Metallic Microlayer Sealing for HIP-Densified 3D Microfeatures
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Solution Overview
Problem
Additively-manufactured high-temperature components with microfeatures often exhibit porosity near surfaces, which affects their performance and makes them unsuitable for hot isostatic pressing, and conventional infiltration methods can degrade the material properties, making them unsuitable for high-temperature applications.
Innovation Solution
A process involving additive manufacturing of components with microfeatures, followed by coating the external and internal surfaces with a metallic microlayer to seal porosity and subsequent densification using hot isostatic pressing to achieve full or near-full density without degrading the material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional infiltration by low-melting point alloy is used to address near-surface porosity, then porosity is reduced, but the properties of the 3-D printed parent alloy are degraded
Solution Approach 1:
A metallic microlayer coating is applied as an intermediary substance between the porous 3-D printed component and the densification process. This microlayer seals the porosity on external and internal surfaces, enabling subsequent hot isostatic pressing to densify the component without the microlayer degrading the parent alloy properties, thus resolving the contradiction between porosity reduction and material property preservation
2Manufacturing precision
If hot isostatic pressing is attempted on components with surface-connected porosity, then densification is attempted, but the process is impossible due to unsealed porosity
Solution Approach 1:
The metallic microlayer coating is applied as a preliminary action before hot isostatic pressing. This coating pre-seals the surface-connected porosity on external and internal surfaces, transforming the component from an unsuitable state for HIP to a suitable state, thereby enabling the subsequent densification process to proceed effectively
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 process effectively seals porous surfaces, enables hot isostatic pressing of high-temperature components with microfeatures, and improves mechanical properties, making them suitable for high-temperature applications while maintaining material integrity.
Implementation Method 1
coating the external surface and the internal surface of the printed article with a metallic microlayer
Implementation Method 2
densifying the coated article to form a component
Data Source
AI summary
A process includes forming a printed article having an external surface and at least one microfeature with an internal surface by additive manufacture, coating the external surface and the internal surface of the printed article with a metallic microlayer to form a coated article, and densifying the coated article to form a component. After formation, the printed article has a porosity such that the printed article is not at full density. A densified component includes a printed article having an external surface and at least one microfeature with an internal surface and a metallic microlayer coating the external surface and the internal surface of the printed article. The printed article is formed by additive manufacture.