Core-Shell Composite Powder for Stronger Metal Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing techniques for metal articles face limitations in strength and physical properties, making them unsuitable for applications like aerospace, particularly with alloys such as Al12Si, which have limitations in weldability and processability.
Innovation Solution
A method involving the creation of metal-ceramic composite powder particles with a composite core comprising a first metal and a ceramic phase, and a shell of a second metal, which are fabricated into a porous pre-form, infiltrated with a liquid metal, and then broken down into powder form for use in additive manufacturing, allowing for improved properties through selective fusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional metal alloys such as Al12Si are used for additive manufacturing, then weldability is improved, but strength and physical properties deteriorate
Solution Approach 1:
The patent uses metal-ceramic composite powder particles with a core-shell structure where the core comprises a first metal and a ceramic phase, and the shell comprises a second metal. This composite structure combines the weldability benefits of aluminum alloys (from the shell) with the strength benefits of ceramic-reinforced metals (from the core), thereby resolving the contradiction between ease of manufacture and strength.
2Ease of manufacture
If traditional metal alloys are used for additive manufacturing, then processability is improved, but physical properties deteriorate
Solution Approach 1:
The metal-ceramic composite powder particles maintain processability through their designed core-shell structure while improving physical properties. The ceramic phase in the core provides enhanced physical properties such as heat resistance and structural stability, while the metal shell ensures good processability during additive manufacturing.
3Device complexity
If conventional metal fabrication techniques are used, then manufacturing simplicity is maintained, but structural complexity deteriorates
Solution Approach 1:
The patent segments the powder particle into a core-shell structure with distinct functional zones. The core contains the ceramic phase for strength and physical property enhancement, while the shell contains the metal phase for weldability and processability. This segmentation allows conventional additive manufacturing processes to create complex structures that would be difficult to achieve with monolithic materials.
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
This approach enhances the strength and physical properties of additively manufactured metal articles, addressing the limitations of traditional metal alloys by promoting weldability and process capabilities, resulting in structures with reduced impurities and improved density.
Implementation Method 1
selective exposure to an energy source such as a laser or electron beam
Implementation Method 2
Metal powder in this layer is selectively fused such as by selective exposure to an energy source
Implementation Method 3
infiltrating the porous ceramic pre-form with a liquid comprising a first metal
Data Source
AI summary
A method for making an article is disclosed. According to the method, a digital model of the article is generated. The digital model is inputted into an additive manufacturing apparatus comprising an energy source. The additive manufacturing apparatus applies energy from the energy source to successively applied incremental quantities of a powder to fuse the powder to form the article corresponding to the digital model. The powder particles individually include a composite core including a first phase of a first metal and a second phase of a ceramic. A first shell including a second metal is disposed over the core.