Non-Weldable Superalloy Ink for Crack-Free Sintering
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Solution Overview
Problem
High-γ′ superalloys are difficult to weld or print using fusion-based additive manufacturing due to their susceptibility to cracking, limiting the manufacturing of articles with enhanced mechanical properties for extreme environments.
Innovation Solution
An ink formulation comprising non-weldable superalloy particles with a primary element of Ni, Co, or Fe, and a secondary element from Group 4 to Group 14, combined with a polymer binder and solvent, is used for direct ink writing and thermal sintering to produce articles with a high volume fraction of γ′ precipitates, avoiding the formation of brittle carbides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-γ′ superalloys are used to enhance mechanical properties, then strength and thermal stability are improved, but susceptibility to cracking increases making them difficult to weld or print by fusion-based additive manufacturing
Solution Approach 1:
The patent changes the manufacturing parameters from fusion-based additive manufacturing to direct ink writing followed by thermal sintering. This parameter change allows the use of high-γ′ superalloys that would otherwise be unsuitable for AM, as the sintering process enables proper bonding without the cracking issues associated with fusion methods. The ink formulation parameters (particle size, binder type, solvent composition) are also optimized to enable successful manufacturing.
Solution Approach 2:
The patent introduces a polymer binder as an intermediary substance that facilitates the manufacturing process. The binder allows the superalloy particles to be deposited and bonded together through thermal sintering, acting as a temporary medium that enables formability without requiring direct fusion of the superalloy particles themselves, thus avoiding cracking issues.
2Ease of manufacture
If fusion-based additive manufacturing is used to manufacture superalloy articles, then manufacturing capability is improved, but cracking occurs due to high susceptibility of high-γ′ superalloys
Solution Approach 1:
The patent replaces the fusion-based manufacturing mechanism with a sintering-based mechanism. Instead of melting and fusing superalloy particles (which causes cracking), the process uses thermal sintering of bonded particles, substituting the physical mechanism to eliminate the harmful cracking effect while maintaining manufacturing capability.
Solution Approach 2:
The polymer binder serves as an intermediary that enables the sintering process to proceed without direct fusion of superalloy particles. The binder facilitates particle bonding during sintering, allowing manufacturing to proceed while avoiding the cracking associated with fusion methods.
3Reliability
If non-weldable superalloys are manufactured using direct ink writing and thermal sintering, then cracking is prevented and mechanical properties are improved, but the process complexity increases
Solution Approach 1:
The patent segments the manufacturing process into distinct stages: ink formulation, direct ink writing/deposition, and thermal sintering. This segmentation allows each stage to be optimized independently and facilitates better process control, reducing overall complexity despite the multi-step nature of the process. The ink formulation itself is segmented into particles, binder, and solvent components.
Solution Approach 2:
By changing the fundamental process parameters from fusion-based to sintering-based, the patent achieves crack prevention while managing process complexity through established sintering technology. The parameter changes allow use of conventional sintering equipment and procedures, limiting the increase in device complexity.
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 fabrication of non-weldable superalloys with improved mechanical properties, suitable for high-temperature applications like aircraft and turbines, by preventing cracking and achieving denser structures with enhanced strength and ductility.
Implementation Method 1
thermal sintering to produce articles with a high volume fraction of γ′ precipitates
Implementation Method 2
These precipitates can produce a precipitation-hardening mechanism to strengthen the γ matrix during deformation
Data Source
AI summary
An ink formulation for manufacturing a non-weldable superalloy, the ink formulation including: a superalloy particle, the superalloy particle including a primary element of Ni, Co, Fe, or a combination thereof, and a secondary element including an element of Group 4 to Group 14, or a combination thereof, of the Periodic Table of the Elements, other than the primary element, wherein the superalloy particle has a size of less than 30 micrometers; a binder including a polymer, and a solvent.