Electron Beam Melted Superalloys With Seeded Texture Control
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Solution Overview
Problem
Current rapid prototyping and additive-layer manufacturing techniques lack control over the microstructure of metal formations, leading to lower moduli and increased wear, particularly in nickel-based superalloy products.
Innovation Solution
A process involving electron beam melting of a metal alloy powder composition in the presence of a seed crystal to achieve highly textured or single crystal microstructures, with optional use of inoculants and subsequent heat treatment or hot isostatic pressing to control the microstructure and enhance properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If rapid prototyping or additive-layer manufacturing techniques are used to fabricate metal products, then complex shapes can be achieved, but the microstructure of the metal formations cannot be controlled
Solution Approach 1:
A seed crystal is introduced at the beginning of the electron beam melting process to establish the desired microstructure before the bulk material is formed. This preliminary action of nucleation control allows the subsequent additive manufacturing process to produce parts with controlled microstructures while maintaining complex geometries
Solution Approach 2:
The invention applies different microstructural characteristics to different regions of the part by controlling seed crystal placement and orientation. This allows specific areas to have optimized microstructures for their functional requirements while other areas maintain the complex shape requirements, achieving local quality optimization throughout the part
2Ease of manufacture
If current rapid prototyping techniques are used without microstructure control, then manufacturing complexity is reduced, but the modulus and wear resistance decrease
Solution Approach 1:
The invention changes the physical and chemical parameters of the melting process by controlling seed crystal characteristics (size, orientation, composition) and processing conditions (electron beam parameters, heating rates, cooling rates). These parameter changes enable the production of parts with enhanced modulus and wear resistance while maintaining the simplicity of additive manufacturing processes
3Device complexity
If electron beam melting is used without seed crystal, then process simplicity is maintained, but crystallographic texture cannot be controlled
Solution Approach 1:
The seed crystal serves as an intermediary element that mediates between the simple electron beam melting process and the desired controlled crystallographic texture. This intermediary provides the nucleation sites and orientation templates needed for texture control without requiring complex modifications to the electron beam melting equipment or 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 process enables the production of superalloy metals with controlled crystallographic textures, improving mechanical properties such as ductility and creep resistance, and reducing crystallographic texture, resulting in enhanced performance for aerospace applications.
Implementation Method 1
processing the metal alloy powder composition in the presence of the seed crystal to provide a superalloy metal having a highly textured or single crystal microstructure; and characterised in that the processing step is performed by electron beam melting
Implementation Method 2
providing a seed crystal; processing the metal alloy powder composition in the presence of the seed crystal to provide a superalloy metal having a highly textured or single crystal microstructure
Implementation Method 3
the process for the preparation of a superalloy metal according to the invention further comprises subjecting the superalloy metal, after processing, to heat treatment
Implementation Method 4
the process for the preparation of a superalloy metal according to the invention further comprises subjecting the superalloy metal, after processing, to heat treatment, hot isostatic pressing (HIP), or both
Data Source
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AI summary
The present disclosure provides a method of preparing superalloy metals having a crystallographic texture controlled micro structure by electron beam melting.