Multi-Component Build Powder for Dense 3D Printed Metal Articles
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Solution Overview
Problem
Existing three-dimensional printing methods for producing dense metallic articles require complex setups with infiltrant reservoirs and stilts, leading to significant work and scrap generation, especially for small articles, due to the need for conducting molten metal into a metal skeleton, which impacts furnace size and efficiency.
Innovation Solution
A multiple-component build powder comprising a first material with a higher melting temperature and limited solubility in a second material is used for three-dimensional printing, allowing the second material to infiltrate between the first material particles upon heating, achieving a relative density of at least 85% of theoretical density without the need for external stilts or reservoirs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a metal skeleton is created by three-dimensional printing and then infiltrated with molten metal using external stilts and reservoirs, then dense metallic articles can be produced, but the process complexity and scrap generation increase significantly
Solution Approach 1:
The invention extracts and eliminates the external infiltration system (stilts and reservoirs) by incorporating the infiltration function directly into the build powder mixture. The build powder itself contains both the skeleton-forming material and the infiltrant material, removing the need for separate infiltration components.
Solution Approach 2:
The invention merges the skeleton material and infiltrant material into a single multi-component build powder mixture. This combination allows both materials to be deposited together in the desired spatial distribution, eliminating the need for separate infiltration operations and external delivery systems.
2Manufacturing precision
If external stilts are used to conduct molten metal into the metal skeleton, then infiltration can be achieved, but significant work and scrap generation occur
Solution Approach 1:
The build powder mixture serves itself by containing both the skeleton material and infiltrant material in the correct proportions and spatial distribution. The infiltration process uses the same deposited structure as both the recipient and the delivery mechanism, eliminating the need for separate stilts that would become scrap.
3Manufacturing precision
If traditional infiltration methods with reservoirs are used, then dense articles can be produced, but the furnace size and operational efficiency are impacted
Solution Approach 1:
The infiltrant material is pre-positioned within the build powder mixture at the exact locations where infiltration is needed. This preliminary distribution eliminates the need for large reservoirs and complex delivery systems during the infiltration process, allowing for more efficient furnace operations and smaller equipment sizes.
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 production of fully dense articles with reduced operational complexity and scrap generation, achieving high relative density without the need for external infiltration systems, making the process more efficient and cost-effective for producing small and large articles alike.
Implementation Method 1
heating the printed article to a temperature at which a sufficient amount of the second material powder melts to enable it to infiltrate throughout the interstices between the first material powder particles
Implementation Method 2
The first material powder has a melting temperature, melting temperature range, or dissociation temperature which is higher than the melting temperature or melting temperature range of the second material powder
Data Source
Figure 1~2
Figure 3~4
AI summary
Methods are disclosed for making articles (2) by three-dimensional printing. The methods include three-dimensional printing a build powder mixture which includes a first material powder and a second material powder to form a printed article and subsequently heating the printed article to a temperature at which a sufficient amount of the second material powder melts to enable it to infiltrate throughout the interstices between the first material powder particles so that the article (2) achieves a room temperature relative density of at least 85 percent of its theoretical density, the theoretical density being the density the article (2) would have if it contained no porosity. The first material powder has a melting temperature, melting temperature range, or dissociation temperature which is higher than the melting temperature or melting temperature range of the second material powder and the first material powder has no more than a limited amount of solubility in the second material powder.