Title: Additive manufacturing methods using aluminum-rare earth alloys and products made using such methods

Abstract

Described herein are additive manufacturing methods and products made using such methods. The alloy compositions described herein are specifically selected for the additive manufacturing methods and provide products that exhibit superior mechanical properties as compared to their cast counterparts. Using the compositions and methods described herein, products that do not exhibit substantial coarsening, such as at elevated temperatures, can be obtained. The products further exhibit uniform microstructures along the print axis, thus contributing to improved strength and performance. Additives also can be used in the alloys described herein.

Inventors:

Plotkowski, Alex J.; Rios, Orlando; Babu, Sudarsanam Suresh; Dehoff, Ryan R.; Ott, Ryan T.; Sims, Zachary C.; Sridharan, Niyanth; Weiss, David S.; Henderson, Hunter B.

Issue Date:

2020-09-01

Research Org.:

Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Ames Lab., Ames, IA (United States)

Sponsoring Org.:

USDOE

OSTI Identifier:

1735204

Patent Number(s):

10760148

Application Number:

15/650,664

Assignee:

UT-Battelle, LLC (Oak Ridge, TN); University of Tennessee Research Foundation (Knoxville, TN); Iowa State University Research Foundation, Inc. (Ames, IA); Eck Industries Incorporated (Manitowoc, WI)

Patent Classifications (CPCs):

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02P - CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

C - CHEMISTRY C22 - METALLURGY C22C - ALLOYS

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Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02P - CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

Y02P10/25 - by increasing the energy efficiency of the process

C - CHEMISTRY C22 - METALLURGY C22C - ALLOYS

C22C21/00 - Alloys based on aluminium
C22C1/0416 - {Aluminium-based alloys}
C22C1/03 - using master alloys

B - PERFORMING OPERATIONS B23 - MACHINE TOOLS B23K - SOLDERING OR UNSOLDERING

B23K26/354 - by melting

B - PERFORMING OPERATIONS B33 - ADDITIVE MANUFACTURING TECHNOLOGY B33Y - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING

B33Y80/00 - Products made by additive manufacturing

C - CHEMISTRY C22 - METALLURGY C22C - ALLOYS

C22C23/06 - with a rare earth metal as the next major constituent
C22C21/08 - with silicon
C22C30/06 - containing zinc
C22C28/00 - Alloys based on a metal not provided for in groups C22C5/00 - C22C27/00
C22C21/06 - with magnesium as the next major constituent

C - CHEMISTRY C21 - METALLURGY OF IRON C21D - MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS

C21D1/10 - by electric induction

B - PERFORMING OPERATIONS B33 - ADDITIVE MANUFACTURING TECHNOLOGY B33Y - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING

B33Y10/00 - Processes of additive manufacturing

C - CHEMISTRY C22 - METALLURGY C22F - CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS

C22F1/04 - of aluminium or alloys based thereon

B - PERFORMING OPERATIONS B22 - CASTING B22D - CASTING OF METALS

B22D21/007 - {with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C}

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DOE Contract Number:  

AC02-07CH11358; AC05-00OR22725

Resource Type:

Patent

Resource Relation:

Patent File Date: 07/14/2017

Country of Publication:

United States

Language:

English