Spherical Titanium Powder Blends for Additive Manufacturing

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Solution Overview

Problem

The high cost and machining difficulties of titanium-based alloys for aerospace applications, particularly in additive manufacturing, are exacerbated by the need for spherical metallic powders with precise oxygen concentrations to maintain mechanical properties, while existing low-oxygen powders are expensive and costly to produce.

Innovation Solution

A method involving grinding and spheroidizing a metallic starting material to create a blend of spherical powder components with varying oxygen concentrations, allowing for the mixing of high-oxygen and low-oxygen titanium powders to achieve the desired oxygen threshold in the final blend, reducing material costs and maintaining mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If spherical titanium powders with low oxygen concentration (at most 2000 ppm) are used to meet industry specifications, then mechanical properties (ductility and toughness) are maintained, but the cost exceeds $100 per pound

Engineering Contradiction:

Improvemechanical propertiesVSAvoidcost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent divides the powder blend into two distinct spherical powder components: a first component with oxygen concentration of 2100-4000 ppm and a second component with oxygen concentration of at most 1800 ppm. This segmentation allows each component to serve a specific function - the first component reduces cost while the second component ensures mechanical property requirements are met when mixed together

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates a composite powder blend by mixing two spherical titanium powder components with different oxygen concentrations. The resulting blend (e.g., 50:50, 40:60, or 30:70 ratios) combines the cost advantages of higher-oxygen powder with the mechanical property benefits of lower-oxygen powder, achieving a balance between cost and performance

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If spherical metallic powders are used for additive manufacturing to meet flowability and packing requirements, then manufacturing capability is improved, but the cost increases significantly

Engineering Contradiction:

ImproveflowabilityVSAvoidcost

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The patent segments the powder system into two spherical components that can be independently optimized for cost while maintaining the flowability and packing characteristics required for additive manufacturing. Both components are spherical, ensuring the blend maintains operational ease

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the oxygen concentration parameter of the powder components to achieve cost reduction. By using a first component with 2100-4000 ppm oxygen (lower cost) mixed with a second component with at most 1800 ppm oxygen, the blend achieves acceptable mechanical properties at lower overall cost while maintaining spherical morphology for good flowability

Inventive Principle:

Principle #35Parameter changes

3Strength

If titanium-based alloys are used for aerospace components to achieve high strength-to-weight ratios, then mechanical performance is improved, but machining difficulty and cost increase

Engineering Contradiction:

Improvestrength-to-weight ratioVSAvoidmachining difficulty

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent changes the chemical composition parameters of the titanium powder by controlling oxygen concentration in the blended powder. The first component contains 2100-4000 ppm oxygen while the second contains at most 1800 ppm, creating a balanced composition that achieves desired mechanical properties while reducing overall material cost

Inventive Principle:

Principle #35Parameter changes

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 method produces spherical metallic powder blends with oxygen concentrations at or below industry thresholds, enhancing ductility and toughness while offering significant cost savings compared to using only high-quality, low-oxygen virgin powders.

Implementation Method 1

grinding a metallic starting material to yield an intermediate powder

Methodology Applied

Scientific EffectGrinding: Abrasion

Implementation Method 2

spheroidizing the intermediate powder to yield a first spherical powder component

Methodology Applied

Scientific EffectSpheroidizing:

Implementation Method 3

mixing the first spherical powder component with a second spherical powder component

Methodology Applied

Scientific EffectMixing:

Data Source

PatentUS11130175B2Spherical metallic powder blends and methods for manufacturing the same

Publication Date: 2021.09.28 THE BOEING CO

AI summary

A method for manufacturing a spherical metallic powder blend using a metallic starting material, the method including steps of grinding the metallic starting material to yield an intermediate powder, spheroidizing the intermediate powder to yield a first spherical powder component, and mixing the first spherical powder component with a second spherical powder component, wherein the first spherical powder component and the second spherical powder component have substantially the same chemical composition.