Surface Layer on Additive Manufactured Components
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Solution Overview
Problem
Additively manufactured components often exhibit surface porosity and irregularities that hinder mechanical properties and require additional processing, such as hot isostatic pressing, which can be inefficient and costly due to the absence of a nonporous outer surface.
Innovation Solution
A surface layer is formed by depositing a powder from a slurry, suspension, or tape onto the additively manufactured component, which is then sintered and subjected to hot isostatic pressing, filling surface channels and improving surface finish, mechanical properties, and allowing for differential grain sizes and compositions between the surface and internal regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hot isostatic pressing is applied to additively manufactured components, then porosity is reduced and mechanical properties are improved, but the process becomes more costly and time-consuming due to the absence of a nonporous outer surface
Solution Approach 1:
A surface layer is deposited onto the additively manufactured component before hot isostatic pressing, creating a nonporous outer surface in advance. This preliminary action allows the subsequent HIP process to be more efficient, as the surface layer provides a barrier that enables better pressure transmission and porosity reduction throughout the component.
Solution Approach 2:
The invention creates a composite structure consisting of the additively manufactured component core and a deposited surface layer. This composite material approach combines the complex geometry capabilities of additive manufacturing with the dense, nonporous surface properties of traditionally deposited materials, achieving both structural complexity and surface integrity.
2Reliability
If hot isostatic pressing is applied to additively manufactured components, then porosity is reduced and mechanical properties are improved, but the process becomes more costly due to the absence of a nonporous outer surface
Solution Approach 1:
The surface layer is deposited beforehand to create a nonporous outer surface, which preliminarily prepares the component for more efficient and cost-effective hot isostatic pressing. This advance preparation reduces the overall processing cost by making the subsequent HIP process more effective.
Solution Approach 2:
The composite structure of additively manufactured core plus deposited surface layer provides a cost-effective solution by combining the economic advantages of additive manufacturing for complex geometries with the cost benefits of efficient HIP processing enabled by the surface layer.
3Manufacturing precision
If a surface layer is deposited from slurry or suspension, then surface finish and porosity are improved, but additional processing steps are required
Solution Approach 1:
The invention changes the physical state and composition parameters by depositing material from slurry or suspension rather than conventional powder or wire forms. This parameter change enables the surface layer to better fill surface irregularities and porosity, improving surface finish and reducing defects.
Solution Approach 2:
The surface layer acts as a copy or replica of a desired nonporous surface structure, transferring the properties of densely packed deposited material onto the additively manufactured component surface, thereby replicating the surface quality of traditionally manufactured parts.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The surface layer enhances the mechanical properties, corrosion resistance, and thermal properties of the additively manufactured components, facilitates further processing like hot isostatic pressing, and reduces porosity, leading to improved fatigue performance and wear resistance.
Implementation Method 1
sintering the powder to form a surface layer on the additively manufactured component
Implementation Method 2
hot isostatic pressing the additively manufactured component and the surface layer
Data Source
AI summary
A method may include depositing, from a slurry, suspension, or tape, on a surface of an additively manufactured component comprising a metal or alloy, powder comprising at least one of a metal, an alloy, or a ceramic; sintering the powder to form a surface layer on the additively manufactured component; and hot isostatic pressing the additively manufactured component and the surface layer.