Additive manufacture of complex intermetallic and ceramic structures
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Solution Overview
Problem
Current 3D printing techniques for intermetallic and ceramic structures require binders that result in porous objects, necessitate self-supporting structures, and demand inert atmospheres, increasing costs and limiting structural complexity and density.
Innovation Solution
3D printing a greenware surrounded by an excess of a first powder, compressing it with a hydraulic press, and heating it to a reaction temperature to form intermetallic or ceramic objects without binders, using the excess powder for structural support and protection from oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If binders are used in 3D printing to hold greenware together, then structural integrity during handling is improved, but the resulting objects become porous and contaminated
Solution Approach 1:
The invention removes binders entirely from the 3D printing process. Instead of using binder materials to hold greenware together, the process relies on the inherent strength of the powder compact itself and the support provided by excess powder, eliminating the source of porosity and contamination that binders create
Solution Approach 2:
Excess powder acts as an intermediary support material during the 3D printing process. This excess powder provides mechanical support to the greenware structure during handling and sintering, replacing the function previously performed by binders, and can be completely removed after sintering without leaving residues
2Strength
If self-supporting structures are required for 3D printed objects, then structural stability during printing is improved, but the complexity of manufacturable geometries deteriorates
Solution Approach 1:
Excess powder serves as a temporary support medium that allows complex geometries to be printed without requiring the printed structure itself to be self-supporting. The excess powder fills voids and supports overhanging features during printing, enabling geometries that would otherwise be impossible to manufacture
Solution Approach 2:
The invention changes the physical state and distribution of powder material from a precisely deposited layer to an excess bulk material that can be compacted. This parameter change allows the powder to flow into and support complex geometries, then be compacted and removed after sintering
3Object-affected harmful factors
If inert atmospheres are used during kiln heating to prevent oxidation, then protection from oxidation is improved, but the cost and complexity of the process deteriorates
Solution Approach 1:
The invention converts the potentially harmful effect of atmospheric oxygen into a beneficial protective atmosphere. The excess powder compact forms a physical barrier that prevents oxygen from reaching the greenware during heating, allowing atmospheric firing without oxidation of the final product
Solution Approach 2:
The excess powder compact serves a dual function: it acts as both the structural support medium and the protective atmosphere barrier. The material itself provides the protection against oxidation through its physical presence, eliminating the need for external inert gas systems
4Strength
If excess powder is used to surround and support the greenware, then structural support and oxidation protection are improved, but the amount of material to be processed deteriorates
Solution Approach 1:
The excess powder undergoes a phase transition from loose powder to compacted solid through hydraulic pressing. This compacting increases the density of the excess powder, reducing its volume while maintaining its structural support and protective functions, thereby reducing the total amount of material that needs to be handled and processed
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 creation of complex, fully-dense intermetallic and ceramic structures with varied densities and geometries, eliminating the need for binders and inert atmospheres, reducing contamination and production costs.
Implementation Method 1
The hydraulic press is configured to compress the greenware to form a compressed greenware
Implementation Method 2
The kiln is configured to heat the compressed greenware to a reaction temperature to form an object
Implementation Method 3
The kiln is also configured to heat the object surrounded by the excess of the first powder to a melting temperature. The melting temperature is at least the melting point of the first powder and less than the melting point of the object. Heating to the melting temperature melts the excess of the first powder from around the object
Implementation Method 4
The first printhead is configured to deposit a layer of a first powder on the print bed. The second printhead is configured to deposit a layer of a second powder on the print bed
Data Source
AI summary
According to some embodiments, a system includes a three-dimensional (3D) printer, a hydraulic press, and a kiln. The three-dimensional printer includes a print bed, a first printhead, and a second printhead. The first printhead is configured to deposit a layer of a first powder on the print bed. The second printhead is configured to deposit a layer of a second powder on the print bed. The hydraulic press is configured to compress a greenware to form a compressed greenware. The kiln is configured to heat the compressed greenware to a reaction temperature to form an object. The object is surrounded by an excess of the first powder. The kiln is also configured to heat the object surrounded by the excess of the first powder to a melting temperature. The melting temperature is at least the melting point of the first powder and less than the melting point of the object.