Beryllium Additive Manufacturing via Sintering and Infiltration
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Solution Overview
Problem
Beryllium's tendency to oxidize and react with materials, along with its brittleness and complex crystal structure, makes it difficult to manufacture parts using conventional additive manufacturing techniques like electron beam melting and laser sintering.
Innovation Solution
A method involving the deposition of beryllium-containing compositions, followed by sintering and infiltration with metals like aluminum or magnesium, using binder materials such as polyethylene or polyvinyl alcohol to form lightweight, complex parts with desired properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional additive manufacturing techniques like electron beam melting or laser sintering are used to manufacture beryllium parts, then the parts can be produced directly from digital models, but the process fails due to beryllium's tendency to oxidize and react with materials during processing
Solution Approach 1:
The patent applies inert atmosphere by conducting the sintering process in a controlled environment with reduced oxygen content. The sintering step is performed at temperatures below beryllium's melting point in an atmosphere that prevents oxidation, allowing the green parts to be densified without the material reacting with atmospheric gases during processing.
Solution Approach 2:
The patent changes the processing parameters by using a two-step approach: first creating green parts at room temperature through binder jetting, then sintering at elevated temperatures below the melting point. This parameter change avoids the oxidation problem that occurs during conventional high-temperature melting processes while still achieving densification and material bonding.
2Adaptability or versatility
If beryllium is processed using conventional AM methods, then parts can be created with complex geometries, but the brittleness and complex crystal structure of beryllium make the process difficult and unreliable
Solution Approach 1:
The patent applies preliminary action by first forming the green parts with the desired complex geometry through binder jetting at room temperature, establishing the geometric complexity before any high-temperature processing. The sintering step then densifies this pre-formed structure without requiring the material to be molten, avoiding the processing difficulties associated with beryllium's brittleness and crystal structure during melting and solidification.
3Productivity
If beryllium powder is selectively deposited and melted using electron beam or laser, then rapid prototyping and on-demand production are achieved, but oxidation and material reactions occur during the high-temperature processing
Solution Approach 1:
The patent eliminates oxidation and material reactions by performing the sintering process in a controlled inert atmosphere with reduced oxygen content. This allows rapid densification of the green parts through thermal diffusion and bonding without the harmful chemical reactions that occur during conventional high-temperature melting processes in atmospheric conditions.
Solution Approach 2:
The patent changes the temperature parameter by sintering at elevated temperatures below beryllium's melting point, avoiding the high-temperature melting step where oxidation occurs most rapidly. This parameter change maintains the rapid production advantage while eliminating the harmful chemical reactions through lower peak temperature processing in a controlled atmosphere.
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
Enables the production of lightweight, high-stiffness parts with controlled thermal expansion and strength, overcoming the limitations of traditional AM techniques for beryllium, while reducing production time and costs.
Implementation Method 1
The term 'sintering' refers to the process by which particulates adhere into a solid mass due to externally applied energy.
Implementation Method 2
The infiltration fills voids within the sintered preform.
Data Source
AI summary
A method of making an article includes depositing a plurality of layers to form a three-dimensional preform, sintering the preform to form a sintered preform, and infiltrating the preform with at least one metal to form the article. At least one layer of the plurality of layers is formed from a beryllium-containing composition including beryllium powder. The infiltrating metal can be selected from aluminum and magnesium.