Multi-Powder AM Nozzle for Graded High-Entropy Alloys
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Solution Overview
Problem
Conventional methods for manufacturing complex concentrated alloys (CCAs) and high entropy alloys (HEAs) are limited in their ability to produce parts with graded compositions and high throughput, as they typically involve pre-mixed powders leading to uniform compositions.
Innovation Solution
An additive manufacturing nozzle with multiple powder channels and an energy application channel, allowing simultaneous ejection and sintering of multiple powders, along with a controller to manage feed rates and cold working processes, enabling the formation of CCA and HEA articles with graded compositions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pre-mixed powders are used in additive manufacturing, then manufacturing process is simple, but composition uniformity is limited and graded composition cannot be achieved
Solution Approach 1:
The single powder delivery system is segmented into multiple independent powder channels (at least four channels), each capable of delivering different powder materials independently. This segmentation allows each channel to be controlled separately, enabling graded composition while maintaining additive manufacturing process simplicity.
Solution Approach 2:
The additive manufacturing nozzle is designed with multi-functionality to handle multiple powder types simultaneously through separate channels. Each powder channel can be independently controlled to deliver different materials, making the system universal for creating various composition gradients without requiring multiple separate manufacturing processes.
2Productivity
If traditional arc melting or drop casting is used, then alloy production is achieved, but high throughput manufacturing and graded composition are limited
Solution Approach 1:
The system employs dynamic control of powder delivery rates through independently controllable powder channels. Each channel can adjust its powder delivery rate in real-time, enabling the system to dynamically create graded compositions while maintaining high manufacturing throughput characteristic of additive manufacturing processes.
Solution Approach 2:
The invention utilizes parameter changes in powder delivery rates across multiple channels to achieve graded compositions. By varying the delivery rate parameters of each powder channel independently, the system can create spatial and temporal gradients in alloy composition while maintaining high production rates.
3Adaptability or versatility
If multiple powders are delivered through separate channels, then graded composition is achieved, but device complexity increases
Solution Approach 1:
The multiple powder channels are nested within a single additive manufacturing nozzle body, with each channel independently controllable. This nested configuration allows the complex multi-powder delivery system to be integrated into a unified nozzle structure, reducing overall system complexity while maintaining graded composition capability.
4Stability of the object's composition
If pre-mixed powders are used, then constant composition throughout build is achieved, but ability to manufacture parts with graded composition is limited
Solution Approach 1:
The system implements local quality control by enabling different powder delivery rates and compositions at different locations and times during the build process. Each powder channel can be independently controlled to deliver specific materials to specific regions, achieving graded compositions while maintaining uniformity where required through precise local adjustment of delivery parameters.
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 rapid production of parts with tailored compositions and properties, facilitating high throughput manufacturing and characterization of HEAs for high-temperature applications.
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
AI summary
A complex concentrated alloy (CCA) and/or high entropy alloy (HEA) additive manufacturing nozzle can include a nozzle body defining at least four powder channels. Each powder channel can be configured to be connected to a powder supply 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.