Refractory Metal Wire Feedstock for Low-Defect 3D Printing
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Solution Overview
Problem
Additive manufacturing of metallic parts faces challenges such as sparking, blistering, splattering, excessive porosity, cracking, and insufficient density due to the melting of conventional precursor materials, which are exacerbated by high concentrations of volatile impurities.
Innovation Solution
The development of wires with reduced gaseous and volatile impurities, such as oxygen, sodium, and phosphorus, made from refractory metals like niobium, tantalum, rhenium, tungsten, and molybdenum, fabricated through arc melting in a vacuum or inert ambient, minimizing impurities and enabling successful additive manufacturing with minimal defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional precursor materials are used in additive manufacturing, then the manufacturing process can be performed, but sparking, blistering, and splattering occur due to volatile impurities
Solution Approach 1:
The patent applies inert atmosphere by conducting arc melting in a vacuum or inert gas environment to prevent oxidation and minimize volatile impurity formation in the metallic wire feedstock, thereby eliminating sparking, blistering, and splattering during additive manufacturing
Solution Approach 2:
The patent applies preliminary action by pre-fabricating the wire feedstock through arc melting in vacuum or inert atmosphere before the additive manufacturing process, removing volatile impurities in advance to prevent harmful effects during subsequent melting operations
2Productivity
If conventional precursor materials are used in additive manufacturing, then the process can proceed, but excessive porosity and cracking occur in the final part
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the wire feedstock through arc melting in vacuum or inert atmosphere, reducing volatile impurity concentrations to below detectable levels, which eliminates porosity and cracking while maintaining high density (>96% theoretical density)
3Ease of manufacture
If conventional precursor materials are used, then additive manufacturing can be performed, but insufficient density and poor machinability result
Solution Approach 1:
The patent applies inert atmosphere during arc melting to prevent oxidation and volatile impurity formation, producing wire feedstock with superior density and machinability that maintains high structural integrity throughout the additive manufacturing process
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
The resulting three-dimensional parts exhibit high density (>96% of theoretical density) with minimal porosity and cracking, and are suitable for various applications including MIG welding, with improved machinability and structural integrity.
Implementation Method 1
The precursor wire itself may include, consist essentially of, or consist of one or more refractory metals, e.g., niobium (Nb), tantalum (Ta), rhenium (Re), tungsten (W), and/or molybdenum (Mo). The wire may be utilized in an additive manufacturing process to form a three-dimensional part, e.g., a refractory crucible.
Implementation Method 2
The precursor wire is fabricated, at least partially, via arc melting in a vacuum or a substantially inert ambient. The arc-melting process advantageously minimizes or reduces the concentration of volatile impurities within the wire
Implementation Method 3
The platform (and/or the wire) moves such that the molten wire traces out the pattern of a substantially two-dimensional slice of the final part; in this manner, the final part is fabricated in layer-by-layer fashion via melting and rapid solidification of the wire. In such additive manufacturing processes, the wire is successfully melted during formation of the three-dimensional part, e.g., by an electron beam or a laser.
Implementation Method 4
The platform (and/or the wire) moves such that the molten wire traces out the pattern of a substantially two-dimensional slice of the final part; in this manner, the final part is fabricated in layer-by-layer fashion via melting and rapid solidification of the wire. In such additive manufacturing processes, the wire is successfully melted during formation of the three-dimensional part, e.g., by an electron beam or a laser.
Data Source
AI summary
In various embodiments, wire composed at least partially of arc-melted refractory metal material is utilized to fabricate three-dimensional parts by additive manufacturing.