial steel powder. Additionally, our multi-material 3D printer has a maximum external feature resolution of approximately 100 μm and a minimum feature size of approximately 0.5 mm.

[0058] Multi-material printing of powders allows for the fabrication of components with different densities in a structure. The particle size distribution and particle morphology determine the as-printed density of the powder. For example, unimodal spherical particles will have a higher as-printed density than irregularly shaped particles of the same material. For example, the as-printed density of spherical Cu powder with a diameter of 50 to 100 microns is approximately 60%. In contrast, the as-printed density of irregular copper powder with an average particle size of approximately 150 microns is approximately 40%. This technique allows for the fabrication of components with materials of different densities, assuming the materials are not sintered to full density, which can be achieved through appropriate processing times and temperatures. For example, Cu can be fully sintered to nearly 100% dense at 1074 °C, but processing at 900 °C results in a partially sintered material that is approximately 70% dense.

[0059] In Figures 7.1(a) to 7.1(f) and 7.2(a) through 7.2(e), two examples of advanced multi-material additive manufacturing processes are schematically shown.

[0060] Figures 7.1(a) to 7.1(f) The fabrication of a component using multi-material 3D printing of powders into a non-conformal welded HIP jacket 40A is shown. The end-to-end process consists of six general steps as described below.

[0061] Figure 7.1(a): HIP jacket fabrication. The non-conformal welded HIP jacket is fabricated using low-carbon steel sheets as used in conventional PM-HIP processes. These jackets can be expected to be cylindrical or rectangular.

[0062] Figure 7.1(b): Multi-material computer-aided design (CAD). A two-powder CAD model 46A is developed and designed using a metal powder and a support powder 48A for the component 42A. The support powder 48A is used to hold the shape of the metal powder during 3D printing and to transfer pressure to the component 42A during the HIP process.

[0063] Figure 7.1(c): Multi-material printing. Successive layers are multi-material layers printed inside the HIP jacket 40A based on the CAD model in the HIP jacket 40A after the HIP jacket 40A has been fabricated. Samples can be printed using our set of multi-material printers, where the build size ranges from 250 mm to 1000 mm. Our powder printers allow for the deposition of 3D structures in a powder bed without using carbon-containing binders. These binders are commonly used in PM and must be carefully removed during debinding heat treatments. The direct multi-material printing of 3D structures in the HIP jacket 40A without using binders avoids this problem.

[0064] Figure 7.1(d): Evacuate / Seal HIP Jacket. After multi-material printing, each non-conformal HIP jacket 40A is degassed and sealed by tungsten inert gas (TIG) welding. All sealed jackets are helium leak checked.

[0065] Figure 7.1(e): HIP Process. During this step, the HIP jacket 40A and the component 42A are inserted into the HIP, and the HIP is used to generate an external pressure on the HIP jacket 40A. The HIP container 40 deforms. Depending on the geometry, the component 42A may also deform.

[0066] Figure 7.1(f): Near Net Shape Component. The NNS component is recovered from the non-conformal welded HIP jacket after machining. This includes the removal of the HIP jacket 40A and the extraction of the component 42A from the support powder 48A. Mechanical and dimensional properties are measured in-house.

[0067] Figures 7.2(a) to 7.2(e) Shown is the fabrication of a component using multi-material 3D printing of powders to form both a component 42B and a HIP jacket 40B in the same build box. The end-to-end process consists of five general steps.

[0068] Figure 7.2(a): Multi-Material CAD Model Design. A multi-material CAD model 46B is designed using at least two metal powders and a support powder 48B. The metal powders are used to print the component 42B and the HIP jacket 40B that encapsulates the component 42B. The support powder 48B is used to hold the shape of the metal powder component and the HIP jacket 40B during 3D printing and to transfer pressure to the metal powder component during the HIP process. In this fabrication method, the 3D printed HIP jacket may or may not conform to the shape of the component 42B.

[0069] Figure 7.2(b): Multi-Material Printing. Successive layers are multi-material layers printed based on the CAD model 46B, and each of the printed successive layers includes a corresponding sheet of the HIP jacket 40B. Samples can be printed using our set of multi-material printers, where the build volume dimensions range from 250 mm to 1000 mm. All samples are printed in the build box with three or four different materials. Each layer includes a first support powder for the main material and auxiliary powder for the component 42B and a second support powder for the powder of the HIP jacket 40B.

[0070] Figure 7.2(c): 3D Printed HIP Can Manufacturing. After multi-material 3D printing, the build box is processed in an inert atmosphere at a temperature that results in the formation of a dense HIP can 40B of unconsolidated powder around the final part 42B. This high temperature process is designed to consolidate the HIP can 40B by sintering and / or metal infiltration, but it is not necessary to sinter the part 42B within the HIP can 40B. After heat treatment, the 3D printed HIP can is subjected to a helium leak check before being transported to the HIP processing equipment.

[0071] The processes shown in Figure 7.2(d) (HIP Processing) and Figure 7.2(e) (NNS Component) are the same as Figure 7.1(d) and 7.1(e) the last two processing steps shown in

[0072] For very large part sizes on the order of 1m and above, we expect that the non-conformal welding AM-HIP manufacturing method using the HIP can 40A schematically shown in Figures 7.1(A) through 7.1(f) will be more practical than the in-situ manufacturing method of the HIP can 40B shown in Figures 7.2(A) through 7.2(e). Figures 8(a) through 10 show our large-scale AM-HIP manufacturing system 50, which consists of a high-speed multi-material print head mounted on a Cartesian gantry. The Z-axis on this system is actuated by a lift-type platform that has an XY gantry and an on-board TIG welding system. The build box is located on a track assembly to facilitate transportation after the 3D printing process is complete. The modular HIP ring system allows the system to be easily scaled in the Z height for different part sizes. As shown in Figure 8(a), printing starts at the lowest level, which is a cylindrical build box with a single ring height. As the build progresses, additional rings with stepped edges are inserted on top of the previous ring so that the printing process can continue, as shown in Figure 8(b). After printing is complete, the on-board TIG welding system joins each ring together, as Figure 9 shown. As a final step, the powder level is raised to the top of the welding assembly, and the lid / port fixture is welded to the top of the cylinder. Figure 10 Shows the GL-1000 large-scale 3D powder printer from Grid Logic with a maximum build volume of 1m 3 (1000mm × 1000mm).

[0073] Refractory and other high-temperature materials can form complex parts through multiple HIP processes. Figures 11(a) to 11(h) Shows the manufacturing of a refractory part within a non-conformal cylindrical HIP can 52C by 3D printing a refractory metal HIP can 40C around the part 42C. In this process, a multi-material powder printing process based on the CAD model 46C is used ( Figures 11(a) to 11(c)) to print the component 42C, the first support powder 48C(i) for the component 42C, the refractory metal HIP jacket 40, and the second support powder for the HIP jacket 40. After printing is completed, the non-conformal HIP jacket 52C is evacuated and sealed according to standard procedures on-site (Figure 11(d)). The non-conformal HIP jacket 52C contains the second support powder 48C(ii) on the outside, a 3D powder structure in the shape of the refractory metal HIP jacket 40C supported by and within the second support powder 48C(ii), the second support powder 48C(ii) on the HIP jacket 40C side, and a 3D powder structure of the component 42C composed of materials that must be processed at very high temperatures.

[0074] After multi-material printing the powder in the HIP jacket 52C, the entire assembly including the non-conformal HIP jacket 52C is then HIP processed at a temperature that consolidates the 3D printed refractory metal HIP jacket 40C within the HIP jacket 52C, but not necessarily the component 42C within the 3D printed HIP jacket 40C (Figure 11(e)). Thus, the successive layers printed in the non-conformal HIP jacket 52C are processed at temperatures and pressures that result in the formation of a dense HIP jacket 40C around the unconsolidated powder for the component 42C and deform the non-conformal jacket.

[0075] As an example, zirconium diboride is an ultra-high temperature ceramic material that can be consolidated in HIP at temperatures above 1600 °C. Standard steel or nickel alloy HIP cannot be used at these temperatures. However, molybdenum (Mo), tantalum (Ta), or other refractory metals can be used. These materials are difficult to form into jackets due to the high melting temperature of the materials and poor mechanical properties at room temperature. Generally, Mo is the material of choice for high-temperature HIP processing because of its relatively low cost and ease of welding.

[0076] For example, HIP processing at 1350 °C and 14,000 psi will consolidate the Mo powder but not the zirconium diboride powder within the Mo jacket. After an initial treatment at 1350 °C, the sealed Mo can be removed from the second support powder 48C(ii) and HIP processed again at a high temperature (i.e., > 1350 °C) to sinter / consolidate the refractory material within the HIP jacket 40C (Figure 11(f) and (g)).

[0077] This method allows the fabrication of conformal HIP jackets using very high-temperature materials in order to process extremely high-temperature materials without having to fabricate and leak-check expensive refractory metal jackets.

[0078] If other materials are prone to consolidation at temperatures achievable by standard steel or nickel alloy jackets, they can also be used to form a high-temperature HIP jacket at 40 °C. For example, many high-temperature glasses can be used instead of refractory metal powders to fabricate the internal HIP jacket at 40 °C. The part 42C (Figure 11(h)) is then removed from the HIP jacket 40C.

[0079] Typically, cylindrical HIP jackets are commonly used to consolidate metal and ceramic powders in hot isostatic pressing. These jackets usually deform into an irregular hourglass shape during the HIP process. Due to the anisotropic mechanical properties of the HIP jacket 40 at high temperature and high pressure, and the change in powder filling density within the HIP jacket 40, fluctuations are usually generated in the side walls of the cylinder.

[0080] Alternative cross-sections of the HIP jacket are shown in Figure 12 . These shapes consist of simple polygons that, in a cross-sectional view from top to bottom, have an increasing number of flat sides of equal length. During the HIP process, the flat walls of these structures collapse in a more controlled manner compared to the cylindrical HIP on the right. Typically, the pressure applied to the part (located at the center of the HIP jacket) will increase uniformly with the increase in the number of sides. The hexagonal HIP jacket structure is expected to have the largest volume of uniform pressure at the center of the HIP jacket with the fewest number of sides. However, as shown, the cylindrical jacket does not have a flat surface and will collapse with irregular fluctuations. These fluctuations can lead to an anisotropic pressure distribution in the support medium and a related change in the density of the HIP-processed part. There is a balance between the size of the part to be 3D printed, the overall shape of the part, and the complexity of the HIP jacket construction.

[0081] Multi-material printing of the powder in the HIP jacket 40 allows the possibility of synthesizing materials from precursor materials during the HIP process. Reaction-bonded silicon carbide (SiC) and γ-titanium aluminide (TiAl) are two composite materials that can be formed in-situ during the HIP process.

[0082] Ultra-high temperature ceramics (UHTCs) have properties that make them an attractive option for various engineering applications. Due to their melting temperature above 3000 °C (5432 °F), high thermal and electrical conductivity, and excellent oxidation resistance at high temperatures, these materials are ideally suited for extreme temperature applications.

[0083] Zirconium diboride (ZrB2) is a major candidate material for extreme temperature applications because of its very high melting point, low density, relatively low electrical resistivity, high thermal conductivity, and strength at high temperatures. Additionally, the addition of sintering aids such as molybdenum disilicide (MoSi2) and silicon carbide (SiC) can significantly improve the material properties of ZrB2. ZrB2 / SiC composites (T.G. Aguirre et al., “Zirconium diboride-silicon carbide composites: A review,” Ceramics International 28 (2022) 7344-7361; G. Zhang et al., “Reactive hot pressing of ZrB2-SiC composites,” J. Am. Ceram. 83[9] 2330-2332 (2000); W.C. Tripp et al., “Effect of SiC addition on the oxidation of ZrB2, A. Ceram. Bull. 52[8] 612-16 (1973); R. Inoue et al., “Oxidation of ZrB2 and its composites: A review” J Mater Sci (2018) 53:14885-14906) have, for example, been shown to have significantly improved oxidation resistance at high temperatures in air, making them ideal candidates for hypersonic applications if geometrically complex shapes can be reliably fabricated. (D.R. Tenney et al., “Materials and structures for hypersonic vehicles,” ICAS-88-2.3.1 (1988); M. Opeka et al., “Oxidation-based material selection for 2000°C+ hypersonic airfoils: Theoretical considerations and historical experience,” J. Mater. Sci., 39, 5887–904 (2004); L. Kaufman and H. Nesor, “Characterization of the stability of refractory materials under high-speed atmospheric flight conditions”; Volume III, Part 3, Pages 1–370, Experimental results of high-speed hot gas / cold wall tests. AFML-TR-69-84 (DTIC AD 867307), ManLabs Inc., Cambridge, Mass, 1970.; D. Mass Wie et al., “Hypersonic environments: Required operating conditions and design challenges,” J. Mater. Sci. 2004; 39(19):5915–24).

[0084] Typically, UHTC components and parts are manufactured from ceramic powders using a combination of temperature and pressure to form a final component with minimal residual porosity. Hot pressing (HP) (T.G. Aguirre et al., “Zirconium diboride-silicon carbide composites: A review”, Ceramics International 28 (2022) 7344–7361; W.G. Farenholtz et al., “Zirconium hafnium refractory diborides”, J. Am. Ceram. Soc., 90[5] 1347–1364 (2007); R. Telle et al., “Boron-based hard materials”; pp. 802–945, Handbook of Ceramic Hard Materials, Volume 2, edited by R. Riedel. Wiley-VCH, Weinheim, 2000) and spark plasma sintering (SPS) (S.D. Oguntuyi et al., “Spark plasma sintering of ZrB2 and TiB2 ceramic matrix composites: Microstructure, densification and mechanical properties—A review”, Metals and Materials International (2021) 27:2146–2159) techniques, for example, can fabricate simple components (such as disks, plates, rods, etc.) close to the theoretical density. Unfortunately, the high melting point and low fracture toughness of these materials at room temperature make the fabrication of geometrically complex components difficult. However, the development of low-cost, reliable manufacturing processes capable of producing geometrically complex UHTC parts and components will allow these materials to be used in many demanding applications, including advanced aerospace parts, hypersonic thermal protection systems, and custom crucibles for metal casting.

[0085] In principle, AM provides an alternative route for manufacturing components using UHTC materials. In conventional AM systems, a thin layer of powder is applied to the surface of a powder bed, and a localized energy source (e.g., a laser or an electron beam) is used to selectively melt the material in a precise pattern. Both the laser powder bed fusion (LPBF) and electron beam powder bed fusion (EBM) AM processes have successfully fabricated small sample specimens and components using UHTC powders (T.G. Aguirre et al., “Zirconium diboride-silicon carbide composites: A review,” Ceramics International 28. (2022) 7344-7361; M.C. Leu et al., “Laser sintering studies for freeform fabrication of zirconium diboride components,” Virtual and Physical Prototyping, 7:1, 25-36, DOI: 10.1080 / 17452759.2012.666119; M.C. Leu et al., “Freeform fabrication of zirconium diboride components using selective laser sintering technology,” 2008 International Solid Freeform Fabrication and Planetary Manufacturing Symposium, http: / / dox / 10.26153 / tsw / 14963), but due to the very high temperatures required to melt the powder and the rapid cooling of the melt pool, these specimens typically exhibit porosity and microcracks. Alternatively, binder jetting AM technology has been used to fabricate complex ceramic components. In this method, an organic binder is typically used to fabricate a mechanically fragile green component, which is then first processed at a low temperature to remove the binder and then sintered to a high density at a high temperature. Complications arise in this process due to incomplete removal of the binder and detrimental reactions with the ceramic powder, which can lead to increased porosity and reduced phase purity of the ceramic material. To overcome the current technical limitations of manufacturing UHTC components using LPBF, EBM, and binder jetting AM technologies, a new approach is needed.

[0086] Our AM process uses a multi-material printing technique combined with a conventional HIP process to facilitate the manufacture of geometrically complex UHTC components. This 3D printing technique allows UHTC powder and support powder to be selectively deposited layer-by-layer within a standard non-conformal HIP envelope to create a geometrically complex 3D powder structure without using any binder. After the printing process, the HIP envelope is sealed and evacuated for subsequent processing in a hot isostatic press. The end-to-end manufacturing process includes the preparation of UTHC powder, multi-material 3D printing of UHTC and support ceramic powders, and HIP processing of the as-printed 3D powder structure. The combination of the multi-material 3D printing technique and the conventional ceramic HIP processing technique will result in a manufacturing process capable of producing complex ceramic and UHTC components for extreme temperature applications.

[0087] The UHTC manufacturing process is schematically shown in Figures 13(a) to 13(h) and consists of six general steps.

[0088] Figure 13(a) and 13(b) : HIP Can Manufacturing. In Fig. 13(a), non-conformal welded HIP cans 40D are manufactured using molybdenum (Mo) and Mo alloy sheets such as those used in HIP processing at high temperatures (e.g., > 1500 °C). The shape of the HIP can 40D is cylindrical or rectangular. In Fig. 13(a), a multi-material CAD model 46D is designed using UHTC composite powder and support powder 48D. The support powder 48D is used to hold the shape of the ceramic powder during 3D printing and to transfer pressure to the part 42D during HIP processing.

[0089] Figure 13(c) and 13(d) : Cryogenic Milling of UHTC Materials. The UHTC powder is mixed with SiC powder and cryo-milled in liquid argon under an inert atmosphere. This method will produce a tight mixture of all the components for our multi-material powder printing system.

[0090] Fig. 13(e): Multi-Material Printing. A build is printed using our inert atmosphere multi-material printer with a build volume of 200 mm x 100 mm. Grid Logic's 3D powder printer allows the deposition of 3D powder structures in the HIP can 40D without using carbon-containing binders. These binders are typically used in binder jetting AM and must be carefully removed during debinding heat treatment. Direct multi-material printing of 3D structures in the HIP can 40D without using binders avoids this problem.

[0091] Fig. 13(f): Evacuating / Sealing the HIP Can. After multi-material printing, each non-conformal HIP can 40D is degassed and sealed by TIG welding under an inert atmosphere. Before transportation to the HIP processing equipment, the sealed cans are subjected to a helium leak check.

[0092] Fig. 13(g): HIP Processing. See Fig. 7.1(e) above.

[0093] Fig. 13(h): Near-Net-Shape UHTC Part. The NNS ZrB2 / SiC composite part 42D is recovered from the non-conformal welded HIP can 40D after processing. This includes removing the HIP can 40D and the part 42D from the support powder 48D, which can be reused.

[0094] As described above, the geometry of the HIP can affect the overall shape of the 3D printed part located within the HIP. This is mainly a result of the nature of the support powder surrounding the part. Unlike a true fluid, the movement of particulate materials under pressure is not isotropic, and thus the forces to which the part is subjected during the high temperature / high pressure HIP process are anisotropic and cause deformation of the part during consolidation.

[0095] Figure 14(a) and 14(b) FIG. 14 shows a schematic view of a 3D printed powder part 42E in support powder 48E. The outer cylindrical HIP is not shown in this representation. During the HIP process, the HIP is heated to an elevated temperature and an isostatic pressure is applied on the outer side of the HIP at a certain temperature (as indicated by the arrow in FIG. 14(a)). The temperature / pressure profile of this method depends on the specific material to be consolidated in the HIP. As previously mentioned, the hydrostatic pressure applied to the HIP can result in different force distributions, which cause the surface of the HIP to collapse. The hourglass shape in FIG. 14(b) is a typical deformation observed during the HIP process. This collapse is due to the densification of the powder portion during HIP and the anisotropic forces applied to the HIP due to the geometry of the HIP itself.

[0096] Figures 15(a) to 15(c) FIG. 15 shows identical cylindrical tubes manufactured using different shaped HIPs. In all cases, the part has an hourglass shape due to the anisotropic forces applied to the powder part during the HIP cycle. As Figure 15(d) and 15(e) shown, generally, the degree of deformation is a function of the printed density of the powder portion, the printed density of the support powder, the distance from the HIP wall to the powder parts 42F(i) to 42F(iv), and to some extent the shape of the HIP.

[0097] One method of manufacturing NNS parts using this multi-material AM HIP process is to develop and 3D print a deformed CAD model powder part such that during the HIP cycle, the deformed part deforms to the target NNS geometry. This is schematically shown in Figure 16(a) and 16(b) .

[0098] Method 1

[0099] · Modify the CAD model of the part to account for the non-isotropic forces on the HIP

[0100] · Calculate the required deformation using finite element analysis

[0101] · Input

[0102] · CAD model 46G(i) of the part

[0103] · Material properties of the metal powder

[0104] · Shape of the HIP can

[0105] · Material properties of the HIP can and the weld seam

[0106] · Material properties of the support powder

[0107] In this case, the deformed powder component 46G(ii) is printed in the support powder (similar to the deformed CAD model 46G(ii) shown in FIG. 16), and when processed in HIP, the deformation in the printed powder component causes the formation of an undeformed NNS component 42G(ii) instead of the deformed component 42G(i). Many parameters are required to calculate the deformation in the original component to generate the NNS component during the HIP cycle. While these calculations can be performed on simple components, for complex geometries such as those shown in Figures 17(a) to 17(e) , the problem quickly becomes intractable. Thus, this method is much more difficult for components with complex geometries.

[0108] As an alternative, another powder can be 3D printed in the support powder, which allows for a more isotropic pressure distribution on the original powder component. This is schematically shown in Figure 18(a) and 18(b) , which shows a side view of a multi-material print that includes a powder component 42H, a support powder 48H(i) surrounding the component 42H, a glass shell 54H in powder form surrounding the powder component 42H and the internal support powder 48H(i), and a support powder 48 surrounding all other powders. The printed horizontal layers sequentially include, from the inside, a layer of the component 42H, a first support powder 48H(i) for the component 42H, a portion of the glass 54H, and a second support powder 48H(ii) for the portion of the glass 54H. Again, the HIP can is not shown in this schematic representation.

[0109] The difference in this case is that the glass powder forms a viscous liquid at elevated temperatures, which serves as the force-distributing material. The viscous glass 54H then causes a more uniform distribution of pressure / force on the internal support powder 48H(i) and the powder of the component 42H, and reduces the deformation of the component 42H. The arrangement of this viscous liquid boundary between the HIP envelope and the external support powder 48H(ii), the internal support powder 48H(i), and the powder of the component 42H effectively reduces the anisotropy associated with the external geometry of the HIP envelope on the other side. In other words, the molten glass 54H at high temperature creates a medium that results in a uniform pressure distribution on the internal support powder 48H(i) and / or the powder of the component 42H, which subsequently allows for a more uniform densification of the powder, thereby producing the NNS component 42H.

[0110] Figure 19 An example of a component manufactured using this process is shown. The model consists of a cylindrical portion 42H surrounded by a spherical shell of spherical support powder 48H(i) (which has been removed) and glass 54H (which has been removed) powder. The HIP process results in significant deformation of the shell structure made of glass 54H, but the geometry of the powder component is substantially maintained. Similarly, at elevated temperatures, the glass 52 acts as a viscous liquid, and the pressure on the internal powder is substantially uniform. The HIP envelope 40 deforms together with the support powder 48H(i).

[0111] Figure 20 The viscosities of some glasses as a function of temperature are shown. In the AM / HIP process described here, it is important that the viscosity of the glass 54H shell remains high enough to maintain the shape of the internal 3D-printed powder, but low enough to allow for a small to non-existent pressure difference within the volume of the glass 54H. These temperatures are approximately within the softening point and melting point of the specific glass 54H. Generally, the softening point of the glass 54H is when the viscosity is less than about 10 8 P (see the dashed line in the figure). Due to having this viscosity, the glass 54H can still be processed without significant dimensional changes, but can be machined carefully. At viscosities below the softening point but above the working point, the glass 54H is prone to deformation but remains highly viscous (e.g., the glass 54H can be processed and blown at these viscosities). At higher temperatures near and above the melting point, the viscosity decreases to the point where the glass 54H behaves like a freely flowing liquid.

[0112] Typically, the temperature used to form the NNS component using glass powder should be carried out at a temperature above the softening point of the glass 54H and below its melting point. Depending on the glass, there is a wide range of operating temperatures available in the AM / HIP process. For example, soda-lime glass has a potential operating temperature range between 700 °C and 1400 °C. On the other hand, borosilicate glass has an operating range of about 800 °C to over 1600 °C.

[0113] The present invention introduced above incorporates the glass 54H as a uniform pressure medium. The general requirement is that the material (i.e., the glass 54H in this case) has a temperature-dependent viscosity that allows for a uniform distribution of the force on the powder of the component at the temperature / pressure used to consolidate the powder component material. In addition to various glasses, candidate uniform pressure materials can include certain salts, mixtures of molten salts, and ceramic / salt mixtures. For example, a spherical shell structure made of Figure 18(a) and 18(b) as well as the glass 54H shown in FIG. 19 can be a mixture of zircon and sodium chloride (NaCl). For example, if the shell material is 80% by volume zircon sand and 20% by volume NaCl, at a temperature above the melting point of NaCl (about 800 °C), the material will act like a thick paste and have an effective viscosity within the operating range described above. Essentially, the paste will distribute the force evenly onto the glass 54H in a similar manner. Other molten salts or mixtures of molten salts can also be used in this application. The advantage of using salts in this method is that the sand / salt mixture can be immersed in water to dissolve the salt and release the component 42H.

[0114] Alternatively, the entire support powder 48 (without an inner shell, e.g., FIG. 18(b)) can also be composed of a sand / salt mixture such as Figure 21(a) and 21(b) shown, where the support powder 48I includes a small amount of molten salt (fluid) added to zircon powder or other primary powder. The composite material mixture allows for a uniform redistribution of the force on the internal powder of the component 42I.

[0115] The general approach is to place a material (e.g., glass, composite ceramic / salt, etc.) between the HIP envelope and the component 42H or 42I that behaves more like a viscous liquid than a particulate solid at the temperature encountered during the HIP cycle. In this way, during the temperature / pressure-induced sintering process, the force on the component 42H or 42I is more uniform, the geometry of the component 42H or 42I is closer to the designed shape, and is less dependent on the shape of the HIP envelope. This can be achieved with glass, mixtures of materials with solid and small liquid components (e.g., sand / glass, sand / molten salt, ceramic / glass, metal / glass, etc.), or certain metal alloys at temperatures within the so-called "pasty" zone above the solidus temperature and below the liquidus temperature.

[0116] The viscous structure surrounding component 42H or 42I need not be a spherical shell as shown in Figure 18(a) and 18(b) and as shown in 19. To evenly distribute the acting force on part 42H or 42I, the shell should surround component 42H or 42I and be thick enough so that there is no pressure difference in the viscous layer, which could significantly change the shape of component 42H or 42I. Figure 22(a) and 22(b) show a simple cylindrical surrounding made of glass 54J around the tubular powder component 42J. During the HIP process, this surrounding is thick enough to equalize the pressure around component 42J when the powder of glass 54J softens and reaches the desired viscosity. In this example, the support powder 48J (such as zircon, alumina, etc.) surrounds the powder of the component and is located inside the powder component tube. In this position, the material 48J acts like a mandrel around which the powder material of component 42J is extruded. The internal dimension (ID) of component 42J will closely match the external dimension (OD) of the mandrel formed by the support material 48J.

[0117] Alternatively, Figure 23(a) and 23(b) show the same tubular powder component 42K, but in this case, the material of glass 54K is also located in the center of the tube and thus penetrates the support powder 48K. In this case, the force on the powder of component 42K is applied from the outside of the tube and from the inside of the tube through the surrounding structure formed by the viscous glass 54K, which penetrates the center of the cylinder formed by the powder of component 42K. In this case, due to the specific application of the force allowed by the 3D printed geometry of the viscous structure in the HIP envelope, the final component 42K will have an ID greater than the original CAD model and an OD less than the original CAD model. This AM / HIP process allows for the application of HIP-induced forces specific to certain regions of the internal structure by 3D placing the viscous structure within the HIP envelope. Although the present invention has been described using relatively simple geometries, the application of this manufacturing process can be used to fabricate extremely complex structures such as Figures 17(a) to 17(e) and Figure 24(a) and 24(b) as shown in.

[0118] A typical HIP process cycle is shown in Figure 25 . The HIP envelope is first heated to about 500 °C at low pressure to soften the steel HIP envelope and anneal the welds. After some time, both the pressure and temperature are increased. In this embodiment, the HIP envelope 40 is processed at 950 °C / 14,000 psi for 4 hours.

[0119] Figure 26Shows a typical HIP process flow diagram for manufacturing NNS components using glass parts around the components. After loading the HIP envelope, the system is pressurized to a low pressure (e.g., 500 psi), and the HIP envelope is heated and soaked at approximately 500 °C to anneal the welds and soften the metal envelope. Then the temperature is raised above the softening temperature of the glass, which is used to sinter / consolidate the glass powder into a partially dense to fully dense viscous material around the component. At this point, as the temperature is raised to the consolidation temperature of the component, the pressure in the system increases. As the temperature and pressure increase, the HIP deforms, which causes the now viscous glass component to deform into an entrapped liquid that applies a uniform force distribution on the component. This results in near-uniform densification of the component. After a period of time at high temperature / high pressure, the temperature is decreased with a corresponding decrease in pressure. Variations of this process are specific to the HIP envelope material, powder component material, glass powder, and support powder.

[0120] Figures 27(a) to 27(e) Shows the manufacturing of a tubular spherical component 42L. The CAD model 46L (Figure 27(A)) consists of three different materials: 316L metal alloy powder, zirconia support powder, and glass powder for forming a leak-free HIP cylinder around the component 42L.

[0121] The glass powder is selected from Figure 20 the various possible glass combinations shown. The compositional details of the glass powder are customized according to the HIP process parameters (e.g., temperature and pressure) and the characteristics of the powder material to be consolidated.

[0122] A conformal shell made of glass 54L is printed around the portion 42L shown in the center of the 3D model 46 (Figure 27(A)) (Figure 27(b)). After printing, a 3D powder structure including the HIP envelope 40L, glass 54L, support powders 48L(i) and 48L(ii), and the powder for the component 42L is processed using a HIP cycle that first fuses the glass 54L into a leak-free shell made of glass 54L before applying pressure to consolidate the 316L powder (Figure 27(c)). Different from Figures 7.1(a) to 7.1(f) the AM-HIP process shown, the consolidation process of the shell of glass 54L is carried out in an open HIP envelope 40L. After the HIP process, the HIP envelope made of glass 54L is retrieved from the loose sand forming the support material 48L(ii) (Figure 27(d)), the opening is broken, and the tubular spherical component 42L is removed from the loose sintered zirconia powder forming the support material 48L(i) inside the shell formed by glass 54L ( Figure 27e )).

[0123] Using Figures 27(a) to 27(e) the AM-HIP process shown, multiple geometrically complex parts are manufactured; examples of which are inFigures 28(a) to 28(e) These are shown in Figures 28(a) to 28(e) . These examples include components with thin walls, concave / convex structures, and internal voids, which are designed to test the limits of the AM-HIP process.

[0124] Table 1 shows the densities of selected materials processed using the AM-HIP technique, which were measured by helium pycnometry. The AM-HIP processed 304L, 316L, and Inconel 625 have high densities, but retain a certain degree of residual porosity at this temperature. Tungsten has the highest porosity (i.e., the lowest density) with HIP process parameters still in use to date.

[0125] Table 1: Density measurements of materials processed by AM-HIP.

[0126]

[0127] Although certain exemplary embodiments have been described and shown in the drawings, it should be understood that these embodiments are merely illustrative and not limiting of the invention, and the invention is not limited to the specific constructions and arrangements shown and described, as modifications can be envisioned by those of ordinary skill in the art.

Claims

1. A method of forming a component, comprising: Printing successive layers, where each layer comprises at least one layer of the component and where the layers of the component are surrounded by sheets of a hot isostatic pressing (HIP) envelope.

2. The method according to claim 1, wherein: The HIP envelope is a sealed container and the component is within the HIP envelope such that the HIP envelope can be inserted into a HIP to increase the pressure on the outside of the HIP envelope to deform the HIP envelope.

3. The method according to claim 1, further comprising: Positioning the HIP envelope such that the component within the HIP envelope is located within the HIP; Using the HIP to increase the temperature within the HIP envelope and the pressure on the outside of the HIP envelope to deform the HIP envelope; Removing the HIP envelope and the component within the HIP envelope from the HIP; And Removing the component from the HIP envelope.

4. The method according to claim 3, wherein, The pressure deforms the component.

5. The method according to claim 1, further comprising: Fabricating the HIP envelope; Developing a multi-material computer-aided design (CAD) model, where the successive layers are multi-material layers printed within the HIP envelope based on the CAD model within the HIP envelope after the HIP envelope has been fabricated; Evacuating the HIP envelope after the layers have been printed inside the HIP envelope; And Sealing the HIP envelope after the HIP envelope has been evacuated.

6. The method according to claim 5, wherein, The multi-material layers are printed from a powder for forming the component and a support powder for supporting the powder for forming the component.

7. The method according to claim 6, wherein, When using the HIP to raise the temperature within the HIP envelope and the pressure on the outside of the HIP envelope to deform the HIP envelope, the support powder transfers the pressure to the powder for the component.

8. The method according to claim 1, further comprising: Developing a multi-material computer-aided design (CAD) model, where the successive layers are multi-material layers printed based on the CAD model and each of the printed successive layers comprises a corresponding sheet of the HIP envelope.

9. The method according to claim 8, further comprising: Treating a structure formed by printing of successive layers at a selected temperature in an inert atmosphere to form a dense HIP envelope around the unconsolidated powder for the component.

10. The method according to claim 9, wherein, The temperature consolidates the HIP envelope without sintering the powder for the component within the HIP envelope.

11. The method according to claim 10, wherein The temperature consolidates the HIP envelope by at least one of sintering and metal infiltration.

12. The method according to claim 8, wherein Each layer comprises a first support powder for the powder for the component and a second support powder for the powder for the HIP envelope.

13. The method according to claim 8, wherein, Treating the successive layers printed within the non-conformal envelope and the non-conformal envelope at a temperature and pressure that results in forming a dense HIP envelope around the unconsolidated powder of the component and deforming the non-conformal envelope.

14. The method according to claim 1, wherein, The HIP envelope is non-cylindrical in a top-down cross-sectional view.

15. The method according to claim 14, wherein, The HIP envelope has a polygonal shape.

16. The method according to claim 14, wherein, The sides of the polygon shape have equal lengths.

17. The method according to claim 15, wherein, The HIP envelope has at least three relatively flat sides.

18. The method according to claim 17, wherein, The HIP envelope has at least five relatively flat sides.

19. The method according to claim 1, wherein, The component is made of ultra-high temperature ceramic powder.

20. The method according to claim 1, wherein Each layer includes a part of a force distribution material between the layer of the component and the sheet of the HIP envelope, wherein the force distribution material allows for a more uniform distribution of force at elevated temperatures to reduce deformation of the component.

21. The method according to claim 20, wherein, The force distribution material is glass.

22. The method according to claim 21, wherein Each printed layer sequentially includes the layer of the component, a first support powder for the component, a portion of the glass, and a second support powder for the portion of the glass.

23. The method according to claim 22, wherein The glass acts as a viscous liquid at elevated temperatures, which allows the force to be more evenly distributed on the first support to reduce deformation of the component.

24. The method according to claim 21, wherein The operating temperature of the glass is between 700°C and 1600°C.

25. The method according to claim 20, wherein The printed layer is printed from a powder for forming the component and a support powder for supporting the powder for forming the component, wherein the support powder includes a main powder and a molten salt added to the main powder, and the composite mixture allows for a uniform redistribution of force on the powder of the component.

26. The method according to claim 21, wherein, The glass is melted at elevated temperatures, and the method further includes: Removing the molten glass and the component inside the molten glass from the HIP envelope; and Opening the molten glass to remove the component from the molten glass.

27. The method according to claim 26, wherein, When the glass is melted, the HIP envelope is open.

28. A method of forming a component, comprising: Positioning a hot isostatic pressing (HIP) envelope forming a sealed container and a component inside the HIP envelope in a HIP, wherein the component includes continuously printed layers, wherein each layer includes at least one layer of the component, and wherein the layers of the component are surrounded by sheets of the HIP envelope; Using the HIP to increase the temperature inside the HIP envelope and the pressure outside the HIP envelope, thereby deforming the HIP envelope; Removing the HIP envelope and the component inside the HIP envelope from the HIP; And Removing the component from the HIP envelope.

29. The method according to claim 28, wherein, The pressure deforms the component.

30. The method according to claim 28, further comprising: Fabricating the HIP envelope; Developing a multi-material computer-aided design (CAD) model, wherein the continuous layers are multi-material layers printed inside the HIP envelope based on the CAD model in the HIP envelope after the HIP envelope has been fabricated; Evacuating the HIP envelope after the layers have been printed inside the HIP envelope; And Sealing the HIP envelope after the HIP envelope has been evacuated.

31. The method according to claim 30, wherein, The multi-material layer is printed from a first powder for forming the component and a second powder for supporting the first powder.

32. The method according to claim 31, wherein When using the HIP to increase the temperature inside the HIP envelope and the pressure outside the HIP envelope to deform the HIP envelope, the second powder transfers the pressure to the first powder.

33. The method according to claim 28, further comprising: Develop a multi-material computer-aided design (CAD), where the continuous layers are multi-material layers printed based on the CAD model, and each of the printed continuous layers includes a corresponding sheet of the HIP jacket.

34. The method according to claim 33, further comprising: Processing the structure formed by the printing of the continuous layers in an inert atmosphere at a selected temperature to form a dense HIP jacket around the unconsolidated powder of the component.

35. The method according to claim 34, wherein, The temperature consolidates the HIP jacket without sintering the powder of the component within the HIP jacket.

36. The method according to claim 35, wherein, The temperature consolidates the HIP jacket by at least one of sintering and metal infiltration.

37. The method according to claim 33, wherein, Each layer includes a first support powder for the powder of the component and a second support powder for the powder of the HIP jacket.

38. The method according to claim 33, wherein, Processing the continuous layers printed within the non-conformal jacket and the non-conformal jacket at a temperature and pressure that result in the formation of a dense HIP jacket around the unconsolidated powder of the component and the deformation of the non-conformal jacket.

39. The method according to claim 28, wherein, The HIP jacket is non-cylindrical in a top-down cross-sectional view.

40. The method according to claim 39, wherein, The HIP jacket has a polygonal shape.

41. The method according to claim 39, wherein, The sides of the polygonal shape have equal lengths.

42. The method according to claim 40, wherein, The HIP jacket has at least three relatively flat sides.

43. The method according to claim 42, wherein, The HIP jacket has at least five relatively flat sides.

44. The method according to claim 28, wherein, The component is made of ultra-high temperature ceramic powder.

45. The method according to claim 28, wherein Each layer includes a portion of a force distribution material located between the layer of the component and the sheet of the HIP jacket, where the force distribution material allows for a more uniform distribution of forces at elevated temperatures to reduce deformation of the component.

46. The method according to claim 45, wherein, The force distribution material is glass.

47. The method according to claim 46, wherein, Each printed layer sequentially includes the layer of the component, the first support powder for the component, the portion of the glass, and the second support powder for the portion of the glass.

48. The method according to claim 47, wherein, The glass acts as a viscous liquid at elevated temperatures, which allows for a more uniform distribution of forces on the first support to reduce deformation of the component.

49. The method according to claim 46, wherein The working temperature of the glass is between 700°C - 1600°C.

50. The method according to claim 45, wherein, The printed layer is printed from the powder for forming the component and a support powder for supporting the powder for forming the component, where the support powder includes a main powder and a molten salt added to the main powder, and the composite mixture allows for a uniform redistribution of forces on the powder of the component.

51. The method according to claim 46, wherein, The glass is melted at elevated temperatures, and the method further comprises: Removing the molten glass and the component inside the molten glass from the HIP jacket; and Opening the molten glass to remove the component from the molten glass.

52. The method according to claim 51, wherein When the glass is melted, the HIP jacket is open.

53. An article, comprising: A hot isostatic pressing (HIP) jacket that forms a sealed container; And A component inside the HIP jacket, the component including continuously printed layers, where each layer includes at least one layer of the component, and where the layer of the component is surrounded by a sheet of the HIP jacket, Where the HIP jacket can be inserted into a HIP to increase the pressure on the outside of the HIP jacket, thereby deforming the HIP jacket.

54. The article according to claim 53, wherein Pressure deforms the component.

55. The article according to claim 53, wherein, The continuous layer is a multi-material layer printed based on a computer-aided design (CAD) model within the HIP envelope after the HIP envelope has been manufactured. The HIP envelope is evacuated after the layer has been printed within the HIP envelope, and the HIP envelope has been sealed after the HIP envelope has been evacuated.

56. The article according to claim 55, wherein, The multi-material layer is printed from a first powder for forming the component and a second powder for supporting the first powder.

57. The article according to claim 56, wherein When using the HIP to raise the temperature within the HIP envelope and the pressure outside the HIP envelope to deform the HIP envelope, the second powder transfers the pressure to the first powder.

58. The article according to claim 53, wherein, The continuous layer is a multi-material layer printed based on computer-aided design (CAD), and each of the printed continuous layers includes a corresponding sheet of the HIP envelope.

59. The article according to claim 58, wherein, Processing the structure formed by printing of the continuous layer at a selected temperature in an inert atmosphere results in the formation of a dense HIP envelope around the unconsolidated powder of the component.

60. The article according to claim 59, wherein, The temperature consolidates the HIP envelope without sintering the powder for the component within the HIP envelope.

61. The article according to claim 60, wherein, The temperature consolidates the HIP envelope by at least one of sintering and metal infiltration.

62. The article according to claim 58, wherein, Each layer includes a first support powder for the powder of the component and a second support powder for the powder of the HIP envelope.

63. The article according to claim 58, further comprising: A non-conformal envelope, wherein the continuous layer is printed within the non-conformal envelope, and processing the non-conformal envelope at selected temperature and pressure results in the formation of a dense HIP envelope around the unconsolidated powder for the component and deforms the non-conformal envelope.

64. The article according to claim 53, wherein The HIP envelope is non-cylindrical in a top-down cross-sectional view.

65. The article according to claim 64, wherein, The HIP envelope has a polygonal shape.

66. The article according to claim 64, wherein, The sides of the polygonal shape have equal lengths.

67. The article according to claim 65, wherein, The HIP envelope has at least three relatively flat sides.

68. The article according to claim 67, wherein, The HIP envelope has at least five relatively flat sides.

69. The article according to claim 53, wherein The component is made of ultra-high temperature ceramic powder.

70. The article according to claim 53, wherein each layer comprises a portion of a force-distributing material between a layer of the part and a sheet of the HIP can, wherein, The force distribution material allows for a more uniform distribution of force at elevated temperatures to reduce deformation of the component.

71. The article according to claim 70, wherein, The force distribution material is glass.

72. The article according to claim 71, wherein, Each printed layer sequentially includes the layer of the component, a first support powder for the component, a portion of the glass, and a second support powder for the portion of the glass.

73. The article according to claim 72, wherein, The glass acts as a viscous liquid at elevated temperatures, which allows for a more uniform distribution of force on the first support to reduce deformation of the component.

74. The article according to claim 71, wherein The glass has a working temperature between 700 °C and 1600 °C.

75. The article according to claim 70, wherein, The printed layer is printed from a powder for forming the component and a support powder for supporting the powder for forming the component, wherein the support powder includes a main powder and a molten salt added to the main powder, and the composite mixture allows for a uniform redistribution of force on the powder of the component.

76. The article according to claim 71, wherein, The glass is melted at elevated temperatures.

77. The article according to claim 76, wherein, The HIP envelope is open.

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