Titanium Alloy Composition for Equiaxed Grains in Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing of titanium alloys often results in coarse columnar grains, leading to undesirable anisotropic mechanical properties, which requires additional post-deposition heat treatments to achieve desired properties.
Innovation Solution
Incorporating a beta cutectoid stabilizer, such as iron, copper, or nickel, into titanium alloys to produce an equiaxed grain structure during the additive manufacturing process, eliminating the need for post-deposition heat treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional titanium alloys are used in additive manufacturing, then the material can be processed, but coarse columnar grains form leading to anisotropic mechanical properties
Solution Approach 1:
The patent changes the chemical composition parameters of the titanium alloy by adding specific elements (Fe: 0.5-5 wt%, Ni: 0.5-5 wt%, Cu: 0.5-5 wt%, or combinations) to modify the solidification behavior and grain structure formation during additive manufacturing, transforming the material parameters to achieve equiaxed grains instead of columnar grains
Solution Approach 2:
The patent creates a composite alloy system by combining titanium with multiple potential alloying elements (Fe, Ni, Cu) where at least one must be present in specified amounts. This composite approach leverages the grain-refining effects of different elements to consistently produce equiaxed grain structures while maintaining titanium's base properties
2Strength
If post-deposition heat treatments are performed to break down columnar grain structure, then mechanical properties improve, but manufacturing time and cost increase
Solution Approach 1:
The patent performs preliminary action by incorporating grain-refining alloying elements into the titanium alloy composition before additive manufacturing. This pre-treatment ensures that equiaxed grains form directly during the building process, eliminating the need for subsequent heat treatments to break down columnar structures
Solution Approach 2:
The patent extracts the unnecessary post-deposition heat treatment step from the manufacturing process by designing an alloy composition that self-produces the desired equiaxed grain structure during additive manufacturing, thereby removing the time-consuming and costly intermediate processing step
3Stability of the object's composition
If post-deposition heat treatments are performed to eliminate columnar grain structure, then anisotropic properties are reduced, but additional processing steps are required
Solution Approach 1:
The patent performs preliminary action by incorporating grain-refining alloying elements into the titanium alloy composition before additive manufacturing. This pre-treatment ensures that equiaxed grains form directly during the building process, eliminating the need for subsequent heat treatments to break down columnar structures
Solution Approach 2:
The patent makes the alloying elements serve multiple functions: they not only strengthen the titanium alloy but also control grain structure formation to produce equiaxed grains. This multi-functionality eliminates the need for separate grain-refining heat treatment steps, simplifying the overall 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 use of beta cutectoid stabilizers in titanium alloys results in objects with improved mechanical properties, allowing them to be directly used without additional processing steps, thereby saving time and resources.
Implementation Method 1
the columnar grain structure (and by extension the anisotropic mechanical properties) of the build can be reduced or eliminated when the titanium alloy is melted or sintered during an additive manufacturing process
Data Source
AI summary
Disclosed are titanium alloys for use in additive manufacturing that comprise a titanium material and a beta eutectoid stabilizer. The beta eutectoid stabilizer can be present in an effective amount to produce an equiaxed grain structure when the titanium alloy is melted or sintered during an additive manufacturing process. Also provided are methods of forming objects via additive manufacturing processes as well as methods of forming titanium alloys for use in additive manufacturing.