Multi-Powder AM Nozzle for Graded High-Entropy Alloys
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Solution Overview
Problem
Current additive manufacturing systems for complex concentrated alloys (CCAs) and high entropy alloys (HEAs) lack the capability to efficiently produce parts with graded compositions and high throughput, limiting their application in high temperature and irradiation-resistant applications.
Innovation Solution
A novel additive manufacturing nozzle with multiple powder channels and an energy application channel, allowing for simultaneous ejection of multiple powders and controlled energy application to form CCAs/HEAs, along with a method that includes cold working and gradient composition formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional additive manufacturing methods use pre-mixed powder for HEAs, then the manufacturing process is simple, but the ability to manufacture parts with graded composition is limited
Solution Approach 1:
The nozzle is divided into multiple independent powder delivery channels (at least five channels), each capable of delivering a different powder material. This segmentation allows independent control of each powder stream, enabling graded composition manufacturing while keeping each channel relatively simple in structure.
Solution Approach 2:
The nozzle design integrates multiple powder delivery functions into a single device, allowing it to handle at least five different powder materials simultaneously. This multi-functionality enables the system to manufacture various HEA compositions and graded structures using one nozzle, improving versatility without requiring multiple specialized nozzles.
2Productivity
If traditional additive manufacturing methods are used for HEAs, then the equipment is simple, but the throughput for manufacturing and characterization is low
Solution Approach 1:
The nozzle system is segmented into at least five independent powder channels, allowing simultaneous delivery of multiple powders in a single manufacturing process. This enables high-throughput production of HEA parts with complex compositions, as all required materials can be deposited concurrently rather than requiring multiple sequential operations.
Solution Approach 2:
The nozzle combines multiple powder delivery streams into a single deposition zone, merging at least five different powder materials simultaneously. This consolidation allows high-throughput manufacturing of HEA parts with complex multi-element compositions in a single continuous process, significantly improving productivity compared to sequential powder delivery methods.
3Adaptability or versatility
If conventional additive manufacturing nozzles are used, then the nozzle structure is simple, but the capability to deliver multiple powders simultaneously is limited
Solution Approach 1:
The nozzle is segmented into at least five separate powder channels, each independently configured to deliver a specific powder material. This segmentation provides the capability to deliver multiple powders simultaneously while maintaining relatively simple individual channel structures, making the multi-powder delivery system manageable and manufacturable.
Solution Approach 2:
The nozzle is designed as a multi-functional device that can deliver at least five different powder materials through its multiple channels. This universal design allows the single nozzle to handle diverse HEA compositions, improving adaptability and versatility without requiring multiple specialized nozzles for different material combinations.
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 production of complex alloy parts with tailored compositions and microstructures, enhancing high temperature strength and irradiation resistance, and facilitating high throughput manufacturing and characterization.
Implementation Method 1
The energy application channel can be an optical channel for passing a laser
Implementation Method 2
an energy applicator (e.g., a laser) configured to provide energy to the powder to sinter the powder to form an additively manufactured article
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A complex concentrated alloy (CCA) and/or high entropy alloy (HEA) additive manufacturing nozzle (100) can include a nozzle body (101) defining at least four powder channels (103). Each powder channel can be configured to be connected to a powder supply (317a-h) of a plurality of powder supplies to receive a powder from the powder supply for ejecting the powder toward a build area to form an additively manufactured article having a CCA and/or an HEA.