In Situ Cu-Cr2Nb Alloying via Selective Laser Melting

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Solution Overview

Problem

The conventional production of Copper-Chromium-Niobium (Cu—Cr—Nb) alloys, known as GRCop, faces issues with impurities, long lead times, and high costs due to the need for pre-alloyed powders, which are expensive and have limited compositions, and are produced using processes that involve high temperatures and refractory containers, leading to contamination and restricted availability.

Innovation Solution

A method involving the selective laser melting of elemental copper, chromium, and niobium powders to form in situ Cu—Cr2Nb alloys, allowing for the production of GRCop alloys with adjustable compositions and reduced impurities, using a process that eliminates the need for pre-alloyed powders and reduces procurement lead times.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If pre-alloyed powders are used for GRCop alloy production, then the alloy can be manufactured with desired composition, but the production process becomes complex and time-consuming with long lead times

Engineering Contradiction:

Improvealloy composition controlVSAvoidprocurement lead time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-mixing elemental powders in precise stoichiometric ratios before additive manufacturing. This pre-preparation of powder mixtures with exact compositions eliminates the need for lengthy procurement of pre-alloyed powders, reducing lead times while maintaining composition control through careful powder blending procedures

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent extracts the alloying step from the traditional process by forming Cr2Nb intermetallic phases in situ during additive manufacturing rather than using pre-alloyed powders. This separates the composition control (achieved through powder mixing) from the manufacturing process, eliminating procurement delays while maintaining precision

Inventive Principle:

Principle #2Taking out (Extraction)

2Strength

If conventional gas atomization is used to produce pre-alloyed powders, then Cr2Nb precipitates can be formed, but impurities are introduced from refractory containers and oxygen reactions

Engineering Contradiction:

Improvedispersion strengtheningVSAvoidalloy impurities

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful effect of oxygen and container reactions into a benefit by using in situ alloying during additive manufacturing. The controlled atmosphere and direct melting process transform what would be contamination sources into a clean manufacturing environment, producing purer alloys while maintaining Cr2Nb precipitate formation for dispersion strengthening

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent introduces an intermediary controlled atmosphere (inert or vacuum environment) between the melt and contaminants. This mediator prevents harmful reactions with oxygen and refractory materials while allowing the Cr2Nb intermetallic phases to form correctly, eliminating impurities without sacrificing strengthening properties

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If pre-alloyed powders with specific compositions are procured commercially, then GRCop-84, GRCop-42, and GRCop-21 alloys are available, but the variety of alloy compositions is limited

Engineering Contradiction:

Improvealloy composition varietyVSAvoidcommercial availability

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The patent applies dynamics by making alloy composition adjustable and flexible rather than fixed. The additive manufacturing process allows real-time modification of Cr and Nb content by changing powder mixture ratios, enabling customization of alloy compositions beyond commercial catalogs while maintaining production capability through standard manufacturing processes

Inventive Principle:

Principle #15Dynamics

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 method enables the on-demand production of GRCop alloys with tailored compositions and microstructures, similar to commercially available alloys, while minimizing contamination and costs, by forming the alloys directly from elemental powders using selective laser melting, resulting in high-quality components with reduced impurities and improved properties.

Implementation Method 1

melting at least a portion of the mixture using a laser

Methodology Applied

Scientific EffectLaser melting: Laser

Implementation Method 2

cooling a melted portion of the mixture to form the dispersion strengthened Cu—Cr2Nb alloy

Methodology Applied

Scientific EffectRapid cooling: Cooling

Data Source

PatentUS11859272B1In situ alloying of Cu—Cr—Nb alloys using selective laser melting

Publication Date: 2024.01.02 UNITED STATES GOVERNMENT ADMINISTRATOR OF NASA

AI summary

In situ alloying of elemental Cu, Cr, and Nb powder using laser melting to form a Cu—Cr2Nb alloy. The elemental powders are initially mixed to form a homogeneous mixture, which mixture is then subjected to laser radiation to melt the mixture. In the melt, the Cr and Nb react to form Cr2Nb, which when cooled form precipitates that are dispersed in a nearly pure Cu matrix to thus dispersion strengthen the material. The methods can be used to additively manufacture a 3D component of Cu—Cr2Nb alloy using a selective laser melting machine.