Titanium Alloy Composition for Equiaxed Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing of titanium alloys results in coarse columnar grains, leading to undesirable anisotropic mechanical properties, necessitating additional post-deposition processes like HIP'ing or heat-treatments, which increase costs and limit direct serviceability.
Innovation Solution
Incorporating a beta eutectoid stabilizer such as Fe, Ni, or Cu into titanium alloys to produce an equiaxed grain structure during the additive manufacturing process, eliminating the need for post-deposition treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional titanium alloys are used in additive manufacturing, then the manufacturing process can be completed, but coarse columnar grains form leading to anisotropic mechanical properties
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition of titanium alloys through the addition of beta eutectoid stabilizers (such as Fe, Ni, Cu, or their combinations in specific weight percentages). This compositional parameter change fundamentally alters the solidification behavior during additive manufacturing, transforming the grain structure from coarse columnar to fine equiaxed, thereby resolving the contradiction between manufacturing feasibility and mechanical property uniformity.
Solution Approach 2:
The patent employs composite materials by creating multi-element titanium alloys that combine Ti with beta eutectoid stabilizers (Fe, Ni, Cu) and other alloying elements. These composite alloy systems produce synergistic effects during solidification, where the interaction between different elements promotes equiaxed grain formation and eliminates the anisotropic properties inherent in traditional single-phase or simple alloy systems.
2Strength
If post-deposition HIP'ing or 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 applies preliminary action by incorporating beta eutectoid stabilizers into the titanium alloy composition before the additive manufacturing process. This pre-alloying approach ensures that the equiaxed grain structure forms directly during solidification, eliminating the need for subsequent post-deposition heat treatments or HIP'ing steps. The desired grain structure is achieved in advance, during the manufacturing process itself, thereby saving time and reducing manufacturing complexity.
Solution Approach 2:
The patent applies the extraction principle by removing the necessity for post-deposition heat treatment steps from the manufacturing workflow. By designing the alloy composition to inherently produce equiaxed grains during additive manufacturing, the patent extracts or eliminates the separate HIP'ing or heat-treatment operations that would otherwise be required, thereby reducing manufacturing time, cost, and process complexity.
3Stability of the object's composition
If post-deposition treatments are performed to eliminate columnar grain structure, then anisotropic properties are reduced, but additional processing steps are required
Solution Approach 1:
The patent applies parameter changes by modifying the alloy composition parameters (adding beta eutectoid stabilizers) to fundamentally change the solidification behavior. This parameter modification ensures that equiaxed grains form during the additive manufacturing process itself, eliminating the need for additional post-deposition treatment steps and thereby reducing overall process complexity while maintaining grain structure uniformity.
Solution Approach 2:
The patent applies universality by designing a titanium alloy composition that performs multiple functions: it provides the base structural properties of titanium, enables equiaxed grain formation during solidification, and eliminates the need for subsequent heat treatment steps. This multi-functional alloy design integrates grain structure control directly into the manufacturing process, reducing the number of separate processing steps required.
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 equiaxed grain structure enhances mechanical properties, allowing titanium alloy components to be directly used without extra processing steps, reducing time and cost.
Implementation Method 1
by incorporating an effective amount of a beta eutectoid stabilizer, one can form titanium alloys which produce an equiaxed grain structure when 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.